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HomeMy WebLinkAboutPK Contractors Inc; 2002-07-22; 3675-2 Part 5 of 10fP (Carlsbad Water) 09940 Aluminum ductwork indoors. ! F Finish Coating System F1 ! f Finish Coating System F2 I f Other I I I t f Not applicable I I [When "Other" is selected, indicate i I I I (the alternative finish coating system./ 1 Ielements outdoors I Aluminum ductwork exposed to IF Finish Coating System F6 1 f Finish Coating System F7 If Other f Not applicable - When "Other" is selected, indicate 1 the alternative finish coating System.: Aluminum materials exposed to the 1 (i Finish Coating System F6 elements outdoors. j i Ir Finish Coating System F7 If Other I !r Not applicable When "Other" is selected, indicate the alternative finish coating system. Tilting weirs r Finish Coating System E4 f Other C Not applicable the alternative finish coating system.! When "Other" is selected, indicate , Concrete and Masonry Surfaces ' Coating Schedule I All concrete and concrete block in (i Finish Coating System C2 corrosive areas (Except floors and I surfaces scheduled to receive other r Other coatings) which are exposed to viewir Not applicable in interior locations (two coats). I I When "Other" is Selected, indicate the alternative finish coating system. flumes. Interior Surfaces of filter wash water ~ r Finish Coating System C3 1 I r Other (i Not applicable When "Other" is selected, indicate lthe alternative finish coating system. Filter wash water troughs. C Finish Coating System C3 i i jr Other I C Not applicable ~~ (Recycling Facility) -1 0- /the alternative finish coating system. /When "Other" is selected, indicate 'Interior surfaces of sludge drawoff boxes. C Finish Coating System C9 C Other F Not applicable i When "Other" is selected, indicate 'Concrete block surfaces in carbon i r Finish Coating System C2 handling rooms and janitors closets. i the alternative finish coating system. I I 1 ~ 1 1: :Eedpplicable i When "Other" is selected, indicate /Where indicated on the drawings, / C Finish Coating System C2 walls, floors, and curbed areas, adjacent to corrosive chemical Other storage and feed equipment. When "Other" is selected, indicate the alternative finish coating system. All walls in contact with liquid where , r Finish Coating System C2 the opposite face forms a part of an I interior room or dry pit. C Finish Coating System C3 i i When "Other" is selected, indicate the alternative finish coating system., All dampproofed Walls in Contact i C Finish Coating System C3 i with treated or potable water where i the owosite face is above grade or ! Other - the alternative finish coating system. I ri Not applicable I i C Other I ! i ri Not applicable ! which form is a part of an interior Not applicable room or a dry pit. I When "Othet' is selected.-indicate the alternative finish coating system. All dampproofed surfaces, including basin walls, in contact with treated C Finish Coating System C3 1 C Other I or potable water. ~ ! c Not applicable When "Other" is selected, indicate the alternative finish coating system. All dampproofed interior surfaces of walls in flocculation basins where C Finish Coating System C3 Other the wall is also part of an interior I 1 room or dry pit ~ c Not applicable I the alternative finish coating system.1 When '"Other" is selected, indicate I (Carlsbad Water) (Recycling Facility) 09940 -11- All dampproofed interior Surfaces of walls in a clearwell where the wall is 'c Finish Coating System C3 (i Not applicable I pit. 0th also part of an interior room or dly Ithe alternative finish coating system.: IlnteriOr walk of filter boxes, full ir Finish Coating System C3 'height above underdrains and i including edges of walkways. Ir Other ~ I !When "Other" is selected, indicate 1 I , Not applicable ! ~ I When "Other" is selected, indicate 1 the alternative finish coating system.1 Miscellaneous Surfaces Coating j I ~ I p Indoor Finish Coating System P2 Plastic Surfaces. including PVC and ! Schedule I I CRD I1.1 . cj Outdoor Finish Coating System P6 C Other C' Not applicable When "Other" is selected, indicate the alternative finish coating system. ! Color Coding of Piping c AS specified Color Coding and Lettering of Pipe I r Other i r Not applicable When "Other" is selected, indicate the alternative finish coating system Additional color coding of piping. r Yes No When "Yes" is selected, indicate additional requirements. ~ (Carlsbad Water) (Recycling Facility) 09940 -12- Section 09940 PROTECTIVE COATINGS PART 1 - GENERAL 1-1. SCOPE. This section covers field applied protective coatings, including surface preparation, protection of surfaces, inspection, and other appurtenant work for equipment and surfaces designated to be coated with heavy duty maintenance coatings. Regardless of the number of coats previously applied, at least two field coats in addition to any shop or field prime coats shall be applied to all surfaces unless otherwise specified. 1-1.01. Tenninoloqy. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-2. GENERAL. Cleaning, surface preparation, coating application, and thickness shall be as specified herein and shall meet or exceed the coating manufacturer's recommendations. When the manufacturer's minimum recommendations exceed the specified requirements, CONTRACTOR shall comply with the manufacturer's minimum recommendations. When equivalent products are acceptable to ENGINEER, CONTRACTOR shall comply with this specification and the coating manufacturer's recommendations. 1-2.01. Governina Standards. All cleaning, surface preparation, coating application, thickness, testing, and coating materials (where available) shall be in accordance with the referenced standards of the following American Water Works Association (AWWA), American National Standard Institute (ANSI), NACE International (NACE), SSPC: The Society for Protective Coating (SSPC), NSF International (NSF), and ASTM requirements. 1-2.02. Deliverv and Storaqe. All coating products shall be received and stored in accordance with the coating manufacturer's recommendations. 1-3. SUBMITTALS. CONTRACTOR shall submit color cards for all coatings proposed for use, together with complete descriptive specifications and the completed Coating System Data Sheets, to ENGINEER for review and color selection. Requests for review submitted directly to ENGINEER by coating suppliers will not be considered. CONTRACTOR shall submit a Coating System Data Sheet for each separately identified surface in the Coating Schedule that will be used on the contract, using (Carlsbad Water) (Recycling Facility) 09940 -13- the appropriate Coating System Data Sheet forms (Figures 1-09940 and 2-09940) at the end of this section. Each field coating system shall be acceptable to the coating material manufacturer. Each Coating System Data Sheet shall include application temperature requirements including recoat window requirements for the ambient conditions at the site, including elevated temperatures up to 130°F. Temperature requirements shall be specified by the coating manufacturer. Each proposed coating system shall be assigned a unique number with a prefix letter based on the following: A 1 Equipment - submerged E 1 Concrete and concrete block C 2 Iron and steel nonsubmerged 2 ~~~~~ ~~~ F 1 High temperature H 1 Galvanized G 1 Nonferrous metal I P I PVC and FRP I 1 1 Each coating system that will be applied entirely in the field shall be assigned only a prefix letter and no suffix letter. When appropriate under the indicated conditions, the following suffix shall be added to the coating system numbers: -F Each shop-applied coating system that includes a finish coat applied in the field. A separate Coating System Data Sheet shall be developed and submitted for each variation or change in a coating system or surface to be coated. The manufacturer's standard colors will be acceptable for all coatings. 1-4. QUALITY ASSURANCE. 14.01. Coatins Svstem Data Sheet Certifications. Not Used 1-4.02. Special Interior Coatinq Svstems. Not Used (Carlsbad Water) (Recycling Facility) 09940 -14- PART 2 - PRODUCTS 2-1. ACCEPTABLE MANUFACTURERS. 2-1.01. Alternative Manufacturers. In addition to the coatings listed herein, equivalent coatings of the following manufacturers will also be acceptable: IC1 Devoe Rust-Oleum Plasite Sherwin-Williams Sigma PPG 2-1.02. Eauivalent Coatinqs. Whenever a coating is specified by the name of a proprietary product or of a particular manufacturer or vendor, the specified coating shall be understood as establishing the type and quality of coating desired. Other manufacturers' coatings will be accepted, provided that sufficient information is submitted to enable ENGINEER to determine that the proposed coatings are equivalent to those named. Information on proposed coatings shall be submitted for review in accordance with the submittals section. Requests for review of equivalency will be accepted only from CONTRACTOR, and will be considered only after the contract has been awarded. 2-2. MATERIALS. All coatings shall be delivered to the job in original unopened containers with labels intact. Coatings shall be stored indoors and shall be protected against freezing. ' No adulterant, unauthorized thinner, or other material not included in the coating formulation shall be added to the coating for any purpose. All coatings shall conform to the air quality regulations applicable at the location of use. Coating materials that cannot be guaranteed by the manufacturer to conform, whether or not specified by product designation, shall not be used. The coatings specified have been selected on the basis of the manufacturer's statement that the VOC content of the product is 2.8 Ibs per gallon or less, unless otherwise indicated herein; however, it shall be the Contractor's responsibility to use only coating materials that are in compliance with the requirements of all regulatory agencies. Local regulations may require some coatings to have a lower VOC content than specified herein. The coatings specified may meet the VOC limits in the unthinned (as shipped) condition, but may exceed the limits if thinned according to the manufacturer's recommendations. Under these conditions, the coatings shall not be thinned beyond the 2.8 Ibs per gallon limit, and if the product cannot be thinned to suit the application method or temperature requirements, another manufacturer's (Carlsbad Water) (Recycling Facility) 09940 -1 5- coating shall be used, subject to acceptance by ENGINEER. CONTRACTOR shall be responsible for ensuring the compatibility of field coatings with each other or with the coatings on shop coated or previously coated surfaces. Coatings used in successive field coats shall be produced by the same manufacturer. Coatings used in the first field coat over shop coated or previously coated surfaces shall cause no wrinkling, lifting, or other damage to underlying coats. All coatings used on surfaces that will be in contact with potable or treated water shall be certified as being in compliance with ANSVNSF 61. Coatings that cannot be so certified, whether or not specified by manufacturer and by product designation, shall not be used. All intermediate and finish coating materials that will be in contact with wastewater atmosphere shall be guaranteed by the manufacturer to be fumeproof and suitable for wastewater plant atmosphere that contains hydrogen sulfide. Coatings that cannot be so guaranteed shall not be used. Lead-free and mercury-free coatings shall be used if available, but in no case shall coatings containing lead or mercury be used that become discolored when exposed to wastewater plant atmosphere. 2-2.01 Primers. Universal Primer Ameron "Amercoat 385 Epoxy", Carboline "Carboguard 888 Primer", or Tnemec "Series N27 S.T. Typoxy". Epoxy Concrete Block Ameron "Amerlock 400BF Epoxy Block Filler Filler", Plasite "9029 Filler", or Tnemec "54-1500. 2-2.02. Intermediate and Finish Coatinas. Epoxy Enamel (NSF certified systems) Ferrous Metal Surfaces, and Concrete Surfaces in Contact with Treated or Raw Water in Potable Water Facilities Epoxy Enamel Concrete Floors (Carlsbad Water) (Recycling Facility) Ameron "Arnerlock 400 High-Solids Epoxy Coating", Carboline "Carboguard 891", or Tnemec "Series N140 Pota-Pox Plus"; immersion service. Ameron "Amercoat 385 Epoxy", 09940 -16- Ferrous Metal Surfaces, and Masonry or Concrete Surfaces Other Than Floors Aliphatic Polyurethane Coal Tar Epoxy Medium Consistency Coal Tar Vinyl Ester Heat-Resistant High Heat-Resistant Carboline "Carboguard 890, or Tnemec "Series 69 Hi-Build Epoxoline 11"; nonskid. Ameron "Amercoat 385 Epoxy", Carboline "Carboguard 890", or Tnemec "Series 69 Hi-Build Epoxoline 11". Ameron "Amercoat 450HS", Carboline "Carbothane 134HG", or Tnemec "Series 74 Endura-Shield". High-build coal tar epoxy; Ameron "Amercoat 78HB Coal Tar Epoxy", Carboline "Bitumastic 300 M", or Tnemec "46H-413 Hi-Build Tneme-Tar". Carboline "Bitumastic Super Service Black" or Tnemec "46-465 H.B. Tnemecol". Tnemec "Series 120 Vinester". Suitable for temperatures up to 400°F; Ameron "PSX 738 Engineered Siloxane Coating" or Tnemec "43-38 Diffused Aluminum". Suitable for temperatures up to 1000°F; Ameron " PSX 738 Engineered Siloxane Coating". Tnemec "Series 39 Silicone Aluminum", PART 3 - EXECUTION 3-1. SURFACE PREPARATION. All surfaces to be coated shall be clean and dry and shall meet the recommendations of the coating manufacturer for surface preparation. Freshly coated surfaces shall be protected from dust and other contaminants. Oil and grease shall be completely removed by use of solvents or detergents before mechanical cleaning is started. The gloss of previously coated surfaces shall be dulled if necessary for proper adhesion of topcoats. (Carlsbad Water) (Recycling Facility) 09940 -17- Surfaces shall be free of cracks, pits, projections, or other imperfections that would interfere with the formation of a smooth, unbroken coating film, except for concrete block construction where a rough surface is an inherent characteristic. When applying touchup coating or repairing previously coated surfaces, the surfaces to be coated shall be cleaned as recommended by the coating manufacturer and the edges shall be sanded or wire brushed to provide a feathered or otherwise smoothed so that they will not be noticeable after they are coated. All coatings made brittle or otherwise damaged by heat of welding shall be completely removed. 3-1.01, Galvanized Surfaces. Galvanized surfaces shall be prepared for coating in conformity with the instructions of the manufacturer of the epoxy enamel. Any chemical treatment of galvanized surfaces shall be followed by thorough rinsing with clean water. 3-1.02. Ferrous Metal Surfaces. Ungalvanized ferrous metal surfaces shall be prepared for coating by cleaning using one or more of the following methods as specified: solvents (SSPC-SPI); blasting (SSPC-SP5, -SP6, -SP7, or -SPlO); power tools (SSPC-SP3 or -SP11); or hand tools (SSPC-SP2). Oil and grease shall be completely removed in accordance with SSPC-SP1 before beginning any other cleaning method. Surfaces of welds shall be scraped and ground as necessary to remove all slag and weld spatter. Tools which produce excessive roughness shall not be used. All components of equipment that can be properly prepared and coated after installation shall be installed prior to surface preparation. Components of equipment that will be inaccessible after installation shall have the surfaces prepared and coated prior to installation. Motors, drive trains, and bearings shall be protected during surface preparation in accordance with the equipment manufacturer's recommendations. All cut or sheared edges shall be ground smooth to a 118 inch minimum radius for all material 114 inch thickness and larger. For material thickness less than 114 inch [6 mm] all cut or sheared edges shall be ground smooth to a radius equal to 112 the material thickness. Grinding of rolled edges on standard shapes with a minimum radius of the 1/16 inch will not be required. All ferrous metal surfaces shall have all welds ground smooth and free of all defects in accordance with NACE Standard RP0178, Appendix C, Designation C and sharp edges ground smooth, if not previously prepared in the shop. Instead of blending of the weld with the base metal as required by the NACE standard, it will be acceptable to furnish a welded joint that has a smooth transition of the weld to the base metal. All welds shall be ground smooth to ensure satisfactory paint adhesion. (Carlsbad Water) (Recycling Facility) 09940 -18- The cleaning methods and surface profiles specified herein are minimums, and if the requirements printed in the coating manufacturer's data sheets exceed the limits specified, the value printed on the data sheets shall become the minimum requirement. 3-1.02.01. Ferrous Metal Surfaces - Nonimrnersion Service. Ferrous metal surfaces, including fabricated equipment, in nonimmersion service shall be cleaned to the degree recommended by the coating manufacturer for surfaces to be coated with coal tar epoxy, epoxy enamel, and heat-resistant coatings, except galvanized surfaces. Blast cleaning to at least SSPCSPG shall be used where recommended by the coating manufacturer, and may be used elsewhere at the option of CONTRACTOR, provided that no dust is permitted to settle on adjacent wet coating. Surface profile shall be at least 15 percent of the dry film thickness specified for the coating system. 3-1.02.02. Ferrous Metal Surfaces - Immersion Service. Surface preparation of ferrous metal surfaces in immersion service shall consist of blast cleaning to at least SSPC-SPIO and the first application of coating shall be performed on the same day, If more surface area is prepared than can be coated in one day, the uncoated area shall be blast cleaned again to the satisfaction of ENGINEER. Surface profile shall be at least 25 percent of the dry film thickness specified for the coating system. 3-1.03. Concrete Surfaces. All concrete surfaces shall be free of objectionable substances and shall meet the coating manufacturer's recommendations for surface preparation. Any other surface preparation recommended by the coating material manufacturer shall be brought to ENGINEERS attention and may be incorporated into the work if acceptable to ENGINEER. All concrete surfaces shall be dry when coated and free from dirt, dust, sand, mud, oil, grease, and other objectionable substances. Oil and grease shall be completely removed by use of solvents or detergents before mechanical cleaning is started. New concrete shall have cured for at least 4 weeks before coating is applied as recommended by the material manufacturer. Concrete surfaces shall be tested for capillary moisture in accordance with ASTM D4263. There shall be no capillary moisture when coatings are applied on concrete. All surfaces to be coated shall be cleaned in accordance with ASTM D4258 and abraded in accordance with ASTM D4259. Surface profile shall be at least 25 percent of the dry film thickness specified for the coating system. Prior to application of the coating, the surfaces shall be thoroughly washed or cleaned by air blasting to remove all dust and residue. Spalled areas, voids, and cracks shall be repaired in accordance with the concrete section and as acceptable to the Engineer. Fins and other surface projections shall be removed to provide a (Carlsbad Water) (Recycling Facility) 09940 -1 9- flush surface before application of coating. Except where epoxy enamel is applied as dampproofing, the concrete surfaces, including those with bug holes less than 1 inch in any dimension, shall be prepared when required and as recommended by the manufacturer, using an epoxy concrete block filler. 3-1.04. Concrete Block Surfaces. Voids and openings in concrete block surfaces shall be pointed. All exposed exterior surfaces and surfaces to be coated with epoxy enamel, including the joints, shall be filled so that a continuous unbroken coating film is obtained. 3-1.05. Copper Tubinq. All flux residue shall be removed from joints in copper tubing. Immediately before coating is started, tubing shall be wiped with a clean rag soaked in xylol. 3-1.06. Plastic Surfaces. All wax and oil shall be removed from plastic surfaces that are to be coated, including PVC and FRP, by wiping with a solvent compatible with the specified coating. 3-1.07. Hardware. Hardware items such as bolts, screws, washers, springs, and grease fittings need not be cleaned prior to coating if there is no evidence of dirt, corrosion, or foreign material. 3-1.08. Aluminum. When a coating system is required, remove all oil or deleterious substance with neutral detergent or emulsion cleaner or blast lightly with fine abrasive. 3-2. MIXING AND THINNING. Coating shall be thoroughly mixed each time any is withdrawn from the container. Coating containers shall be kept tightly closed except while coating is being withdrawn. Coating shall be factory mixed to proper consistency and viscosity for hot weather application without thinning. Thinning will be permitted only as necessary to obtain recommended coverage at lower application temperatures. In no case shall the wet film thickness of applied coating be reduced, by addition of coating thinner or otherwise, below the thickness recommended by the coating manufacturer. Thinning shall be done in compliance with all applicable air quality regulations. 3-3. APPLICATION. Coating shall be applied in a neat manner that will produce an even film of uniform and proper thickness, with finished surfaces free of runs, sags, ridges, laps, and brush marks. Each coat shall be thoroughly dry and hard before the next coat is applied. In no case shall coating be applied at a rate of coverage greater than the maximum rate recommended by the coating manufacturer. (Carlsbad Water) (Recycling Facility) 09940 -20- Coating failures will not be accepted and shall be entirely removed and the surface recoated. Failures include but are not limited to sags, checking, cracking, teardrops, fat edges, fisheyes, or delamination. 3-3.01. m. Edges, corners, crevices, welds, and bolts shall be given a brush coat (stripe coat) of primer before application of the primer coat. The stripe coat shall be applied by a brush and worked in both directions. Special attention shall be given to filling all crevices with coating. Abraded and otherwise damaged portions of shop-applied coating shall be cleaned and recoated as recommended by the manufacturer of the finish coating. Welded seams and other uncoated surfaces, heads and nuts of field-installed bolts, and surfaces where coating has been damaged by heat shall be given a brush coat of the specified primer. Before the specified spot or touchup coating of metal surfaces, edges, corners, crevices, welds, and bolts in the area of the spot or touchup coating shall be given a brush coat of primer. This patch, spot, or touchup coating shall be completed, and the paint film shall be dry and hard, before additional coating is applied. 3-3.02. EDOW Enamel. When used, epoxy enamel shall be applied in accordance with the coating manufacturer's recommendations, including temperature limitations and protection from sunlight until topcoated. Coatings shall not be applied to concrete surfaces in direct sunlight or when the temperature of the concrete is rising. Preferably the coating shall be applied when the temperature of the concrete is dropping. When applying high build epoxy coatings with a roller or brush and where a dry film thickness of at least 4-6 mils per coat is required, two or more coats shall be applied to achieve the recommended dry film thickness equal to a spray applied coating. 3-3.03. Coal Tar EDOW. When used, the application of coal tar epoxy, including time limits for recoating, shall conform to the recommendations of the coating manufacturer. Coatings shall not be applied to concrete surfaces in direct sunlight or when the temperature of the concrete is rising. Preferably the coating shall be applied when the temperature of the concrete is dropping. 3-3.04. Vinvl Ester. When used, the application of vinyl ester coating system, including time limits for recoating and temperature requirements of the materials, shall conform to the recommendations of the coating manufacturer. 3-3.05. Film Thickness. The total coating film thickness including intermediate (Carlsbad Water) (Recycling Facility) 09940 -21- coats and finish coat, shall be not less than the following: TvDe of Coatinq Medium consistency coal tar Coal tar epoxy Epoxy enamel Floors Surfaces with first coat of epoxy enamel and final coat of aliphatic polyurethane Surfaces with first and second coat of epoxy enamel and final coat of aliphatic polyurethane Other surfaces (two coats) Immersion service (three coats) Vinyl ester Heat-resistant High heat-resistant Other surfaces (one coat) Other surfaces (two coats) Minimum Drv Film Thickness 20 mils 15 mils 5 mils 7 mils (5 mils DFT for epoxy plus 2 mils DFT for aliphatic polyurethane) 12 mils (IO mils DFTfor epoxy plus 2 mils DFT for aliphatic polyurethane) 10 mils 15 mils 30 mils 3 mils 3 mils 5 mils 10 mils 3-3.06. Weather Conditions. Coatings shall not be applied, except under shelter, during wet, damp, or foggy weather, or when windblown dust, dirt, debris, or insects will collect on freshly applied coating. Coatings shall not be applied at temperatures lower than the minimum temperature recommended by the coating manufacturer, or to metal surfaces such as tanks or pipe containing cold water, regardless of the air temperature, when metal conditions are likely to cause condensation. When necessary for proper application, a temporary enclosure shall be erected and kept heated until the coating has fully cured. Coatings shall not be applied at temperatures higher than the maximum temperature recommended by the coating manufacturer. Where coatings are applied during periods of elevated ambient temperatures, CONTRACTOR and (Carlsbad Water) (Recycling Facility) 09940 -22- the coatings manufacturer shall be jointly responsible to ensure that proper application is performed including adherence to all re-coat window requirements. Precautions shall be taken to reduce the temperature of the surface application, especially for metal, at elevated temperatures above 100°F including shading application area from direct sunlight, applying coating in the evening or at night, and ventilating the area to reduce the humidity and temperature, Vinyl ester coating materials, when required, shall be maintained during transportation, storage, mixing, and application at the temperature required by the coating manufacturer, 35°F to 90°F. 3-4. REPAIRING FACTORY FINISHED SURFACES. Factory finished surfaces damaged prior to acceptance by OWNER shall be spot primed and recoated with materials equivalent to the original coatings. If, in the opinion of ENGINEER, spot repair of the damaged area is not satisfactory, the entire surface or item shall be recoated. 3-5. PROTECTION OF SURFACES. Throughout the work CONTRACTOR shall use drop cloths, masking tape, and other suitable measures to protect adjacent surfaces. CONTRACTOR shall be responsible for correcting and repairing any damage resulting from its or its subcontractors’ operations. Coatings spilled or spattered on adjacent surfaces which are not being coated at the time shall be immediately removed. Exposed concrete or masonry not specified to be coated which is damaged by coatings shall be either removed and rebuilt or, where authorized by OWNER, coated with two coats of masonry coating. 3-6. FIELD QUALITY CONTROL. The following inspection and testing shall be performed: visual inspection, surface profile, and wet and dry film thickness. All inspection and testing shall be witnessed by ENGINEER. 3-6.01. Surface Profile Testinq. The surface profile for ferrous metal surfaces shall be measured for compliance with the specified minimum profile. The surface profile for concrete shall comply with SSPC 13/NACE 6 Table 1 for severe service. 3-6.02. Visual InsDection. The surface of the protective coatings shall be visually inspected. 3.6.03. Film Thickness. Coating film thickness shall be verified by measuring the film thickness of each coat as it is applied and the dry film thickness of the entire system. Wet film thickness shall be measured with a gauge that will measure the wet film thickness within an accuracy of f 0.5 mil. Dry film thickness shall be measured in accordance with SSPC-PA 2. 3-6.04. Spark Testinq. Not Used (Carlsbad Water) (Recycling Facility) 09940 -23- 3-6.05. Adhesion Testing. Not Used 3-7. FIELD PRIMING SCHEDULE, In general, surfaces of steel, cast iron, and equipment are specified to be shop primed. Any such surfaces which have not been shop primed shall be field primed. Damaged or failed shop coatings which have been determined unsuitable by ENGINEER shall be removed and the sutfaces shall be field coated, including prime coat (if any). Galvanized, aluminum, stainless steel, wood, and insulated surfaces shall be field primed. Primers used for field priming, unless otherwise required for repair of shop primers, shall be: Surface To Be Primed Equipment, surfaces to be coated with Aliphatic polyurethane Epoxy enamel Coal tar coating Vinyl ester Steel and cast iron, surfaces to be coated with Epoxy enamel Coal tar coating Galvanized Copper Stainless steel Plastic surfaces, including PVC and FRP Insulated piping Concrete, surfaces to be coated with epoxy enamel For dampproofing (Carlsbad Water) (Recycling Facility) 09940 -24- Material Universal primer Same as finish coats Same as finish coats Same as finish coats Same as finish coats Same as finish coats Epoxy enamel Epoxy enamel Epoxy enamel Same as finish coats As recommended by manufacturer of finish coats Epoxy enamel For all other surfaces Epoxy concrete block filler Concrete block exposed in Epoxy concrete block filler exterior locations Concrete block to be coated with Epoxy concrete block filler epoxy enamel Unless otherwise recommended by the coating manufacturer or specified herein, priming will not be required on concrete, or concrete block, nor on metal surfaces specified to be coated with epoxy enamel, coal tar epoxy, and heat-resistant coatings. Concrete surfaces to be coated with epoxy enamel shall be filled with epoxy concrete block filler so that a continuous film is obtained, except where concrete is dampproofed with epoxy enamel. 3-8. FINISH COATING SYSTEMS. The following schedule lists coatings systems and coating system designations. No. Coating System Finish Coating Systems Designation ACEFGHP 1. X xxxxx Epoxy enamel -Two coats 2. X X Epoxy enamel - One coat - 3. xx Epoxy enamel I NSF -Three coats 5. xxx Epoxy enamel -Three coats 4. xx Epoxy enamel I NSF -Two coats 6. Epoxy enamel - First coat Aliphatic polyurethane - Finish coat 7. xxx Epoxy enamel - First and second coat Aliphatic polyurethane - Finish coat 8. X X Universal primer - First coat Aliphatic polyurethane - Finish coat 9. x x x ' Medium consistency coal tar - Two coats (Carlsbad Water) (Recycling Facility) 09940 -25- 3-8.01. Surfaces Not To Be Coated. Unless otherwise specified, the following surfaces shall be left uncoated: Exposed aluminum, except ductwork Polished or finished stainless steel. Unfinished stainless steel, except flashings and counter flashings, shall be coated. Nickel or chromium. Galvanized surfaces, except piping, conduit, ductwork, and other items specifically noted. Rubber and plastics, except as specified. Exterior concrete Surfaces specified to be factory finished. 3-8.02. ShoD Finishing. Items to be shop finished include the following. Shop finishing shall be in accordance with the coating schedule and the manufacturer's recommendations. a. All slide gates. b. All conveyors, c. Other surfaces where blast cleaning cannot be or is not recommended to be performed in the field. d. Other items as otherwise specified. 3-8.03. Field Coatinq. Items to be field coated include the following. Field coating shall be in accordance with the field priming schedule, the coating (Carlsbad Water) (Recycling Facility) 09940 -26- schedule, and the manufacturer's recommendations. a. Exterior surface of the sludge hopper. b. Surfaces not indicated to be shop finished and surfaces where blast cleaning can be performed in the field. c. All interior ferrous metal surfaces except stainless steel on the digester cover. d. Other items as otherwise specified. 3-9. PIPING IDENTIFICATION SCHEDULE. Exposed piping and piping in accessible chases shall be identified with lettering or tags designating the service of each piping system, shall be marked with flow directional arrows, and shall be color coded as indicated in the piping identification data sheet. Piping scheduled to be color coded shall be completely coated with the indicated colors, except surfaces specified to remain uncoated shall include sufficiently long segments of the specified color to accommodate the lettering and arrows. All other piping shall be coated to match adjacent surfaces, unless otherwise directed by ENGINEER. 3-9.01. Location. Lettering and flow direction arrows shall be provided on pipe near the equipment served, adjacent to valves, on both sides of wall and floor penetrations, at each branch or tee, and at least every 50 feet in straight runs of pipe. If, in the opinion of ENGINEER, this requirement will result in an excessive number of labels or arrows, the number required shall be reduced as directed. 3-9.02. Metal Taas. Where the outside diameter of pipe or pipe covering is 518 inch [I5 mm] or smaller, aluminum or stainless steel tags shall be provided instead of lettering. Tags shall be stamped as specified and shall be fastened to the pipe with suitable chains. Pipe identified with tags shall be color coded as specified. 3-9.03. Letterinq. Lettering shall be painted or stenciled on piping or shall be applied as snap-on markers. Snap-on markers shall be plastic sleeves, Brady "Bradysnap-On B-915" or Seton "Setmark". Letter size shall be as follows: Outside Diameter of Pipe or Covering Minimum Heiaht of Letters 518 inch and smaller Metal tags -114 inch 314 to 4 inches 314 inch (Carlsbad Water) (Recycling Facility) 09940 -27- Outside Diameter of PiDe or Covering Minimum Heiqht of Letters 5 inches and larger 2 inches 3-9.04. Color Codinq and Lettering. When required by the piping identification data sheet all 12 inch and smaller piping for the following services shall be color coded. Bands shall be 6 inches wide spaced along the pipe at 5 foot intervals. Service Color of Pipe Potable Water (hot or cold) Light blue Raw Water Light blue with white bands Nonpotable or ' Distilled Water Service Water (lines downstream from an air gap repump system) Light Blue with white bands Dark blue with Red bands Color of Black Black White Settled Sewage Service Water Dark blue with Orange bands White 1 Compressed Air 1 Light green 1 Black I Low Pressure Air (aeration supply) Light green Black Instrument Air Black Light green with dark green bands Combustion Air White Dark green Laboratory Vacuum White Dark'green with light brown Odor Control Red Dark green with light green bands bands Vacuum Pump Discharge Black Aluminum (Carlsbad Water) 09940 (Recycling Facility) -28- Service Color of Color of Pipe Letters Fuel Oil White Black Gasoline 1 Black with red bands I White Oil - Hydraulic 1 Black with white bands 1 White 1 Grease 1 Black with Yellow bands I White I Other Hydrocarbons (identify) Black White 1 Heating Water (supply) 1 Light gray with black bands 1 Black I Steam Black Light gray with red bands Steam Vent Black Light gray with brown bands Condensate Black Light gray with orange bands ~~ I Chilled Water (return) 1 Dark brown with red bands I White I I Sewage 1 Light gray 1 Black I Settled Sewage I Light gray with brown bands I Black I ~ Sludge Heated Sludge Scum White Dark brown White Filtrate 1 Dark gray with red bands 1 White I Drain 1 Dark gray 1 White I Ash 1 Dark gray with green bands I White I 1 Sample 1 Light gray with green bands 1 Black I Electrolyte White Light brown with white bands Lime Sludge Black Aluminum with red bands I Light brown with green bands I White I (Carlsbad Water) (Recycling Facility) 09940 -29- Service Color of Pipe Color of Letters I 1 Polymer I Light brown with red bands 1 White I 1 Polyphosphate 1 Light brown with gray bands 1 White I ~~ ~~~ ~ 1 Sodium Silica (Solution) 1 Light brown with orange bands I White ~~ Activated Silica (solution) Soda Ash (solution) Chlorine (gas, liquid, or vent) Chlorine (solution) ~~ Light brown with blue bands Light brown ~ Yellow Yellow with red bands White Black Black I Black I I Liquid Alum 1 Yellow with orange bands I Black I 1 Alum (solution) 1 Yellow with green bands 1 Black I 1 Ammonia I Yellow with brown bands I Black I I Hydrofluosilicic Acid Carbon Dioxide (liquid or I gas) + Yellow with blue bands Black Yellow with gray bands Black Carbon Dioxide (solution) Refrigerant Ferric Chloride Sulfur Dioxide Sulfur Dioxide (solution) Yellow with black bands Yellow with white bands Black Orange Black Orange with brown bands 1 Black Orange with blue bands I Black 1 Ozone I Orange with green bands I Black I 1 Sodium Chlorite I Orange with red bands 1 Black I I Potassium Permanganate I Orange with white bands 1 Black I 1 Carbon I Black I I I I Electrical conduit shall be coated to match adjacent ceiling or wall surfaces as (Carlsbad Water) (Recycling Facility) 09940 -30- directed by ENGINEER. Vent lines shall be coated to match surfaces they adjoin. In addition, special coating of the following items will be required: - Item Color Valve handwheels and levers Red Hoist hooks and blocks Yellow and black stripes Numerals at least 2 inches high shall be painted on or adjacent to all accessible valves, pumps, flowmeters, and other items of equipment which are identified on the drawings or in the specifications by number. End of Section (Carlsbad Water) (Recycling Facility) 09940 -31 - . SURFACE DESCRIPTION SYSTEM NO. - - . SURFACE PREPARATION DESCRIPTION ~ COATING 1 mils bml DFT 1 MANUFACTURER AND PRODUCT Is I Third Coat Total Not less than minimum thickness specified. System Notes: (Attached if needed.) I Project: Painting Contractor: SHOP PRIMED SURFACE DESCRIPTION SYSTEM NO. - -F SURFACE PREPARATION DESCRIPTION COATING 1 mils bm] DFT MANUFACTURER AND PRODUCT First Coat (Primer) Touchup Coat Second mils pm] DFT Third Coat Total System Not less than minimum thickness specified. ~ ~ Notes: (Attached if needed.) Division 1 1 Equipment Section 11060C EQUIPMENT INSTALLATION Data Sheet lescription Data ieneral ems to be installed. Pumps Vertical End Suction Centrifugal &3 Submersible Pumps Plunger Pumps @ Other Pumps Mechanism Circular Residuals Collecting Mechanism Straight-Line Residuals Collecting r Submersible Mixers C Plate Settlers Surface Aeration Equipment 0 Diffused Aeration Equipment C Multistage Centrifugal Blowers E Engine-Generators Water Pressure Booster Systems (Carlsbad Water) (Recycling Facility) 1 1060C -1 - nits Section 1 1060C EQUIPMENT INSTALLATION PART 1 - GENERAL 1-1. SCOPE. This section covers installation of new equipment units that have been purchased by CONTRACTOR as part of this Work, or purchased by others under procurement specifications. Startup requirements shall be as indicated in Section 01650. 1-2. GENERAL. Equipment installed under this section shall be erected and placed in proper operating condition in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. When pumping units are being installed, hydraulic considerations and definition of terms shall be as set forth in the Hydraulic Institute Standards. Any equipment identified as being provided by others will be furnished complete for installation by CONTRACTOR. Technical specifications under which the equipment will be purchased are available. Any existing equipment which is removed shall be handled as indicated in Section 01 01 5. 1-2.01. Coordination. When manufacturer's field services are provided by the equipment manufacturer, CONTRACTOR shall coordinate the services with the equipment manufacturer. CONTRACTOR shall give ENGINEER written notice at least 30 days prior to the need for manufacturer's field services furnished by others. Submittals for equipment furnished by others under each procurement contract will be furnished to CONTRACTOR upon completion of review by ENGINEER. CONTRACTOR shall review equipment submittals and coordinate with the requirements of the Work and the Contract Documents. CONTRACTOR accepts sole responsibility for determining and verifying all quantities, dimensions, and field construction criteria. Flanged connections to equipment including the bolts, nuts, and gaskets are covered in the appropriate pipe specification section. (Carlsbad Water) (Recycling Facility) 1106oc -2- 1-3. DELIVERY. STORAGE, AND HANDLING. 1-3.01. Storaqe. Upon delivery, all equipment and materials shall immediately be stored and protected by CONTRACTOR in accordance with Section 01614 until installed in the Work. Equipment shall be protected by CONTRACTOR against damage and exposure from the elements. At no time shall the equipment be stored on or come into contact with the ground, grass, or any other type of vegetation. CONTRACTOR shall keep the equipment dry at all times. PART 2 - PRODUCTS 2-1. MATERIALS. Materials shall be as follows: Grout As specified in the equipment grout section. PART 3 - EXECUTION 3-1. INSTALLATION. 3-1.01. General. Equipment shall not be installed or operated except by, or with the guidance of, qualified personnel having the knowledge and experience necessary to obtain proper results as specified in the Section 01650 Startup Requirements. Each equipment unit shall be leveled, aligned, and shimmed into position. Installation procedures shall be as recommended by the equipment manufacturer and as required herein. Shimming between machined surfaces will not be permitted. Unless otherwise indicated or specified, all equipment shall be installed on concrete bases at least 6 inches high, Baseplates shall be anchored to the concrete base with required anchor bolts. For equipment with grouted bases, the space beneath shall be filled with grout as specified in the equipment grout section. The equipment base shall be grouted after initial fitting and alignment. Anti-seize thread lubricant shall be liberally applied to the threaded portion of all stainless steel bolts during assembly. When specified in the equipment sections, the equipment manufacturer will provide installation supervision and installation checks. For installation supervision, the manufacturer's field representative will observe, instruct, guide, and direct CONTRACTORS erection or installation procedures as specified in the procurement specifications. For installation checks, the manufacturer's field representative will inspect the equipment installation immediately following (Carlsbad Water) (Recycling Facility) 11 060C -3- erection by CONTRACTOR, and observe the tests indicated in Section 01650. The manufacturer's representatives will revisit the site as often as necessary to ensure installation satisfactory to OWNER. The manufacturer shall certify, in writing, the equipment is installed correctly, has been tested, and is ready for startup. 3-1.02. Pumpinq Units. When pumping units are to be installed, the equipment shall be installed in accordance with the Hydraulic Institute Standards. When installing pumping units, the equipment base shall be grouted after initial fitting and alignment, but before final bolting of connecting piping. Special care shall be taken to maintain alignment of pumping unit components. No stresses shall be transmitted to the pump flanges. After final alignment and bolting, connections to pumping equipment shall be tested for applied piping stresses by loosening the flange bolts. If any movement or opening of the joints is observed, piping shall be adjusted to proper fit. Couplings shall be realigned after grouting. Final coupling misalignment shall be within one-half of the coupling manufacturer's allowable tolerance. 3-1.02.01. Vertical End Suction Centrifuqal Pumps. Not used. 3-1.02.02. Submersible Pumps. Control cables shall be supported to avoid tension and damage. Mounting of cable supports in wetwells will be coordinated by the pump supplier. Liquid level sensors shall operate freely and shall be adjusted to the levels indicated in the respective pump schedules, or in the electrical schematics or P&ID's. Each system of sensors will be furnished by others, and shall be installed complete with all required mounting brackets, weights, galvanized steel mounting pipes and accessories, control panel transformers, auxiliary relays, cables, and junction boxes. Type 316 kellum grips shall be use for submersible pump cords. 3-1.02.03. Plunqer Pumps. Not used. 3-1.03. Circular Residuals Collectina Mechanism. Not used. 3-1.04. Straiqht Line Residuals Collectinq Mechanism. Not used. 3-1.05. Submersible Mixers. Not used. 3-1.06. Plate Settlers. Not used, 3-1.07. Surface Aeration Equipment. Not used. 3-1 .OB. Diffused Aeration Equipment. Not used. 3-1.09. Multistaqe Centrifugal Blowers. Not used. (Carlsbad Water) (Recycling Facility) 1 1060C 4- 3-1 .IO. Engine-Generators. Not Used. 3-1 .I 1. Water Pressure Booster Systems. Not Used. 3-2. STARTUP AND TESTING. Startup requirements, and tests associated with startup shall be as indicated in Section 01650. Other field tests shall be as indicated in the specific equipment sections. Startup and tests required shall occur in the order listed in the following paragraphs. Tests shall not begin until any installation supervision and installation checks by the equipment manufacturer have been completed, except where noted below. 3-2.01. Preliminary Field Tests. Preliminary field tests shall be conducted on all equipment by CONTRACTOR as indicated in Section 01650. When an installation check is specified in the equipment sections, the equipment manufacturer's representative will participate in these tests to the extent described in Section 01650 and in the equipment sections. 3-2.02. Field System ODeration Tests. Field system operation tests shall be conducted on all equipment by CONTRACTOR as indicated in Section 01650. When an installation check is specified in the equipment sections, the equipment manufacturer's service personnel will participate in these tests to the extent described in Section 01650 and in the equipment sections. 3-2.03. Field Demonstration Tests. Field demonstration tests will be conducted by the equipment manufacturer on equipment as indicated and as specified in the equipment sections. 3-2.04. Field Performance Tests & Distribution Tests. Field performance tests or distribution tests will be conducted by the equipment manufacturer on equipment as indicated and as specified in the equipment sections. 3-2.05. Field Baseline Performance Tests. Not used. End of Section (Carlsbad Water) (Recycling Facility) 1 1060C -5- Section 11 1 15 HORIZONTAL END SUCTION CENTRIFUGAL PUMPS Data Sheet ara- ]Description IData wh General Tag Number. Pump designation. P-1629 MFlRO Building Pump location. One Number of pumping units required. RO CIP Pump required. -2.01 G Yes General Equipment Requirements r NO Power supply. G 480 wlts. 60 Hz, 3 phase r Other When "Other" is selected, indicate the alternative. manuals required. -3.02 Yes Operation and maintenance r NO -7 Non-witnessed Shop testing. r Witnessed C Not required -7 r Yes Test with the motor or drive unit to be installed in the Work. G No Type of contract. General Construction r Procurement Service Conditions Pump application. G Indoor Type of environmental exposure. 4 Seismic zone. Clean-In-Place Chemicals r Outdoor (open) r Outdoor (cowed) Ambient air temperature range. 35 to 100 [1.7 to 381 Liquid temperature range. Maximum solids concentration, by 40 to .I10 I4.5 to 431 nits = ["C] = ["C] ercent (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -1- Std. Rev. 1.4, 8/7/2000 ]Start and stop apainst a closed I r Yes I (valve. .- Site elevation. Requirements Rated head. 140 [43] ft [ml Capacity at rated head. 480 [30] gpm [Us1 Evaluated head (if different than rated head). 2-2 Performance and Design ft [ml Site elevation. Requirements Performance and Design Rated head. 140 [43] ft [ml Capacity at rated head. 480 [30] gpm [Us1 Evaluated head (if different than rated head). ft [ml r Wire to water Efficiency calculated at. IC Rated head r Ewluated head Pump designed for reverse rotation. r yes C No Maximum head for reverse rotation. Minimum NPSHA at rated head. ft Iml Minimum NPSHA at minimum ft [ml 34 [10.4] ~ ~~ ft [ml I IoDeratino head. I I Maximum suction pressure. Maximum "A weighted noise at 3 ft psi [kPa] 14.7 [loll [1 ml. velocity. Maximum unfiltered vibration in./sec. [mmls] Pump rotation as viewed from r Clockwise driven end. dBa [deal C Counterclockwise r See drawings I (Carlsbad Water) (Recvclina Facilitv) 11115 -2- I - _I (I -7-02) ~ Std. Rev. 1.4, 8/7/2000 Minimum pump suction nozzle size. Materials in. [mm] Minimum test sphere diameter. size. in. [mm] 3 (761 Minimum pump discharge nozzle in. [mm] 4 [lo21 -3 See spec r Cast iron Casing and casing covers. r High chrome alloy text. Impeller. r Cast iron C High chrome alloy r Bronze fi Stainless steel Casing wearing ring. fi Stainless steel r Bronze r None Impeller wearing rings. fi Stainless steel r Bronze r None Construction required. -4.01 Flanged cleanout handholes r On discharge r On suction -4.02 r Nonelog Type of impeller. r Recessed, radial me r Recessed, cup type R Open r Enclosed -4.02 r Static Impeller balancing. G Dynamic -4.02 fi Keyed Impeller to shaft attachment. r Threaded 4.02 r Single Maximum number of impeller ports. r2 r3 -4.05 r Packing Type of stuffing box. fi Single mechanical r Double mechanical (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -3- Std. Rev. 1.4, 8/7/2000 . 24.05 1 C Internal Stuffing box lubrication. I IC Piped to suction nozzle (i Piped from discharge nozzle 4.09 C Unfinished carbon steel Anchor bolts. C Galvanized steel C Stainless steel, Alloy Group I or 2 (i Stainless steel, Alloy Group 2 only r BY others Motors and Drive Units 6 C Belt. with fixed sheaws Select type of drive unit. r Belt, with stationary control C Resilient coupling (i Gear coupling 6.03 C Yes Adjustable frequency drives required. (i No 6.05 r NO (i Yes Safety guards required. 6 Spare Parts Number of spare mechanical seals. Number of casing wearing rings. One per pump Number of impeller wearing rings. Number of sets of bearings. Field Services One set per pump Number of sets of bearing seals. 2.01 Yes Installation check required. r NO If "Yes" is selected, indicate number 0.5 of round trips. If "Yes" is selected, indicate number r Yes Installation supervision required. 2.02 1 No If "Yes" is selected, indicate number of days. If "Yes" is selected, indicate number of round trips. (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -4- Std. Rev. 1.4, 8/7/2000 Section 1 11 15 HORIZONTAL END SUCTION CENTRIFUGAL PUMPS Data Sheet graph Para- Description Data General Tag Number. P-162 1 Pump designation. RO Flush Pump Number of pumping units required. One Pump location. MF/RO Building required. 1-2.01 General Equipment Requirements e Yes r NO Power supply. 6 480 wlts. 60 Hz. 3 phase Other When "Other" is selected, indicate the alternative. manuals required. -3.02 Operation and maintenance Yes r NO -7 Shop testing. Non-witnessed r Witnessed C Not required -7 Test with the motor or drive unit to r Yes be installed in the Work. No I rype of contract. General Construction r Procurement Service Conditions Pump application. RO Flush Water Seismic zone. 4 Type of environmental exposure. G Indoor r Outdoor (open) r Outdoor (cowred) 3 [1.7 to 381 welaht. Maximum solids concentration, by lnits : ["CI I'C] ?rcent (Carlsbad Water) (Recycling Facilik) (1 -7-02) 11115 -1- Std. Rev. 1.4, 8/7/2000 Start and stop against a closed r Yes alve. c No I bpproximate minimum pump 7 lpercem Maximum power required at pump head. input shaft at any point from 6 [3.7] C Pump Type of efficiency indicated. percent 56 Efficiency. minimum operating head to shutoff bhp [bkWl C Wire to water Efficiency calculated at. Rated head C Ewluated head Pump designed for reverse rotation. r Yes @ No Maximum head for reverse rotation. operating head. Minimum NPSHA at minimum ft [m1 34 [lo] Minimum NPSHA at rated head. ft [mi Maximum suction pressure. 14.7 [loll psi [kPa] Maximum "A weighted noise at 3 ft dBa [dBa] ft [ml 11 ml , , ,,,,. I I IMaximum unfiltered vibration lin./sec. 1 velocity. driven end. Pump rotation as viewed from (rnmk] r Clockwise C Counterclockwise I I IC See drawinas I I (Carlsbad Water) (Recycling Facility) (1-7-02) 11115 -2 - Std. Rev. 1.4, 8/7/2000 size. Minimum test sphere diameter. in. [mm] Materials 2-3 Casing and casing covers. r Cast iron See spec r High chrome alloy text. Impeller. r Cast iron C High chrome alloy r Bronze 6 Stainless steel Casing wearing ring. Stainless steel r Bronze r None Impeller wearing rings. 6 Stainless steel r Bronze r None ConstNction required. 24.01 Flanged cleanout handholes r On discharge On suction 24.02 Type of impeller. Nonclog r Recessed, radial wne r Recessed, CUP type R Open r Enclosed 2-4.02 llmpeller balancing. Ir Static fi Dynamic 24.02 Impeller to shaft attachment. fi Keyed r Threaded 24.02 /Maximum number of impeller ports. I r Single r3 24.05 Type of stuffing box. r Packing 6 Single mechanical r Double mechanical (Carlsbad Water) (Recycling Facility) (1-7-02) 11115 -3- Std. Rev. 1.4, 8/7/2000 b4.05 [Stuffing box lubrication. r Internal r Piped from external source C Piped to suction nozzle 6 Piped h-om discharge nozzle r Galvanized steel r Stainless steel, Alloy Group 1 or 2 Stainless steel, Alloy Group 2 only r Belt, with stationary control r Resilient coupling (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -4- Std. Rev. 1.4. 8/7/2000 Section 1 11 15 HORIZONTAL END SUCTION CENTRIFUGAL PUMPS Data Sheet r Not required 2-7 c yes Test with the motor or drive unit to be installed in the Work. Type of contract. c General Construction No r Procurement Service Conditions Pump application. r Indoor Type of environmental exposure. 4 Seismic zone. Microfiltered wastewater c Outdoor (open) I I IC Outdoor (cowed) I I Ambient air temperature range. Dercent Maximum solids concentration, by "F ["C] 40 to 110 to [4.5 to 431 Liquid temperature range. "F ["C] 35 to 100 [1.7 to 381 beight. I (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -1- Std. Rev. 1.4, 8/7/2000 Counterclockwise (Carlsbad Water) 11115 (Recycling Facility) -2- (1 -7-02) Std. Rev. 1.4. 8/7/2000 Minimum pump suction nozzle size. Minimum pump discharge nozzle size. Minimum test sphere diameter. Materials 2-3 I; Cast iron Casing and casing covers. C High chrome alloy Impeller. Cast iron r High chme alloy r Bronze r Stainless steel Casing wearing ring. Stainless steel r Bronze r None Impeller wearing rings. c Stainless steel r Bronze r None Construction required. 2-4.01 Flanged cleanout handholes r On discharge r On suction 2-4.02 r NOMI~ Type of impeller. r Recessed, radial mne r Recessed, cup type Open p Enclosed 2-4.02 r Static Impeller balancing. C Dynamic Impeller to shaft attachment. i? Keyed r Threaded 2-4.02 r Single Maximum number of impeller ports. r2 r3 /Type of stuffing box. 11- Packing F Single mechanical r Double mechanical 1. [rnm] I. [rnrn] 1. [rnm] lCarlsbad Water) iRecycling Facilh) (1 -7-02) 11115 -3- Std. Rev. 1.4, 8/7/2000 I I I IC5 Resilient coupling I I r Gear coupling I I djustable frequency drives r Yes required. No I I r Piped from external source C5 Piped from discharge nozzle 2-4.a9 (Anchor bolts. 1 C Unfinished carbon steel I 1 r Galwnized steel r By others Motors and Drive Units 2-6 Select type of drive unit. Belt, with fixed sheaes I IC Belt, with stationary control Safety guards required. (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 4- Std. Rev. 1.4, 8/7/2000 Section 11 115 HORIZONTAL END SUCTION CENTRIFUGAL PUMPS PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing and installing of single-stage, horizontal, end suction centrifugal pumping units as required. Each pumping unit shall be complete with a pump, electric motor, coupling, coupling guard, anchor bolts, and other appurtenances specified or otherwise required for proper operation, all mounted on a common baseplate. Pumps of the close-coupled type, with the impeller attached directly to the motor shaft without pump bearings or flexible couplings, will not be acceptable. 1-1.01. Terminology. When the phrase "as required is stated in this section, it shall mean "as required in the attached Data Sheet". 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, and installed in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Hydraulic considerations and definition of terms shall be as set forth in the Hydraulic Institute Standards. 1-2.01. General Equipment Requirements. The General Equipment Requirements shall apply to all equipment furnished under this section. 1-2.02. Taqqinq. Each item of equipment and each part shipped separately shall be tagged and identified with indelible markings for the intended service. Tag number shall be clearly marked on all shipping labels and on the outside of all containers. 1-2.03. Abbreviations. Reference to standards and organizations in the Specifications shall be by the following abbreviated letter designations: AFBMA Antifriction Bearing Manufacturers Association AIS1 American Iron and Steel Institute ANSI American National Standards Institute (Carlsbad Water) (Recycling Faciliiy) ( 1-7-02) 11115 -5- Std. Rev. 1.4, 8/7/2000 ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials IEEE Institute of Electrical and Electronics Engineers uss United States Standard 1-3. SUBMITTALS. 1-3.01. Drawinqs and Data. Complete fabrication and assembly drawings, together with detailed specifications and data covering materials, drive unit, parts, devices, and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. The data and specifications for each unit shall include, but shall not be limited to, the following: Pumps Name of manufacturer, Type and model. Rotative speed. Size of suction nozzle. Size of discharge nozzle. Net weight of pump only. Net weight with baseplate and coupling. Complete performance curves showing capacity versus head, NPSH required, pump efficiency, and pump input power. Type of coupling Data on shop painting Base and anchor bolt details. Baseplate Detailed fabrication drawings. (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -6- Std. Rev. 1.4, 8/7/2000 1-3.02. Operation and Maintenance Data and Manuals. When required, adequate operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals section. Operation and maintenance manuals shall include the following: a. b. C. d. e. f. 9. h. Equipment function, normal operating characteristics, and limiting conditions. Assembly, installation, alignment, adjustment, and checking instructions. Operating instructions for startup, routine and normal operation, regulation and control, shutdown, and emergency conditions. Lubrication and maintenance instructions. Guide to troubleshooting. Parts lists and predicted life of parts subject to wear. Outline, cross-section, and assembly drawings; engineering data; and wiring diagrams. Test data and performance curves, where applicable. The operation and maintenance manuals shall be in addition to any instruction or parts lists packed with or attached to the equipment when delivered. 1-4. QUALITY ASSURANCE. 1-4.01. Balance. All rotating parts shall be accurately machined and shall be in as nearly perfect rotational balance as practicable. Excessive vibration shall be sufficient cause for rejection of the equipment. The mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided. In any case, the unfiltered vibration velocity, as measured at any point on the machine including the motor, shall not exceed the maximum vibration limits of the governing standard unless otherwise required. At any operating speed, the ratio of rotative speed to the critical speed of a unit or its components shall be less than 0.8 or more than 1.3. 1-5. DELIVERY, STORAGE, AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. (Carlsbad Water) (Recycling Facility) ( 1-7-02) 11115 -7 - Std. Rev. 1.4, 8/7/2000 1-6. SPARE PARTS AND ACCESSORIES. The spare parts and accessories as required shall be furnished in substantial wooden boxes with identifying labels and delivered to the vicinity of the project site. PART 2 - PRODUCTS 2-1. SERVICE CONDITIONS. The pumping units shall be suitable for the service conditions as required. Parts shall be interchangeable between units of similar size and capacity to extent practical. All equipment furnished shall be designed to meet all specified conditions and to operate satisfactorily at this elevation. 2-2. PERFORMANCE AND DESIGN REQUIREMENTS. Pumping units shall be designed for the operating conditions as required and as follows: All specified conditions shall be at rated speed unless otherwise indicated The minimum hydrostatic test pressure shall be 1.5 times shutoff head plus maximum suction pressure. Pump performance shall be stable and free from cavitation and noise throughout the specified operating head range at design suction submergences. The design performance shall be based on a wearing ring diametral clearance of not less than 1 mil per inch [25 pm per 25 mm] of wearing ring diameter, or 12 mils [300 pm] total, whichever is greater. 2-3. MATERIALS. Each pump shall be constructed of the following materials as required. Frame Cast iron, ASTM A48 Casing and Casing Covers Iron, where required Cast iron, ASTM A48 Stainless steel, where 316 Stainless Steel reqiured (Carlsbad Water) {Recycling FaGliiy) (1-7-02) 11115 -8- Std. Rev. 1.4, 8/7/2000 Casing Wearing Ring Martensitic stainless steel, Brinell 400+. Impeller, where iron or cast Iron; Cast iron, ASTM A48 iron is required Impeller, where stainless steel Stainless steel; AIS1 Type 316 is required Impeller Wearing Ring Martensitic stainless steel, Brinell 300 to 350. Shaft Carbon steel, AIS1 1045. Shaft Sleeve Stainless steel, AIS1 316. Stuffing Box Hardware Corrosion-resistant metal. For P-1621 and P-1629, it shall be 316 stainless steel. Mechanical Seal (single) Durametallic "Type RO or John Crane "Type 1" or "Type 21". Flexible Coupling, resilient type Resilient type; Falk "Steelflex" or Woods "Sure-Flex"; spacer type. Flexible Coupling, gear type All metal, oil or grease filled; gear type Bearings Antifriction. Baseplate Cast iron or fabricated steel. 2-4. PUMP CONSTRUCTION. 2-4.01. -. The casing assembly and drive connection shall permit the removal of the rotating element without disconnecting the piping. Casing parts shall have registered fit to maintain alignment. The nozzle flanges shall be flat faced, with ANWASME 816.1, Class 125 diameter and drilling. When flanged cleanout handholes are required, they shall have interior surfaces flush with the casing water passages. Pipe-tapped openings shall be provided for draining, priming, and venting the casing, except where Ni-hard or high-chrome cast iron casings are specified. Casings shall be provided with plugged gauge cock connections on the suction and discharge nozzles. (Carlsbad Water) (Recycling Faciliiy) (1 -7-02) 11115 -9- Std. Rev. 1.4, 8/7/2000 2-4.02. Impeller. The impeller shall be a one-piece casting. The impeller shall be completely machined on all exterior surfaces, except when high chrome alloy material is required. The interior water passages shall have uniform sections and smooth surfaces and shall be free from cracks and porosity. The impeller shall be securely locked to the shaft so that it will not be loosened by reverse rotation, but shall be easily removable. Impeller shall be or enclosed, as required, 2-4.03. Shaft and Shaft Sleeves. The shaft shall be completely machined. Deflection at the stuffing box shall not exceed 0.002 inch [50 pm] at any head in the operating range. A suitable splash deflector shall be mounted on the shaft adjacent to the frame bearing housing. The shaft shall be provided with a replaceable sleeve extending from the impeller through the stuffing box. The sleeve shall be positively secured to the shaft and shall be sealed to prevent leakage between the shaft and the sleeve. After assembly on the shaft, total runout shall not exceed 0.002 inch [50 pm]. 2-4.04. Wearinq Rinas. Renewable wearing rings shall be provided in the casing and on the impeller. The rings shall be positively locked in place. 2-4.05. Stuffinq Box. The stuffing box for each pumping unit shall contain a single mechanical seal. Each mechanical seal shall be provided with a flushing water line from the pump discharge to the stuffing box. 2-4.06. Frame Assemblv. The frame assembly shall rigidly support the rotating element with two bearings. The outboard bearing shall carry both axial and radial pump loads. If wearing clearance is axial, the assembly design shall permit axial adjustment of the rotor without dismantling the pump. Bearing enclosures shall keep out contaminants and retain the lubricant and shall have adequate provisions for adding and draining lubricant. The frame shall provide ample clearance for stuffing box maintenance. 2-4.07. Bearinqs. Bearings shall be either oil or grease lubricated, antifriction type. Bearings shall have an AFBMA Llo Life Rating of 40,000 hours at specified operating conditions. The pump shafl speed shall not exceed the limits specified by the bearing manufacturer. 2-4.08. Equipment Bases. Unless otherwise indicated or specified, all equipment will be installed on concrete bases at least 6 inches [I50 mm] high. (Carlsbad Water) (Recycling Facility) (1 -7-02) 11115 -1 0- Std. Rev. 1.4, 8/7/2000 Cast iron or welded steel baseplates shall be provided. Each unit and its drive assembly shall be supported on a single baseplate of neat design. Baseplates shall have pads for anchoring all components, and adequate grout holes. Baseplates shall have a means for collecting leakage and a threaded drain connection. Baseplates for pumps of at least 60 hp [45 kw] shall provide for tapered dowels to maintain alignment of pump and motor. 2-4.09. Anchor Bolts. Anchor bolts and nuts shall be furnished as required for each item of equipment. Anchor bolts, together with templates or setting drawings, shall be delivered sufficiently early to permit setting the anchor bolts when the structural concrete is placed. The bolts shall be at least 3/4 inch [20 mm] in diameter Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter approximately 2-112 times the bolt diameter and a length approximately 8 times the bolt diameter. A square anchor plate with thickness of approximately 112 the bolt diameter and side dimensions 4 times the bolt diameter shall be welded to the bottom of each sleeve, with the anchor bolt extended through the plate and welded thereto. Two nuts and a washer shall be furnished with each anchor bolt. Anchor Bolts and Nuts. Stainless Steel; AIS1 Type 316, 316L; Bolts ASTM F593, Alloy Group 2; Nuts ASTM F594, Alloy Group 2. Flat Washers ANSI 818.22.1; of the same material as the bolts and nuts. Anchor bolts shall be long enough to accommodate at least 1-1/2 inches (40 mm] of grout beneath the baseplate and to provide adequate anchorage into structural concrete. Anti-seize compound will be applied to the threads of all stainless steel bolts before assembly. 2-4.10. Lubrication. Equipment shall be adequately lubricated by systems which require attention no more frequently than weekly during continuous operation. Lubrication systems shall not require attention during startup or shutdown and shall not waste lubricants. Lubricants shall be provided in sufficient quantities to till all lubricant reservoirs and to replace all consumption during testing, startup, and operation prior to (Carlsbad Water) (Recycling Facility) ( 1-7-02) 11115 -11- Std. Rev. 1.4, 8/7/2000 acceptance of equipment. Unless otherwise specified or permitted, the use of synthetic lubricants will not be acceptable. Lubrication facilities shall be convenient and accessible. Oil drains and fill openings shall be easily accessible from the normal operating area or platform. Drains shall allow for convenient collection of waste oil in containers from the normal operating area or platform without removing the unit from its normal installed position. 2-4.1 1. Shop Painting. All steel and iron surfaces shall be protected by suitable coatings applied in the shop. Surfaces which will be inaccessible after assembly shall be protected for the life of the equipment. Coatings shall be suitable for the environment where the equipment is installed. Exposed surfaces shall be finished, thoroughly cleaned, and filled as necessary to provide a smooth, uniform base for painting. Electric motors, speed reducers, starters, and other self-contained or enclosed components shall be shop primed or finished with an oil-resistant enamel or universal type primer suitable for top coating in the field with a universal primer and aliphatic polyurethane system. All other surfaces to be coated after installation shall be prepared for painting as recommended by the paint manufacturer for the intended service, and then shop painted with one or more coats of universal primer. 2-4.12. SDecial Tools and Accessories. Equipment requiring periodic repair and adjustment shall be furnished complete with all special tools, instruments, and accessories required for proper maintenance. Equipment requiring special devices for lifting or handling shall be furnished complete with those devices. 2-5. ACCESSORIES. Each pump shall be provided with lifting eyebolts or lugs; tapped and plugged openings for casing assembly and bearing housing vents and drains; and appropriate fittings for adding bearing lubricant and seal water. Grease lubricated pumping units shall be provided with a means of venting the casing. Oil lubricated units shall be provided with constant level oilers or with sight glasses arranged to indicate operating and static oil levels. 2-6. DRIVE UNITS. Each pump shall be driven by an electric motor through a flexible coupling. Drive units shall be designed for 24 hour continuous service. Gearmotors shall not be used. 2-6.01. Belt Drives. Not used 2-6.02. Couplinas. Couplings shall have a horsepower [kW] rating 1.25 times the motor nameplate horsepower [kW] when the misalignment is within the manufacturer's tolerance limit. Coupling design shall permit removal of the pump rotating element without disconnecting the piping, moving the drive unit, or axial movement of the coupling halves on the shaft. A suitable service factor shall be (Carlsbad Water) 11115 (Recycling Facility) -12- (1-7-02) Std. Rev. 1.4, 8/7/2000 used when the pump is driven by an internal combustion engine. The coupling shall be a spacer coupling, and either resilient type or gear type as required. 2-6.03. Electric Motors. The electric motors shall be designed as specified in Section 16220. 2-6.04. Adiustable Frequency Drives. Not used 2-6.05. Safew Guards. All moving or rotating parts shall be covered on all sides by a safety guard. Safety guards shall be fabricated from 16 USS gage [I .52 mm] thick or thicker galvanized or aluminum-clad sheet steel or from 1/2 inch [12.7 mm] mesh galvanized expanded metal. Each guard shall be designed for easy installation and removal. All necessary supports and accessories shall be provided for each guard. Supports and accessories, including bolts, shall be galvanized. All safety guards in outdoor locations shall be designed to prevent the entrance of rain and dripping water and meet OSHA requirements. 2-7. SHOP TESTS. Each pump shall be tested at the factory for capacity, power requirements, and efficiency at specified rated head, evaluated head, shutoff head, operating head extremes, and at as many other points as necessary for accurate performance curve plotting. All tests and test reports shall be made in conformity with the requirements and recommendations of the Hydraulic Institute Standards. Acceptance testing shall be Level A, with no minus tolerance or margin allowed. For pumping units under 100 horsepower [75 kw], a certified performance curve including head, pump input power, pump efficiency, shall be prepared by the pump manufacturer. Five copies of the certified curve shall be delivered to ENGINEER not less than 10 days prior to the shipment of the equipment from the factory. For pumping units 100 horsepower [75 kW] and larger, a certified test report shall be prepared. Five certified copies of a report covering each test shall be prepared by the pump manufacturer and delivered to ENGINEER not less than 10 days prior to the shipment of the equipment from the factory. The report shall include data and test information as stipulated in the Hydraulic Institute Standards, copies of the test log originals, test reading to curve conversion equations, and certified performance curves. The curves shall include head, pump input power, pump efficiency, and , rpm, and shop test NPSH available, plotted against capacity. The curves shall be easily read and plotted to scales consistent with performance requirements, with all test points clearly shown. When the pump is not tested at the rated speed, performance charts shall include both the test speed and the calculated speed curves. (Carlsbad Water) (Recycling Facility) ( 1-7-02) 11115 -13- Std. Rev. 1.4, 8/7/2000 PART 3 - EXECUTION 3-1. INSTALLATION. Each pumping unit will be installed in accordance with Section 1 1060. Couplings will be realigned after grouting. Final coupling misalignment will be within one-half of the coupling manufacturer's allowable tolerance. 3-2. FIELD QUALITY CONTROL. 3-2.01. Installation Check. An experienced, competent, and authorized representative of the manufacturer shall visit the site of the Work and inspect, check, adjust if necessary, and approve the equipment installation. The representative shall be present when the equipment is placed in operation in accordance with Section 01650, and shall revisit the job site as often as necessary until all trouble is corrected and the equipment installation and operation are satisfactory in the opinion of ENGINEER. The manufacturer's representative shall furnish a written report certifying that the equipment has been properly installed and lubricated; is in accurate alignment; is free from any undue stress imposed by connecting piping or anchor bolts; and has been operated under full load conditions and that it operated satisfactorily. 3-2.02. Installation Supervision. Not used. End of Section (Carlsbad Water) (Recycling Facility) (1-7-02) 11115 -14- Std. Rev. 1.4, 8/7/2000 Section 11 185 SUBMERSIBLE SUMP AND SEWAGE PUMPS Data Sheet [Para- IDescription I Data (Carlsbad Water) (Recycling Facility) 11185 -1- 2-4.07 r Yes. Sump cover required. No. a C Yes. Simplex piggyback control required. 2-8.01 Controls No. 2-8.02 (i Yes. Medium duty simplex control system required. r NO. 2-8.03 r No. r Yes. Heavy duty simplex control system required. I I Medium duty duplex control system (i Nn required. T Yes. ~~ 2-8.05 r Yes. Heavy duty duplex control system . ". required. Installation Installation check required. Yes. No. r NO. (Carlsbad Water) (Recycling Facility) 11185 -2- Section 11 185 SUBMERSIBLE SUMP AND SEWAGE PUMPS PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing and installation of medium and heavy duty single-stage, submersible, end suction centrifugal pumping units and controls for sewage service as required on the drawings. Each pump shall be guiderail-mounted. Piping, pipe supports, and accessories which are not an integral part of the equipment or are not specified herein are covered in other sections. Each pumping unit shall be complete with a close-coupled, submersible electric motor; controls; and all other appurtenances specified or otherwise required for proper operation. The equipment numbers of the pumps are P-0922-1 and P-0922-2. It is intended that one pump be on standby with manual switchover between pumps. 1-1.01. Terrninoloay. When the phrase "as required" is stated in this section, it shall mean "as required in the attached Data Sheet". 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in operating condition in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Hydraulic considerations and definition of terms shall be as set forth in the Hydraulic Institute Standards. 1-2.01, Coordination. CONTRACTOR shall verify that each component of the system is compatible with all other parts of the system; that all piping, materials, pumps, and motor sizes are appropriate; and that all devices necessary for a properly functioning system have been provided. Where two or more units of the same class of equipment are required, they shall be the product of a single manufacturer; however, all the component parts of the system need not be the products of one manufacturer. Each manufacturer of major equipment shall have a local service center, or with written consent of ENGINEER, shall be able to provide service from other locations within 24 hours. The service center shall be equipped and staffed to (Carlsbad Water) (Recycling Facility) 11185 -3- service the system and shall maintain a local parts supply. Information on equipment manufacturers' representatives shall be included with the submittals. Where several manufacturers' names have been listed in this section as possible suppliers, only the products of the first manufacturer listed have been checked for size, functions, and features. 1-2.02. General Eauipment Reauirements. The General Equipment Requirements shall apply to all equipment furnished under this section. 1-2.03. Power Su~plv. Power supply to equipment will be 480-vok 3-phase, 1-2.04. Mechanical Identification. 1-2.04.01. Number Plates. Equipment specified herein shall be provided with an identifying number plate. The identifying text shall be identical to the symbols indicated herein or on the drawings. The number plates shall be located on the equipment and on the associated control panel. Number plate symbols and numbers shall be capitalized block letters with a minimum height of 3/4 inch . Number plate height shall be twice the letter height. Number plates shall be metal or plastic. Plastic number plates shall be laminated phenolic not less than 1/8 inch thick and shall be black with a white core. Metal number plates shall be stainless steel at least 12 gage thickness with engraved or imprinted symbols. Number plates shall be installed with corrosion-resistant mechanical fasteners. 1-2.04.02. Eauipment Plates. Equipment specified herein shall be identified with engraved or stamped equipment plates securely affixed to the equipment in an accessible and visible location. Equipment plates shall be in addition to the number plates specified in the preceding paragraph. Equipment plates shall indicate the manufacturer's name, address, product name, catalog number, serial number, capacity, operating and power characteristics, labels of tested compliances, and any other pertinent design data. Equipment plates listing the distributing agent only will not be acceptable. 1-3. SUBMITTALS. 1-3.01. Drawinas and Data. Complete fabrication and assembly drawings, together with detailed specifications and data covering materials, parts, devices, and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. The data and specifications for each unit shall include, but shall not be limited to, the following: (Carlsbad Water) (Recycling Facility) 11165 -4- PumDs Name of manufacturer. Weil, or equal Type and model. Rotative speed. 1,750 rpm Size and type of pump discharge connection. Net weight of pump and motor only. Complete performance curves showing capacity versus head, bhp , NPSH required, and efficiency. Seal type and manufacturer. Data on shop painting. Motors Name of manufacturer. Type and model. Type of bearings and method of lubrication. Rated size of motor, hp . 1.5 Full load current. Locked rotor current. Control Panel and ComDonents Name of manufacturer. Type and model. Dimensions and net weight of complete panel. Overcurrent characteristics and details of motor control, Short circuit rating of assembly. Liquid level sensors with mounting details and cable lengths, and sump controls. (Carlsbad Water) (Recycling Facility) 11185 -5- Wiring diagrams. Power and control cable type and size. Accessories Sump Cover (not required) Guiderail System Materials. Dimensions. 1-3.02. Operation and Maintenance Data and Manuals. Operation and maintenance manuals shall be supplied and shall be submitted in accordance with the submittals section. Equipment designations used shall correspond to those indicated on the drawings. Operation and maintenance manuals shall include the following: a. b. C. d. e. f. 9. h. Equipment function, normal operating characteristics, and limiting conditions. Assembly, installation, alignment, adjustment, and checking instructions. Operating instructions for startup, routine and normal operation, regulation and control, shutdown, and emergency conditions. Lubrication and maintenance instructions. Guide to troubleshooting. Parts lists and predicted life of parts subject to wear. Outline, cross-section, and assembly drawings; engineering data; and wiring diagrams. Test data and performance curves, where applicable. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. 14. DELIVERY, STORAGE, AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the (Carlsbad Water) (Recycling Facility) 11185 -6- handling and storage section. 1-5. EXTRA MATERIALS. When extra materials are required, a complete set of seals, O-rings, and gaskets, and one spare set of mechanical seals shall be furnished for each type and size of pump provided. One set of power and seal cords. Extra materials shall be packaged with labels indicating the contents of each package. Each label shall indicate the manufacturer’s name, equipment designation, part nomenclature, part number, address of nearest distributor, and current list price. Extra materials shall be delivered to OWNER as directed. Extra materials subject to deterioration such as ferrous metal and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. PART 2 - PRODUCTS 2-1. SERVICE CONDITIONS. Unless otherwise indicated in the schedules,sewage pumps shall be suitable for pumping sanitary waste and sludge and shall pass a 2 inch sphere. The maximum pumped liquid temperature shall be as required. 2-2. PERFORMANCE AND DESIGN REQUIREMENTS. Pumping units shall be designed for the following operating conditions and requirements: Design flow: 95 gpm Design head: 16 ft Shutoff head: not less than 20 ft Design flow range: 65 - 125 gpm Pump performance shall be stable and free from cavitation and noise throughout the specified operating head range at minimum suction submergences. Minimum pump hydrostatic test pressure shall be 1.5 times the pump shutoff head. Each pumping unit shall be designed so that reverse rotation at rated head will not cause damage to any component. 2-3. MATERIALS. Stator Housing and Pump Cast iron, ASTM A48. Casing Impeller Sewage Pumps (Carlsbad Water) (Recycling Facility) Cast Iron 11185 -7- Shaft Stainless steel, AIS1 Type 316. All Wetted Assembly Fasteners Stainless steel. Mechanical Seals Double mechanical opposed type or tandem mechanical type as required, oil lubricated with silicon carbide upper seal and carbordceramic lower seal. Cast iron. Pedestal Base Epoxy Coating Primer & Finish Coat Carl: loline "Carboguard 891" or Tnemec "Series N140 Pota-Pox Plus". 2-4. PUMP CONSTRUCTION. 2-4.01. Impeller Casing. The impeller casing shall have well-rounded water passages and smooth interior surfaces free from cracks, porosity, blowholes, or other irregularities. Guiderail mounted pumps shall be provided with a flanged discharge nozzle sufficiently rigid to support the pumping unit under all operating conditions. Pedestal mounted pumps shall be provided with a threaded or ANSMASME B1.20.1, NPT. compression discharge connection. Pipe threads shall conform to 2-4.02. Impeller. The impeller shall be a semiopen or enclosed one-piece casting. Sewage pump impellers shall not have more than two nonclog passages. The interior water passages shall have uniform sections and smooth surfaces and shall be free from cracks and porosity. The impeller shall be dynamically balanced and securely locked to the shaft by means of a key and self-locking bolt or nut. 2-4.03. Seal Chamber. Each heavy duty pumping unit shall be provided with an oil-filled chamber for seal lubrication. The chamber shall contain a moisture sensor and shall be provided with a fill/drain plug. 2-4.04. Sealira of MatinQ Surfaces. All mating surfaces of major components shall be machined and fitted with O-rings where watertight sealing is required. Sealing shall be accomplished by O-ring contact on four surfaces and O-ring compression in two planes, without reliance on a specific fastener torque or tension to obtain a watertight joint. The use of elliptical O-rings, gaskets, or seals (Carlsbad Water) (Recycling Facility) 11185 -8- requiring a specific fastener torque value to obtain and maintain compression and watertightness will not be acceptable. The use of secondary sealing compounds, gasket cement, grease, or other devices to obtain watertight joints will not be acceptable. 2-4.05. Guiderail Removal Svstern. pumping units shall be provided with a guiderail removal system. The removal system shall be provided with a discharge base, sliding bracket, guiderails, fasteners, and all other accessories indicated or required for a complete system. 2-4.05.01. Discharae Base. The discharge base shall be sufficiently rigid to firmly support the guiderails, discharge piping, and pumping unit under all operating conditions. The base shall be provided with one or more integral support legs or pads suitable for bolting to the floor of the sump. The face of the discharge elbow inlet flange shall be perpendicular to the floor and shall make contact with the face of the pump discharge nozzle flange. The diameter and drilling of the elbow outlet flange shall conform to ANSI 816.1, Class 125. The pump and motor assembly shall be automatically connected to and supported by the discharge base and guiderails so that the unit can be removed and replaced without the need for operating personnel to enter the sump. 2-4.05.02. Slidins Bracket. The sliding bracket shall be self-aligning type. The bracket shall be designed to obtain a wedging action between flange faces as final alignment of the pump occurs in the connected position. The bracket shall maintain proper contact and a suitably sealed connection between flange faces under all operating conditions. 2-4.05.03. Guiderails. Guiderails shall be sized to fit the discharge base and the sliding bracket and shall extend upwards from the discharge base to the access hatch cover at the top of the sump. Guiderails shall be stainless steel pipe, ASTM A312, Schedule 40s. An upper guiderail bracket of AIS1 Type 304 stainless steel shall be provided. 2-4.06. Liftins Chain. stainless steel chain or cable suitable for removing and installing each pumping unit shall be selected and provided by the pump manufacturer. The chain or cable shall be rated for at least four times the weight of the pumping unit and shall be of adequate length to reach five feet above the sump cover with the pumping unit in the normal operational position. 2-4.07. SumD Cover. Not used. 2-4.08. Lubrication. Equipment shall be adequately lubricated by systems which require attention no more frequently than weekly during continuous operation. Lubrication systems shall not require attention during startup or shutdown and shall not waste lubricants. (Carlsbad Water) (Recycling Facility) 11185 -9- Lubricants of the types recommended by the equipment manufacturer shall be provided in sufficient quantities to fill all lubricant reservoirs and to replace all consumption during testing, startup, and operation prior to acceptance of the equipment by OWNER. Unless otherwise specified or permitted, the use of synthetic lubricants will not be acceptable. Lubrication facilities shall be convenient and accessible. Oil drains and fill openings shall be easily accessible from the normal operating area or platform. Drains shall allow for convenient collection of waste oil in containers from the normal operating area or platform without removing the unit from its normal installed position. 2-4.09. Anchor Bolts. Anchor bolts, expansion anchors, nuts, and washers shall be as indicated in the anchorage in concrete and masonry section unless otherwise indicated on the drawings. 2-4.10. Special Tools and Accessories. Equipment requiring periodic repair and adjustment shall be furnished complete with all special tools, instruments, and accessories required for proper maintenance. Equipment requiring special devices for lifting or handling shall be furnished complete with those devices. 2-5. FABRICATION AND MANUFACTURE. 2-5.01. ShoD Painting. All iron and steel parts of heavy duty pumping units which will be in contact with pumped liquid or submerged after installation, including the inside of the casing, the impeller, and the discharge elbow, shall be shop cleaned in accordance with the coating manufacturer's recommendations and painted with an epoxy coating system. The coating shall have a dry film thickness of at least 10 mils and shall consist of a prime (first) coat and one or more finish coats. At least 1 quart of the finish coat material shall be furnished with each pump for field touchup. All other iron and steel surfaces of the equipment shall be protected with suitable protective coatings applied in the shop. Surfaces of the equipment that will be inaccessible after assembly shall be protected for the life of the equipment. Coatings shall be suitable for the environment where the equipment is installed. Exposed surfaces shall be finished, thoroughly cleaned, and filled as necessary to provide a smooth, uniform base for painting. Electric motors, speed reducers, starters, and other self-contained or enclosed components shall be shop primed or finished with an oil-resistant enamel or universal type primer suitable for top coating in the field with a universal primer and aliphatic polyurethane system. Surfaces to be coated after installation shall be prepared for painting as (Carlsbad Water) (Recycling Facility) 11185 -1 0- recommended by the paint manufacturer for the intended service, and then shop painted with one or more coats of the specified primer. 2-6. BALANCE. All rotating parts shall be accurately machined and shall be in as nearly perfect rotational balance as practicable. Excessive vibration shall be sufficient cause for rejection of the equipment. The mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided. In any case, the unfiltered vibration displacement (peak-to-peak), as measured at any point on the machine, shall not exceed 4 mils for pumping units with a nominal rotative speed of 1500 rpm or greater, 5 mils for pumping units with a nominal rotative speed less than 1500 rpm and greater than 900 rpm, or 6 mils for pumping units with a nominal rotative speed of 900 rpm or less. At any operating speed, the ratio of rotative speed to the critical speed of a unit or its components shall be less than 0.8 or more than 1.3. 2-7. MOTORS. 2-7.01. Motors. Pumps shall be driven by an air-filled, totally submersible electric motor manufactured by the pump manufacturer. Motors shall have a minimum service factor of 1.15. Motor nameplate rating shall exceed the maximum horsepower required by the pump in an operating head range 20 percent above or below the design point. The stator housing shall be an air-filled, watertight casing. Motor insulation shall be moisture resistant, Class F, 155°C. Each motor shall be NEMA Design B for continuous duty at 40°C ambient temperature, and designed for at least 10 starts per hour. Motor bearings shall be antifriction, permanently lubricated type. The lower bearing shall be fixed to carry the pump thrust and the upper bearing free to move axially. The bearings shall have a calculated AFBMA Ll0 Life Rating of 40,000 hours when operating at maximum operating head. Maximum shaft runout at the mechanical seals shall not exceed 2 mils at any point in the operating head range. Each pump shall be equipped with one or more multiconductor cable assemblies for power and control. Each multiconductor assembly containing power cables shall be provided with a separate grounding conductor. Each cable assembly shall bear a permanently embossed code or legend indicating the cable is suitable for submerged use. Cable sizing shall conform to NEC requirements. All cables shall be of sufficient length to terminate in a junction box or control panel outside the sump as indicated on the drawings, with 10 feet of slack which will be coiled in the sump. Each cable shall be supported by AIS1 Series 300 corrosion-resistant stainless steel Kellems or woven grips to prevent damage to the cable insulation. Mounting of cable supports in the sump shall be coordinated by the supplier to prevent damage to the cable. (Carlsbad Water) (Recycling Facility) 11185 -1 1- The cable entry water seal shall include a strain relief and a grommet type seal designed so that a specific fastener torque is not required to ensure a watertight, submersible seal. The cable entry junction box and motor shall be separated by a stator lead sealing gland or a terminal board. The junction box shall isolate the motor interior from moisture gaining access through the top of the stator housing. The motor and its integral protective controls shall be rated and labeled for use in an exposure classification similar to that of the pump, under both submerged and unsubmerged conditions. 2-8. CONTROLS. Each pumping unit shall be provided with a complete control system as indicated herein. 2-8.01. Simplex Piaavback Control. Not used. 2-8.02. Medium Dutv Simplex Control Svstem. Medium duty simplex control systems shall consist of a control cabinet and sump level sensors for control of medium duty simplex pumping systems. 2-8.02.01. Control Cabinet. The control cabinet shall include circuit breaker combination motor starters for each pump and all other controls specified herein, indicated on the drawings, or required for a properly operating system. The cabinet shall include the following features and devices: NEMA Type 4X construction. Assembly rated 42 kAlC at 480 volts. Circuit breaker disconnect switch. NEMA rated magnetic starter with individual circuit breaker, solid-state overloads and phase loss protection. Three-position on-off-automatic selector switch@). High water audible and visual alarm. Power on indicating light (green). Running light (red). Numbered and wired terminal strip. Control transformer. Alarm bell (4 inch [IO0 mm] size) and light. (Carlsbad Water) (Recycling Facility) 11185 -12- Isolated dry type contact for remote high water alarm, rated 5 amperes at 120 volts. Alarm reset pushbutton. Indicator lights identifying the duty pump. Indicator lights identifying each pump alarm. 2-8.02.02. Liauid Level Sensors. Liquid level sensors consisting of an assembly of weighted ball floats with integral switches shall be furnished by the pump manufacturer. The sensors shall be suitable for simplex pump operation with high water alarm and shall be Weil"8230 Series". Each system of sensors shall be furnished complete with all required mounting brackets, weights, galvanized steel mounting pipes and accessories, control power transformers, auxiliary relays, cables, and junction boxes. 2-8.02.03. Control Seauence. Upon an increase in sump liquid level, the pump shall be energized. If the liquid level continues to rise, the high water alarm light located on the face of the pump control panel shall be illuminated, an audible alarm shall be sounded, and the isolated alarm contact shall close. As the sump liquid level decreases to the "Pumps Off' setpoint, the pump shall be de- energized. Sump liquid level setpoints shall be as follows: Pump start: EL 53.5 High level alarm: EL 57.5 Low level "pump off: EL 52.5 2-8.03. Heavv Dutv Simplex Control Svstem. Not used. 2-8.04. Medium Dutv Duplex Control Svstem. Not 2-8.05. Heavv Dutv Duplex Control Svstem. Not PART 3 - EXECUTION 3-1. INSTALLATION. Equipment and materials furnished under this section shall be installed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Pumping units shall be leveled, plumbed, aligned, and wedged into position to fit connecting piping. Installation procedures shall be as recommended by the pump manufacturer and the Hydraulic Institute Standards. Grouting shall be as (Carlsbad Water) (Recycling Facility) 11185 -1 3- specified in the grout section. Special care shall be taken to ensure that piping stresses are not transmitted to the pump connections. After final alignment and bolting, pump connections shall be tested for applied piping stresses by loosening the pump connections. If any movement or opening of the joints is observed, piping shall be adjusted to proper fit. Control cables shall be supported to avoid tension and damage. Liquid level sensors shall operate freely and shall be adjusted to the levels indicated on the drawings. 3-2. INSTALLATION CHECK. An experienced, competent, and authorized representative of the manufacturer shall visit the site of the Work and inspect, check, adjust if necessary, and approve the equipment installation. The representative shall be present when the equipment is placed in operation in accordance with Section 01650, and shall revisit the job site as often as necessary until all trouble is corrected and the equipment installation and operation are satisfactory in the opinion of ENGINEER. The manufacturer’s representative shall furnish a written report certifying that the equipment has been properly installed and lubricated; is in accurate alignment; is free from any undue stress imposed by connecting piping or anchor bolts; and has been operated under full load conditions and that it operated satisfactorily. All costs for these services shall be included in the contract price. 3-3. STARTUP AND TESTING. Startup requirements and field performance testing shall be as indicated in Section 01650. End of Section (Carlsbad Water) (Recycling Facility) 11185 -1 4- SECTION 11213 RO MEMBRANE FEED PUMP PART 1 -GENERAL 1.01 DESCRIPTION Description of Work: 1. The Contractor shall furnish all labor, materials, equipment and incidentals required, install, shop test, field test, and complete for operation of two (2) RO membrane feed pumps including the respective motors as shown on the Drawings and specified herein. All necessary and desirable accessory equipment and auxiliaries whether specifically called out in this specification or not shall be furnished and installed as required for an installation incorporating the highest standards for this type of service. Also included shall be supervisory services during installation and field testing of each unit and instructing the regular operating personnel in the proper care, operation, and maintenance of the equipment. 2. The Contractor shall be responsible for coordinating the pump motor requirements with the adjustable speed drives (AFD) to be supplied under Section 16150. Type: 3. The RO membrane feed pumps shall be a multi-stage vertical turbine can type, with inline above grade suction and discharge flanges, open line shaft design with water lubricated bearings. Equipment List: RO Membrane Feed Pump No. 1 RO Membrane Feed Pump No. 2 1.02 QUALITY ASSURANCE Performance and Design Requirements: 1. Service Conditions: a. Liquid Pumped: RO Feedwater. P-1604-1 P-I 604-2 b. Corrosion Factors: The RO feed will have been pretreated with a threshold inhibitor and 93 percent sulfuric acid. Anticipated pH is between 5 and 7. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -1- c. Temperature at Guarantee Point: 70 OF. d. Specific Gravity: 1 .O 2. Running Clearances: Performance of each pump shall be stable and free from damaging cavitation, vibration, and noise in the operating head range. The performance of each pump shall be based OR a radial running clearance between the bowl wearing ring and impeller as follows: Diameter of Rotating Member Minimum Diametrical at Clearance Clearance [inches] <2.000 [inches] 0.017 5.000 - 5.999 0.016 4.500 - 4.999 0.016 4.000 - 4.499 0.016 3.500 - 3.999 0.014 3.000 - 3.499 0.012 2.500 - 2.999 0.01 1 2.000 - 2.499 0.010 The above requirements shall not apply to bowl, stuffing box or column bearings. 3. Balance: a. All rotating parts shall be accurately machined and shall be in as nearly perfect rotational balance as practicable. b. Excessive vibration shall be sufficient cause for rejection of the equipment. c. The mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided. In any case, the vibration displacement (peak-to-peak) as measured at any point on the assembly shall not exceed 3 mils at the highest point on the motor. d. At any operating speed, the ratio of rotative speed to the critical speed of a unit or components thereof shall be less than 0.8. Pump Motor and Drive Coordination: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -2- 4. The pump shall be matched to the driver, such that pump operation does not exceed the driver rating at any point on the pump operating curve, without consideration of overload capabilities of the drive system. 5. A torsional and lateral analysis shall be performed on the pump and motor as a unit to identify the critical speeds of the system. The contractor shall submit the torsional analysis to the Owner’s Representative for review during the submittal process. The pumps shall not be shipped to the site with calculated critical speed(s) between 980 and 2100 rpm without written approval of the Engineer. Operating Requirements for both Membrane Feed Pumps: Characteristic Value Capacity at first rating point, gpm Total head at first rating point, feet Shutoff head (approximate), feet Minimum guaranteed efficiency at first operating point, % Capacity at second rating point, gpm Minimum total head at second rating point, feet Pump suction diameter, inches Pump discharge diameter, inches Pump speed, maximum, rpm Nominal motor speed, rpm Minimum motor size, hp 300 635 800 75 300 290 4 3 1750 1800 75 The total head requirements specified above shall be as measured at the discharge of the pump head. Therefore, the pump bowl shall have additional head capacity to accommodate the loss through the pump column and elbow. Similarly, the pump efficiency specified shall be as measured at the discharge of the pump head. The pump characteristic curve shall be continuously rising towards the shutoff head without dipping. Seismic Consideration: 6. The anchoring of the pumps and motors shall be designed in accordance with the requirements for Seismic Zone 4 of UBC andlor SEAC. Each piece of equipment shall be anchored to resist a minimum lateral seismic force of 43 percent of the operating weight of the equipment. This force shall be considered acting at the center of gravity of the piece under consideration. Factory Tests: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -3- 7. General: a. Conduct tests on actual equipment to be furnished to the job site, including pump discharge head and barrel, as applicable. b. Notify the Owner's Representative two weeks prior to equipment functional and performance tests. c. Furnish certified test reports which include test data sheets, performance test logs, and equipment performance curves, as applicable. Indicate separately equipment guaranteed operating points identified in the specifications, including efficiency. 8. Materials Certifications a. Provide material certifications for pressure containing components of pump assemblies, including pipe and plate for fabricated assemblies, weld rods, mechanical seal, and the stuffing box. Material certifications for other components shall be furnished if requested by the Owner's Representative. 9. Functional Tests: a. Pumps may be tested with the manufacturer's equivalent calibrated test motor. b. Test for acceptable dynamic balance of components. c. Measured vibration levels shall be as specified herein d. Test both pumps for sound pressure level. Conduct test on combined pump and motor assembly as a single unit. 10. Performance Tests: a. Pumps may be tested with the manufacturer's equivalent calibrated test motor. b. Operate each pump and motor under simulated operating conditions for a continuous three hour period. Record the following parameters on test logs: 1) Capacity over the full operating range of the pump. 2) Total head over the full operating range of the pump. 3) Horsepower requirements over the full operating range of the pump. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -4 - 4) Driving motor voltage, amperage, and kilowatts measured for each phase. 1.03 ENVIRONMENTAL CONDITIONS The equipment furnished under this section will be installed at the locations shown. The ambient temperatures are expected to range between 35 degrees F and 100 degrees F with relative humidity that varies from 10 to 100 percent. 1.04 SUBMITALS Scope: 1. All of the material required for submittal under this section shall be furnished in one complete package. Submittals shall comply with the requirements of Sections 01300, and 16220. In addition, the Contractor shall submit to the Owner's Representative for his acceptance the proposed factory testing procedures for the pumping units at least 30 days prior to the proposed testing date. General: In addition to the items required in Paragraph 11213-1.04 A, submittal data shall be required as follows: 2. 3. 4. 5. 6. Pumps: Manufacturer's qualifications Outline installation drawings for the pumping unit. Certified calculations for design of the equipment anchoring system to demonstrate compliance with seismic requirements herein. Certified copies of the pump test data, calculations and final pump performance curves as specified in Paragraph 11213-1.02 C. Manufacturer's calculation for head loss through pump column and discharge elbow shall also be submitted. Other data as required for complete installation of the pumps. In addition to the items required in Paragraph 11213-1.04 A, submittal data shall be required as follows: 7. Net weight of complete pumps 8. Maximum pump downthrust. 9. Complete shaft dimensions. IO. Impeller diameter (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -5- 11. Pump performance curves for (head-capacity, horsepower- capacity, efficiency-capacity) and head loss for the pump column and discharge elbow. 12. Drawings showing outline dimensions and arrangement of bearings, mechanical seal, wearing rings and suction and discharge nozzles. 13. Details of pump support Motors: In addition to the items required in Subsection 1.04 A, submittal data shall be required as follows: 14. Guide and thrust bearings selected and their AFBMA B-10 rating life for continuous operation conditions of service. 15. The motor manufacturer’s certification of motor compatibility with specified variable speed control systems specified in Section 16150. 1.05 STANDBY COMPONENTS Furnish the following for each pump: 1. Two (2) sets of bearings. 2. Two (2) complete mechanical seals. 3. Two (2) complete sets of auxiliary seals. PART 2 - PRODUCTS 2.01 GENERAL Scope: Furnish two membrane feed pumps complete with electric motors, adjustable frequency drives (AFD), shafting, bearings, sole plates, suction cans, discharge heads, bowl assemblies, anchor bolts, and all other accessories required for complete installation. Pump Manufacturers: 1. Afton Pumps Inc.; 2. Flowserve; 3. Or equal. Motor Manufacturers: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -6- 4. US. Motors; 5. General Electric; 6. Or equal. 2.02 MATERIALS Pump bowls: Stainless steel ASTM A351, Grade CF3M, Type 316L. Bowl Wearing RingsBabbited carbon. Impellers: Stainless steel ASTM A351, Grade CF3M, Type 316L. Impeller Wearing Rings: Stainless steel ASTM A276 or A351, Type 316L. Bowl Assembly Shaft: Stainless steel ASTM A276, Type 316. Bowl and Suction Bell Bearings: Babbited carbon. Mechanical Seal, Stuffing Box, Gland, Seal Sleeve and Drive Collar: 316L stainless steel. Suction Barrel (Can) and Discharge Head: Fabricated Type 316L stainless steel: 1. Pipe: ASTM A312, Grade TP316L. 2. Motor Plate: ASTM A240, Grade TP316L. 3. Flanges: ASTM Al82, Grade F316L. Secondary Elastomeric Seals: EPDM or Viton. Coupling Guard: Type 316 stainless steel. Fasteners: Type 316 stainless steel. Seal Water Pipe, Tube and Fittings: Type 316L stainless steel 2.03 PUMP CONSTRUCTION Discharge Head: 1. Head shall be a one piece fabricated design from seamless 0.375- inch wall pipe to support the drive unit and entire pump assembly. 2. Suitable openings shall be provided for access to the mechanical seal and other accessories. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -7- 3. The motor mounting flange shall have registered ffis to insure accurate alignment of the drive motor to the pump shaft. 4. A suitable mechanical seal leakage collector with a 112-inch tapped drain opening shall be provided. Each pocket shall have a drain connection. 5. The pump suction connections shall be 4-inch, flanged, ANSI Class 150, integral with the discharge head. 6. The pump discharge connections shall be 3-inch, flanged, ANSI Class 300, integral with the discharge head. 7. A 1/2-inch NPT tapped and plugged pressure gauge connection shall be provided on the horizontal centerline of the pump discharge outlet and suction inlet. The connection size and configuration shall conform to Figures 30 and 40 of the Hydraulic Institute Standards. Mounting flanges: 8. A rigid mounting flange shall be provided to support each pump can. 9. The mounting flanges shall have rounded corners; abutting surfaces between components shall be machined to provide uniform bearing. 10. Provide a center opening large enough to permit withdrawal of the entire pump assembly. Suction Barrels: Fabricated, 13-112 inch OD, 3/8-inch minimum wall, for use with the specified discharge head. Impellers and Bowls: 11. Impellers shall be enclosed type 12. Impellers shall be accurately machined, dynamically balanced and securely locked on the pump shaft by means of double longitudinal shaft keys and circular thrust washers for each impeller. 13. Bowls shall be equipped with wearing rings. Wearing rings shall be designed to maintain pump efficiency. Wearing ring's shall be securely locked in place so that they will not move or loosen during any condition of operation or handling, including reverse rotation of the pump. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -0- Shafting: 14. The shaft shall be a one-piece design with no reduction in diameter through the stuffing box. 15. Shafting shall be precision ground and polished pump quality. 16. Shaft diameter shall not be less than the minimum permitted for the applicable driver nameplate horsepower rating. Couplings: 17. A rigid four piece adjustable spacer type coupling shall be furnished for each pump. 18. The spacer length shall be long enough to permit removal of the mechanical seal assembly without removing the drive motor. 19. The coupling shall be nickel plated to prevent atmospheric corrosion. Coupling bolting shall be Type 316 stainless steel. 20. Coupling alignment shall provide for a maximum pump shaft run out of 0.002-inch TIR. Mechanical Seals: The mechanical seal assembly shall be a cartridge type, John Crane Type 8B1. Seal Flush Tubings: Seal flush tubing and fittings shall provide for recirculation from the seal chamber back to the pump suction. 2.04 DRIVE MOTORS A. Motors shall be as specified in Section 16220. PART 3 - EXECUTION 3.01 INSTALLATION General: The Contractor shall be responsible for the proper installation of all system components. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer's printed instructions, and approved shop drawings. 1. Follow the manufacturer's printed installation instructions and recommendations. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 -9- 2. 3. 4. 5. 6. 7. 8. Do not place sensitive components (e.g., pump column or bowl assembly) directly on the ground. Properly support using wooden blocks. Place equipment on concrete base at least 3-inches wider and longer than the base plate. Install anchor bolts plumb and at the proper location Locate and level each of the pump cans using double tack welded steel shims, wedges, or plates to assure in-line and unstressed suction and discharge piping connections to the pump housing. Unbolt completed pipe connections in the presence of a representative of the Owner's Representative to verify correct alignment. Prevent vertical movement of the pump can with 2 nuts on each anchor bolt. Lubricate the bolts to prevent seizing. After the pump, pump can and motor have been secured in position, fill the void between the pump can mounting flange and the equipment base with non-shrink grout of the correct mixture to assure a solid foundation for the equipment. Correct conditions causing excessive pump, motor, or connector noise, chatter, or vibration after installation. 3.02 FIELD TESTING Testing and Startup Responsibilities: 1. Perform all Work for equipment functional and performance tests specified herein and in Section 01650. 2. Complete all Work associated with the unit and related processes before testing, including related manufacturer's representative services. 3. Provide all related operating and maintenance manuals, and spare parts and special tools as specified before testing any unit or system. 4. Furnish qualified manufacturer's representatives when required to assist in testing. 5. Utilize an approved Manufacturer's Certificate of Proper Installation Form, supplemented as necessary, to document all functional and performance procedures, results, problems, and conclusions. (Carlsbad Water) (Recycling Facility) (1 00% Submittal) 11213 -10- 6. Schedule and attend pretest (functional and performance) meetings related to test schedule, plan of test, materials, chemicals, and liquids required, facilities' operations interface, Owner and Contractor involvement. Functional Testing: 7. General: Conduct an initial functional test on each RO membrane feed pump system to demonstrate the proper installation and operation. Submit report documenting each test in a format acceptable to the Owner's Representative. 8. Alignment: Test complete pump assemblies for correct rotation, proper alignment and connection, and quiet operation. 9. Vibration Test: a. Provide a third party contractor to conduct vibration analyses on each pump and motor assembly. b. Operate the installed pumps over the full intended range of operation. Variable speed pumps shall be operated over the intended range in 100 rpm increments. c. Pumps shall not develop at any frequency or in any plane, peak to peak vibration amplitudes in excess of 3 mils, or within manufacturer's tolerances, or more specific tolerances specified for individual equipment items herein-whichever is more stringent. d. The natural frequency of the complete assemblies must be avoided by k25 percent by any exciting frequency of the assembly throughout the entire operating range. e. A certificate of compliance shall be placed in the startup file for the RO membrane feed pumps. f. Units failing to meet the requirements specified shall be adjusted or modified in order to comply. Units which cannot be adjusted or modified to conform as specified shall be replaced, unless otherwise agreed in writing by the Owner. 10. Operating Temperatures: a. Monitor bearing areas on pump and motor for abnormally high temperature. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 - 11 - b. Place a certificate of compliance in the startup file for each equipment item. Performance Testing: 11. General: a. Prior to complete system startup, the RO membrane feed pump system shall undergo an individual performance test to demonstrate and confirm that the equipment meets the performance requirements specified herein. b. Include a compliance report documenting the test in a format acceptable to the Owner’s Representative in the startup file for this system. c. Operate the pumps, motors and drives over a period of at least three hours. d. Adjust pump discharge pressure and flow and plot a system of curves in a format acceptable to the Owner’s Representative. Units of flow shall be gallons per minute. Units of pressure shall be feet of water. Curves shall cover the full safe operating range of the pump, include four intermediate points. e. In addition to pressure and flow, measure at each point and tabulate for each phase voltage, amperage, kilowatts and horsepower. f. Check each power lead to the motor for proper current balance. g. Compare performance test results to the manufacturer’s equivalent shop test data. h. Field test results differing substantially from manufacturer’s shop data shall be investigated, the units adjusted, and re- tested. i. Units failing to meet requirements of the specifications shall be replaced with conforming units. 3.03 TRAINING The services of a qualified representative of the pump manufacturer shall be furnished to instruct the plant personnel in its operation and maintenance. Instruction of plant personnel shall be in accordance with Section 01400. A minimum of four hours training shall be provided. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11213 - 12 - SECTION 11225 SOLIDS CONTACT CLARlFlERmHlCKENER PART 1 - GENERAL 1-1, SCOPE. This section covers the furnishing and installation of a solids contact clarifierlthickener, complete with all equipment and appurtenances specified or required to provide a complete and satisfactory thickening system. Principal items to be furnished and installed hereunder shall include the following: Thickener internal equipment Sludge recirculation pumps 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by the Engineer. Equipment shall be furnished and installed complete with all anchors and supports; all mechanical equipment required for proper operation; all fiberglass reinforced plastic, metal, and other construction indicated on the drawings; and all additional materials of construction required by the manufacturer's design. Contractor shall coordinate with the equipment manufacturer to ensure the concrete basins for the thickener are constructed to the exact dimensions required by the equipment furnished. 1-2.01. GENERAL EQUIPMENT STIPULATIONS. The General Equipment Stipulations shall apply to all equipment furnished under this section. 1-3. POWER SUPPLY. The thickener unit shall be powered from a single 480 volt, 60 Hz, three phase, power supply, 1-4. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with detailed specifications and data covering materials of construction, equipment, parts, devices, motors, arrangement details, loadings, elevations, and other accessories forming a part of the thickening system, shall be submitted in accordance with the submittals section. Complete descriptive data for thickener materials shall be submitted for review prior to shipment. Electrical schematics, wiring diagrams, and panel layout drawings for reactor turbine, sludge scraper mechanism, sludge recirculation pumps, and lamellar tubes shall be included. In (Carlsbad Water) (Recycling Facility) (REV C - 12/11 ) 11225 -i - addition, operation and maintenance manuals for the thickener equipment shall be submitted in accordance with Section 1300-Submittals. Each supplier shall submit a list of at least 5 United States installations on similar applications that have been in continuous operation for at least 2 years in concrete basins. The data and specifications for the solids contact clarifierhhickener shall include, but shall not be limited to the following: A) Product Data: Submit product data, including Manufacturer’s data, for specified products. i) System Description: Include system description including the following: (a) Manufacturer’s data, order sheet, or equivalent for each major piece of equipment, component, instrument or device being supplied. (b) Manufacturer’s outline and mounting dimensions for all field mounted devices, including the sensors, drives, motors, pumps, valves and pneumatic operators, instrumentation and controls, including control panels (if required). (c) Manufacturer’s wiring diagrams for instrumentation and control system, including necessary field connections (if required). (d) Mounting details, color selection and scaled layout drawings for control panels (if required), clarification/thickener equipment, valves and operators, piping, and instruments. (e) All equipment to be furnished under this Section must be approved prior to being released for manufacturing unless otherwise noted by the Engineer. (f) Instrument and control panel layout to scale and dimensioned, with overall size, mounting and field entries dimensioned. (9) Clarification equipment, valves, operators, piping, control panels (if required), etc., required for the treatment unit. ii) Statement: Confirmation that system including work and equipment locations is acceptable, or a list of those areas that must be changed to be compatible with the equipment being proposed. B) Shop Drawings: Submit shop drawings showing layout, profiles and product components, including accessories, finish colors, etc. C) Wiring Diagrams: Submit “as installed” straight-line wiring diagrams showing electrical connections of equipment. Furnish legend sheet with appropriated schematic reference number with drawings to provide (Carlsbad Water) (Recycling Facility) (REV C - 12/11 ) 11225 -2- electrical information. Wiring and labeling on electrical panels shall required approval. D) Quality Assurance Submittals: Submit the following: i) Certificates: Product certificates signed by Manufacturer certifying materials comply with specified performance characteristics and criteria, and physical requirements. ii) Manufacturer‘s Instructions: Manufacturer’s installation instructions. E) Closeout Submittals: Submit the following: i) Operation and Maintenance Data: Operation and maintenance data for installed products in accordance with Division 1 Closeout Submittals (Maintenance Data and Operation Data) Section. Include methods for maintaining installed products, and precautions against cleaning materials and methods detrimental to performance. Manuals shall include the following: (a) Index. (b) Complete instructions on equipment supplied including: physical description, installation requirements, startup procedures, adjustments, operation, technical information and servicing, including parts list with stock numbers (c) All material that is to be furnished as part of the Operation and Maintenance Manuals shall be submitted in bound volumes with hard cover binders. This material shall be furnished complete in one (1) submittal for review and final acceptance. The Manufacturer shall provide one (1) copy for approval and six (6) copies as final issues. system, including instrumentation system schematics. (d) The manuals shall include a functional description of the entire ii) Warranty: Warranty documents specified herein. iii) Record Documents: Provide record documents for installed materials in accordance with Division 1 Closeout Submittals (Project Record Documents) Section. (a) Record Drawings: Submit, within 6 weeks prior to issue of the Certificate of Final Completion to Owner, record drawings comprising plans, sections, and elevations. 1-5. WARRANTY. Refer to Conditions of Contract for project warranty provisions. A) Manufacturer’s Warranty: Submit, for Owner’s acceptance, Manufacturer’s standard warranty document executed by authorized company official, Manufacturer’s warranty is in addition to, and not a limitation of, other rights Owner may have under Contract Documents. (Carlsbad Water) (Recycling Facility) (REV C - 12/11 ) 11225 -3- i) Warranty Period: The Manufacturer shall warrant the equipment being supplied to the Owner against all defects in workmanship and materials for a period of one (1) year from the date of startup or eighteen (18) months from shipment. This warranty shall be in force provided that the plant installation, startup and subsequent operations are performed in strict accordance with written and oral instructions provided by the Manufacturer. The Manufacturer shall replace or repair any part or parts that are determined to be defective during the warranty period, provided that the defects are not a result of misuse or neglect. PART 2 - PRODUCTS 2-1. ACCEPTABLE MANUFACTURERS. Thickener equipment shall be “Densadeg High-Rate Clarifier and Thickener” as manufactured by lnfilco Degremont, Inc. or equal (the Owner knows of no equal). The drawings and specifications have been prepared using the dimensions and details for the “Densadeg High-Rate Clarifier and Thickener” equipment as manufactured by lnfilco Degremont, Inc. 2-2. MATERIALS A. System Materials Requirements: 1. Carbon steel components shall be blasted and have a primer coat. Contractor shall provide all finish painting. Exterior finish of painted assemblies shall be of a color as directed by the Owner. 2. Dissimilar metals, when used, shall be protected against electrolytic actions. 2-3. MANUFACTURED UNITS AND EQUIPMENT. Each treatment unit shall have an individual design capacity of 700 gpm, with a rise rate of 10.25-gpm/f? across the lamellar tubes. Equipment requirements specific to the reactor, clarifierlthickener, reactor turbine, scraper drive, bridge and walkway, sludge recirculation pump, sludge blowdown valve, control panel, and sludge discharge pump (if necessary): A. Reactor: 1. The concrete reactor basin (by Qtbe~~ Contractor) shall have a maximum depth of 15 feet and shall be square in dimension. (Carlsbad Water) (Recycling Facility) (REVC-12/11) 11225 4- 2. An inner draft tube, sized to promote proper recirculation and flocculation, is suspended within the walls. The draft tube and all other internal components, baffles, etc., shall be Type 304 stainless steel). 3. Inlet piping shall be provided and installed by the Contractor. 4. The reactor components shall receive an SP-6 shop blast and one coat of Shop Primer prior to shipment to the jobsite. Finish painting shall be as specified by the Owner and is the responsibility of the Contractor. B. Clarifierfrhickener: 1, The clarifierlthickener portion of the basin shall have a maximum depth of 2. The internal mechanism shall consist of a torque tube with collector arms. 15 feet and shall be square in dimension. A center scraper shall extend below the torque tube into the sludge hopper. The collector arms and center scraper shall be Type 304 stainless steel. 3. An effluent trough and external sludge recycle noule(s) shall be provided. An adjustable sludge drawoff system shall be furnished for the recycle system. 4. This basin is additionally supplied with a sludge sampling system; taps, valves, piping, and sink. A drawdown nozzle shall also be provided. 5. The clarification area consists of a section of 2-0" high lamellar tubes. Fiberglass effluent collection launders shall be provided. Flow proportioning baffles, lamellar tube module support structure, and all other internal components shall be Type 304 stainless steel. Should the lamellar tubes ever require cleaning or replacement, the clarifier contents may be withdrawn through the drawdown nozzle, thus completely exposing the tube modules. The modules may then be lifted from their support structure. C. Reactor Turbine: 1. A turbine shall be provided to produce mixing, precipitation, and recirculation of solids drives the axial flow turbine. The motor shall be minimum I-hp, TEFC, 230-460/60/3, severe duty. The turbine consists of curved blades especially designed to result in a high-efficiency, low-shear pump and is provided with a Variable Speed drive. D. Scraper Drive: 1. The scraper drive shall be Variable Speed. The motor shall be minimum 0.5-hp, TEFC, 230-460/60/3, severe duty. A torque overload device and visual torque indicator gauge shall be furnished with the drive. E. Bridge and Walkway: 1. A beam type walkway support bridge shall span the reactor, andlor clarifier thickener basins. Aluminum Grating shall be provided for the 36- (Carlsbad Water) (Recycling Facility) (REVC-12/11) 11225 -5- inch minimum wide walkway. The platform shall expand at the reactor basin and thickener drive units. Aluminum handrail and kickplates shall also be furnished. The walkway l platform shall provide access to all equipment requiring maintenance and shall extend the entire length of the thickener. F. Sludge Recirculation Pump: 1. Two (2) Variable Speed progressive cavity pumps shall be furnished per unit to recirculate preformed solids from the clarifier-thickener basin to the reactor inlet. The motor shall be minimum I-hp, TEFC, 230-460/60/3, severe duty with a adjustable frequency drive (AFD) (see Section 161 50). The pump shall be capable of recirculating a minimum of 21-gpm at 21- feet of head. Each pump shall have a high discharge pressure cutoff and low suction pressure cutoff. 2. There shall also be provided one (1) spare pump. 3. The recycle pump operation is to occur in conjunction with the sludge drawoff system furnished with the clarifier-thickener. The actual rate of recycle shall be determined during start-up testing. The capacity of the pumps herein proposed shall be adequate to provide a range of operation within which a desired recycle rate may be established. isolation valves, and pressure gauge. 4. The pumps shall be complete with suctionldischarge piping, manual G. Sludge Blowdown Valve: 1. One (1) 4-inch diameter plug valve shall be furnished for the sludge blowdown piping. Valve body construction shall conform to General Service standards with motorized actuation designed for OpenlClose service. The valve shall be controlled by the control panel timers in conjunction with operation of the sludge discharge pump. H. Control Panel: 1. There shall be furnished one (1) control panel of NEMA 4x construction with a 304 SS enclosure. The control panel shall contain all integrators, programmers, timers, function relays, counters, indicator lights, selector switches, wiring, etc., required to operate the treatment units. The panel shall be suitable for outdoor installation and shall have rain/drip shields and thermostatically controlled internal strip heater. 2. The control panel will receive a single 480 volt, three phase power feed terminating in a panel-mounted disconnect with an externally operable and lockable handle. The panel shall contain any necessary control power transformers, variable frequency drives, motor starters, and power distribution equipment, as required for the thickener operation. Each motor starter for constant speed applications shall have a separate circuit breaker and starter with solid-state overloads sized for the equipment. (Carlsbad Water) (Recycling Facility) (REV C - 1211 1 ) 11225 -6- 3. The panel shall contain all controls necessary for unattended automatic operation of the thickener unit. The thickener control panel shall contain indicating lights, alarms, and control switches as indicated on the P&ID drawings, and as required for proper operation of the thickener unit. The thickener control panel shall send the following alarmktatus signals to the plant control system, in the form of dry contacts: System running status System alarm Sludge Blowdown pump on system based on flow rate to the thickener. 4. Polymer and Ferric chemical addition will be controlled by the plant control I. Sludge Depth Level Sensor: 1. A sludge blanket depth metering system shall be provided. Sludge blanket depth shall be indicated on the Thickener Control Panel, but shall not automatically control any thickener functions. The sludge depth sensor shall be an ultrasonic unit, as manufactured by Royce, or Drexelbrook. J. Sludge Discharge Pump: 1. One (1) Constant Speed sludge discharge pump shall be furnished to remove the thickened sludge from the clariier thickener basin. The capacity of the pump shall be adequate to provide proper removal of the thickened sludge. Pump operation shall be based on a time-cycle program, which shall be easily adjustable on the face of the Thickener Control Panel. 2. The pump shall be complete with suctionldischarge piping, manual isolation valves, and pressure gauges. The pump shall have a high discharge pressure cutoff and low suction pressure cutoff. PART 3 EXECUTION 3-1. RESPONSIBILITY FOR EQUIPMENT A. Contractor Responsibiltty: 1. The Contractor shall be responsible for furnishing, installing, testing, and placing in satisfactory operation all mechanical equipment, instruments, monitoring devices, appurtenant process equipment, piping, electric and manual operated valves, control instrumentation and equipment, and accessories. The Contractor shall coordinate all work with the Manufacturer to guarantee a complete, operating and satisfactory system. personnel during construction, testing, startup, calibration and acceptance 2. The Contractor shall coordinate the work of the system supplier's service (Carlsbad Water) (Recycling Facility) (REV C - 1211 1 ) 11225 -7- of the system, and also operator training. The system design shall provide for complete operation of all signals from point to point, and shall assure complete compatibility of all instrumentation and equipment. B. Manufacturer Responsibility 1. The system supplier shall have in his steady employ, during the entire project period, capable personnel for administration; detailed engineering and drafting; coordination; procurement and expediting: scheduling; construction inspection; installation, testing, and startup assistance; and final commissioning. The system supplier shall also have available, for the duration of the specified warranty period, capable personnel for all necessary administration, engineering, and/or service. 2. The Manufacturer shall have available supervisory service during construction to review and advise the Contractor in the method of mounting, piping and wiring of each device, and advising protective measures needed for the equipment prior to placing it into service, if needed. C. Engineer Responsibility: 1. The Engineer shall be responsible for coordinating any signal pacing and chemical feed pump control interface with the instrumentation system supplier and/or chemical feed supplier. interconnecting or interfacing problems, in order to ensure a complete and acceptable operating system. 2. It shall be the Engineer's sole responsibility to resolve any and all 3-2. INSTALLATION BY THE CONTRACTOR A. Contractor Performance: 1. All materials and equipment shall be installed in a neat, workmanlike 2. All wiring of the equipment shall be as specified under the electrical manner. section of these specifications and shall terminate at diagram connection points at devices and in panels. Manufacturer's recommendations and the contract drawings. shall be furnished by Contractor. Pre-embedded anchoring is not required. Such installation shall be performed in accordance with Division 3 Concrete. 5. The Contractor shall not energize the instrumentationlcontrol system prior to receipt of a certified statement of approval from the Engineer, containing his authorization for energizing the system (if required to be supplied by the Manufacturer). 3. All equipment specified herein shall be installed in accordance with the 4. Where anchor bolts and other parts in concrete are required, such parts (Carisbad Water) (Recycling Facility) (REVC-12/11) 11225 -8- 6. Field painting and the surface preparation is separate from the work specified in this section and shall be as specified in Division 9 Finishes. 7. Prior to startup and field testing, all foreign matter shall be removed from the equipment, inside of the control panel (i required), interconnecting piping and chemical lines, and spillage of lubricants used in servicing the equipment shall be cleaned from pumps, piping and concrete surfaces. 3-3. MANUFACTURER'S SERVICES A. Installation and Startup Assistance 1, The Manufacturer shall furnish the services of a qualified field service engineer to supervise installation and startup of all the components of the clarifierhhickener unit. This shall also include the treatment equipment, instrument control panel (if required), instrumentation equipment (if supplied), pumps, drives, scraper mechanism for a period of four (4) days per unit and two (2) trips to the job site. All costs for services furnished by the water treatment system manufacturer shall be included in the total price, with no additional compensation provided. Services shall be limited to two (2) days per unit supplied and two (2) trips to the job site. 2. The Manufacturer shall provide supervision services as specified herein. B. Manufacturer's Training 1. A fully qualified field service engineer to provide this training shall furnish a minimum of two (2) eight-hour days, not including travel time to and from the site. 2. Training shall include a classroom session of one (1) day, at a minimum, and one (1) day of field training on the equipment. The time for training shall be exclusive of time used for startup, demonstration or testing of new equipment. 3. The Manufacturer's services shall be included in the contract price. The service times specified shall be considered as full eight (8) hour working days and do not include travel time. A unit price per day shall be included in the proposal, should the Owner request additional time. 3-4. MANUFACTURER'S INSTRUCTIONS A. Compliance: Comply with Manufacturer's product data, including product technical bulletins, product catalog installation instructions and product container instructions for installation. End of Section (Carlsbad Water) (Recycling Facility) (REV C - 12/11 ) 11225 -9- SECTION 11247 TANK MECHANICAL MIXERS PART 1 -GENERAL 1.01 DESCRIPTION A. Description of Work: 1. The Contractor shall furnish all labor, materials, equipment and incidentals required, install, field test, and complete for operation the tank mounted mechanical mixers including the respective motor as shown on the drawings and specified herein. 2. All necessary and desirable accessory equipment and auxiliaries whether specifically called out in this specification or not shall be furnished and installed as required for an installation incorporating the highest standards for this type of service. Also included shall be supervisory services during installation and field testing of each unit and instructing the regular operating personnel in the proper care, operation, and maintenance of the equipment. B. Type: 1. Mixer shall be of the direct drive type furnished complete with 1/4 hp minimum electric motor, gear, impeller, shaft, bearings, anchor bolts, and other necessary appurtenances for a complete installation. C. Equipment List: 1. Threshold Inhibitor Tank Mixer: M-I 177 1.02 QUALITY ASSURANCE A. Performance and Design Requirements: 1. Threshold Inhibitor Tank Mixer: The mixer will be used to batch approximately 585 gallons of inhibitor solution in a polyethylene tank. The inhibitor (undiluted) will be furnished in drums from the manufacturer and diluted with water. 8. Operating Requirements: 1. Threshold Inhibitor Tank Mixer: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11247 -1 - Characteristic Value Liquid Mixed Corrosion Factor Liquid Depth Range 10% inhibitor solution 0 - 3 feet pH=l - 6 1.03 ENVIRONMENTAL CONDITIONS A. The equipment furnished under this section will be installed at the locations shown. The ambient temperatures are expected to range between 35 degrees F and 100 degrees F with relative humidity that varies from 10 to 100 percent. 1.04 SUBMllTALS A. Scope: All of the material required for submittal under this section shall be furnished in one complete package. Submittals shall comply with the requirements of Section 01300. B. Requirements: In addition to the items required in Paragraph 11247-1.04 A, submittal data shall be required as follows: 1. Manufacturer's qualifications 2. Outline installation drawings for each mixing unit. 3. Other data as required for complete installation of the mixers. 1.05 STANDBY COMPONENTS A. Scope. Furnish the following for each mixer: 1. One (1) Impeller 2. One (1) Set of Bearings 3. One (1) Set of all gaskets and O-rings PART 2 - PRODUCTS 2.01 GENERAL A. Scope: Each mixer shall be complete with an electric motor, shafting, bearings, local control station and all other accessories required for a complete installation. B. Mixer Manufacturers: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11 247 -2- 1. Lightnin Corporation; 2. Or equal. 2.02 MATERIALS A. Mixers: 1. Impellers: A-I00 stainless steel. 2. Shaft: Type 316 stainless steel. 2.03 DRIVE MOTORS A. Type: TEFC, constant speed. B. Size: See design requirements for minimum horsepower. C. Voltage: 115-volt, I-phase, 60-Hz. D. Base Speed: 1800 rpm. E. Service Factor: 1.15. F. Enclosure: TEFC 2.04 CONTROLS A. Each mixer shall be provided with a minimum 154 power cord and a local hand switch in a NEMA 4X, 316 stainless steel enclosure. See Division 16 for requirements. PART 3 - EXECUTION 3.01 INSTALLATION A. General: 1. The Contractor shall be responsible for the proper installation of all system components. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer's printed instructions, and approved shop drawings. a. Follow the manufacturer's printed installation instructions and recommendations. (Carlsbad Water) (Recycling Facility) (1 00% Submittal) 11247 -3- b. Do not place sensitive components directly on the ground. Properly support using wooden blocks. c. Correct conditions causing excessive mixer, motor, or connector noise, chatter, or vibration after installation. 3.02 FIELD TESTING A. Testing and Startup Responsibilities: 2. Perform all Work for equipment functional and performance tests specified herein and in Section 01650. 3. Complete all Work associated with the unit and related processes before testing, including related manufacturer's representative services. 4. Provide all related operating and maintenance manuals, and spare parts and special tools as specified before testing any unit or system. 5. Furnish qualified manufacturer's representatives when required to assist in testing. 6. Utilize an approved Manufacturer's Certificate of Proper Installation Form, supplemented as necessary, to document all functional and performance procedures, results, problems, and conclusions. 7. Schedule and attend pretest (functional and performance) meetings related to test schedule, plan of test, materials, chemicals, and liquids required, facilities' operations interface, Owner and Contractor involvement. B. Functional Testing: 1. General: Conduct an initial functional test on each mixer system to demonstrate the proper installation and operation. Submit report documenting the test in a format acceptable to the Owner's Representative. 2. Alignment: Test complete mixer assemblies for correct rotation, proper alignment and connection, and quiet operation. 3. Operating Temperatures: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11247 -4- d. Monitor bearing areas on mixer and motor for abnormally high temperature. e. Place a certificate of compliance in the startup file for each equipment item. C. Performance Testing: 1. General: f. Prior to complete system startup, each mixer shall undergo an individual performance test to demonstrate and confirm that the equipment meets the performance requirements specified herein. g. Include a compliance report documenting the test in a format acceptable to the Owner's Representative in the startup file for each item of equipment. 2. Operate the installed mixer over a period of at least one hour. 3. Units failing to meet requirements of the specifications shall be replaced with conforming units. 3.03 TRAINING A. The services of a qualified representative of the mixer manufacturer shall be furnished to instruct the plant personnel in its operation and maintenance. Instruction of plant personnel shall be in accordance with Section 01400. A minimum of two hours training shall be provided. End Of Section (Carlsbad Water) (Recycling Facility) (100% Submittal) 11247 -5- Section 11250 GRANULAR MEDIA FILTRATION EQUIPMENT PART 1 - GENERAL 1-1, SCOPE. This section covers the furnishing and installation of a continuous- backwash, top-feed, upflow, deep bed, single-media filter system package, complete with all equipment and appurtenances specified or required to provide a complete and satisfactory filtration system. The filter system shall include 12 filter modules installed in 2 cells as shown on the drawings and specified herein, The Contractor shall provide and coordinate with the filter supplier an aluminum basin cover system. Principal items to be furnished and installed hereunder shall include the following: Filter internal equipment. Filter media. Compressed air system. Airflow control panels. Equipment supports and anchor bolts. Access grating and supports. Aluminum Basin Covers The following items of related work and equipment are specified under other sections: Concrete and grout. Piping and valves. Miscellaneous metals. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by the Engineer. Equipment shall be furnished and installed complete with all anchors and supports; all mechanical equipment required for proper operation; all fiberglass reinforced plastic, metal, and other construction indicated on the drawings; and all additional materials of construction required by the manufacturer's design. (Carlsbad Water) (Recycling Facility) 11250 -1- Contractor shall coordinate with the equipment manufacturer to ensure the concrete basins for the filter modules are constructed to the exact dimensions required by the equipment furnished. Components of the compressed air equipment shall be the latest standard products of manufacturers regularly engaged in the production of equipment of this type. 1-2.01. General Equipment Stipulations. The General Equipment Stipulations shall apply to all equipment furnished under this section. 1-2.02. Governina Standards. Except as modified or supplemented herein, filter media shall conform to the applicable requirements of AWWA 8100. 1-2.03. PowerSupplv. Power supply to the air compressors will be 480 volts, 60 Hz, 3 phase. Power supply to the air dryer will be 120 volts, 60 Hz, single phase. 1-3. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with detailed specifications and data covering materials of construction, equipment, parts, devices, motors, arrangement details, loadings, elevations, and other accessories forming a part of the filtration system, shall be submitted in accordance with the submittals section. Complete descriptive data for filter materials shall be submitted for review prior to shipment. Electrical schematics, wiring diagrams, and panel layout drawings for air compressor, aftercooler, and airflow controls shall be included. In addition, operation and maintenance manuals for the filtration equipment, compressed air package, and airflow control panel shall be submitted in accordance with the submittals section. Each supplier shall submit a list of at least 5 United States installations on similar applications which have been in continuous operation for at least 2 years in concrete basins. The data and specifications for the filters shall include, but shall not be limited to the following: Filter Equipment Complete specifications and dimensional drawings. Installation drawings. Piping specifications, layouts, and support details. Materials of construction. Grating and grating support layout and materials. (Carlsbad Water) (Recycling Facility) 11250 -2- Filter Media Name of supplier. Specific gravity. Sieve analysis. Effective size and uniformity coefficient. Acid solubility. Loss on ignition. Airflow Control Panels Individual item specifications. Dimensional drawings. Installation details. Process schematic drawings. Interconnection drawings. The data and specifications for the compressed air package shall include, but shall not be limited to, the following: Baseplate Overall dimensions. Number, size, and location of structural members. Thickness of top plate. Number, size, and location of grout openings. Drawings indicating pipe routing and traps and valve locations. Compressor Manufacturer. Type and model. Dimensions. Weight including motor. Performance data at variable discharge pressures. Bearing data. Filter details. (Carlsbad Water) (Recycling Facility) 11250 -3- Accessory details. Piping schematic. Control equipment. Sequence of operation. Motors Manufacturer. Type and model. Horsepower rating and service factor. Temperature rating. Full load rotative speed. Oil Filter Manufacturer. Model. Pressure drop. 1-4. QUALITY ASSURANCE. 14.01. Field Testinq. The Contractor shall conduct all tests required by the filtration system manufacturer to verify proper installation. All testing shall be performed under the supervision of the manufacturer's field representative. The Contractor shall furnish all power, material, instrumentation, equipment, personnel, etc., for conducting tests. The Contractor shall give the Engineer sufficient advance notice of the testing to enable the Engineer to witness the tests. The Contractor shall submit to the Engineer three copies of complete reports for all tests, describing the units tested; the type of test; test setups, procedures, and instrumentation; and test flow rates, pressures, levels, and all other data and results as required to demonstrate that all items meet specified requirements. 14.02. Shop Testinq. Prior to shipment, each airflow control panel and compressor module shall be operated to check alignment; faulty equipment and controls; proper wiring; leaks in piping, seals, or wells; and proper operation of the safety and'operating controls. Compressor pressure controls shall be adjusted to the specified pressures. Defective equipment and controls disclosed by such tests shall be replaced and the package placed in satisfactory operating condition before shipping. A statement from the package supplier certifying that the specified shop test has been performed shall be submitted to the Engineer (Carlsbad Water) (Recycling Facility) 11250 4- prior to shipment. A test report showing capacity, differential pressure, power requirements, and other data shall be submitted for Engineer approval prior to shipment. 1-4.03. Responsibility. To ensure that all the equipment required for the installation of the filter modules and air control system is properly coordinated and will function as a unit in accordance with the intent of these specifications, the Contractor shall obtain all the equipment specified under this section, from a single supplier in whom the responsibility for the proper function of all the equipment, regardless of manufacturer, as an integrated and coordinated system shall be vested. The intent of this paragraph is to establish unit responsibility for all the equipment with the filter equipment supplier. The use of the word "responsibility" relating to the equipment supplier is in no way intended to relieve the Contractor's ultimate responsibility for equipment coordination, installation, operation, and guarantee. 1-5. SPARE PARTS. The following spare parts shall be furnished for the filter equipment: - Item O-ring for airlift pump chamber O-ring for airlift inlet nut Quantity 6 6 Screen for airlift pump 6 Regulator for air control panel 2 Airflow indicator for airflow control panel 2 The following spare parts shall be furnished for the compressed air package: Part Description Intake air filters elements Number Reauired L V-belts 2 matched sets Air-oil separator filter element 4 Coolant 5 gallons Spare parts.shall be suitably packaged in accordance with the General Equipment Stipulations, with labels indicating the contents of each package. Spare parts shall be delivered to the Owner as directed. (Carlsbad Water) (Recycling Facility) 11250 -5- PART 2 - PRODUCTS 2-1, SERVICE CONDITIONS. All equipment shall be designed for Continuous, 24-hour operation, and all parts of the mechanism shall be amply proportioned for all stresses which may occur during fabrication, erection, and operation. The filters will receive secondary effluent from the adjacent EWPCF. Influent to the filters will overflow influent weirs into an influent box to the filter influent piping. Filtrate will overflow the effluent weirs into the effluent channel to the chlorine contact basin. Filtrate will be pretreated with aluminum sulfate (alum) and polymer as required for coagulation. Provisions for sodium hypochlorite addition will also be provided for filter disinfection as necessary. The filter backwash reject stream will flow by gravity to the thickener. The compressed air system will supply dry, oil-free air to the filter modules. 2-2. PERFORMANCE AND DESIGN REQUIREMENTS. 2-2.01. m. Filters shall produce a continuous filtrate stream and a continuous backwash reject stream without using any moving parts. Filters shall not require shutting down for backwashing cycles. No backwash water supply pumps, valves, or instrumentation shall be required for backwashing. No external sand movement or washing will be allowed. Continuous sand cleaning shall be accomplished with the filter using filtered water; filter influent (feed) shall not be used for sand cleaning. Media shall be continuously backwashed internally and shall be redistributed on top of the bed an average of 4 to 6 times in 24 hours. Mixed or multiple media shall not be allowed. Filters shall operate countercurrently. Feed shall be upflow with the media moving downward. Filters shall not require screens, wedgewires, grids, or other devices to retain the media in place. Each filter shall be a continuous backwash, upflow, single media filter. The backwash surface loading rate shall exceed 50 gpmlsq ft to ascertain a superior scouring and cleaning of the sand. The air scouring of the sand shall exceed 100 scfmlsq ft which shall be accomplished by the supply of 2 to 3 scfm of air per module at 15 to 25 psi. The filtration system shall be designed for the following requirements: Design flow, gpm 3.7 Number of filter cells 2 Number of modules per filter cell 6 (Carlsbad Water) 11250 (Recycling Facility) -6- Total number of filter modules Minimum media depth, in Filter area per module, sq ft Design loading rate, gpm/sq ft Filter cell designation Average influent turbidity, NTU Influent water temperature, OC Minimum Maximum Influent pH Maximum effluent turbidity, NTU Maximum headloss through filter, in. At design flow Total maximum backwash reject flow, gpm At design flow Air requirements for sand scouring Design airflow rate per module, scfm Supply pressure, psi 12 40 50 4.3 Filter No. 1 and Filter No. 2 20 28 7.4 2 36 278 31.2 15 to 25 2-2.02. Compressed Air System. .A compressed air system shall be provided to include air compressors, remote receiver, dryer, oil filters, air control panel, air piping and valves, and miscellaneous accessories. .I (Carlsbad Water) (Recycling Facility) 11250 -7- Each compressor shall be designed to meet the demand with an 85 percent duty cycle maximum and shall be designed to operate at 100 percent duty cycle. The compressors shall maintain the receiver pressure between 100 and 110 psig. The compressed air equipment shall be designed for the following operating conditions: Ambient conditions Air temperature, OF Minimum Maximum Relative humidity, percent Altitude. feet Air Compressors Number required Unit designation Minimum discharge pressure, psig Minimum inlet capacity of each compressor when operating at the specified discharge pressure, icfm Minimum motor size, hp Maximum motor speed, rPm 32 100 20-60 161 2 (1 duty, 1 standby) C-0805-1 and C-0805-2 110 90 15 3,600 Receiver Number required Minimum design pressure, psig Minimum nominal volume, gal (Carlsbad Water) (Recycling Facility) 1 150 240 11250 -0- Air dryer Type Number required Minimum capacity at 100 psi at IOOEF, dm Oil removal filters Refrigeration 1 80 Type Coalescing Number required 2 Minimum capacity at 100 psi, cfm Minimum design pressure, Psig 80 150 2-3. ACCEPTABLE MANUFACTURERS. Filtration equipment shall be "DynaSand Filter" as manufactured by Parkson Corporation, "Hydrsand Filter" as manufactured by Andritz-Ruthner, Inc., or equal. The drawings and specifications have been prepared using the dimensions and details for the "DynaSand Filter" equipment. The air compressor system shall be as manufactured by Gardner- Denver, Ingersoll-Rand, Quincy, or equal. 2-4. MATERIALS. Materials used shall be: Bottom Hopper Cones Fiberglass-reinforced plastic. Feed Inlet Pipe Type 304/304L stainless steel. Feed Distribution Radials Type 304/304L stainless steel. Reject Compartment Fiberglass-reinforced plastic. Washer Rings Polyethylene. Reject Weirs Polypropylene. Sand Distribution Cones Type 3041304L stainless steel. Airlift Pipes (Carlsbad Water) (Recycling Facility) Type 304/304L stainless steel. 11250 -9- Airlift Housing Type 304/304L stainless steel. Reject and Grating Supports Aluminum Grating for platform Aluminum Nuts, Bolts, and Fasteners Type 316 stainless steel. Anchor Bolts Type 316 stainless steel. Air Control Panel Type 304/304L stainless steel. \ All wetted filter system parts shall be Type 304 stainless steel, fiberglass-reinforced plastic, polyacetyl, or polypropylene. No carbon steel shall be allowed. All filter equipment parts which will be fully or partially submerged or subject to splashing shall be Type 304 stainless steel, fiberglass-reinforced plastic, polyacetyl, or polypropylene. 2-4.01, Filter Media. Filter media shall be natural silica sand complying with AWWA 6100, except as modified herein. Sand shall be at least 95 percent silica. The grain shape shall be essentially round with a smooth, nonangular surface. Crushed gravel will not be acceptable. Gradation sizes shall be based on square hole sieves conforming to ASTM El 1. The media shall be clean, dry, natural sand, free from contaminants, trash, and other debris. Sand shall have the following characteristics: Maximum effective size (Dlo), mm Uniformity coefficient (Cu), max Specific gravity, min Acid solubility, max, percent Loss on ignition 1.3 1.5 2.5 5 ASTM C25,4 percent max 2-4.02. Anchor Bolts. All anchor bolts, nuts, and washers shall be Type 316 stainless steel, shall be of ample size and strength for the purpose intended, and shall comply with the anchor bolts and expansion anchors section. The filter manufacturer shall furnish with the equipment all anchor bolts, nuts, and washers. The Contractor shall install the anchor bolts in accordance with the manufacturer's instructions. Anti-seize thread lubricant shall be liberally applied to the threaded portion of all stainless steel bolts. (Carlsbad Water) (Recycling Facility) 11250 -1 0- 2-4.03. Fasteners. All field assembly bolts, nuts, washers, and other fasteners shall be Type 316 stainless steel, Anti-seize thread lubricant shall be liberally applied to the threaded portion of all stainless steel bolts. 2-40, Aluminum Covers. Aluminum covers shall be provided to cover the filter basins and the inlet channel. The aluminum covers shall be solid (not grating) to prevent exposure' of the liquid in the basin and channel to sunlight. The covers shall be designed to handle foot-traffic, shall be provided with a nonslip surface, and shall provide the necessary hatches to accommodate access to equipment components. The design shall include all aluminum structural support and type 316 stainless steel hardware. Aluminum shall be in accordance with Division 5. The design shall be stamped by a licensed structural engineer. The cover design shall be coordinated with the filter supplier. The cover system shall be designed to allow easy installation and removal by two staff members (removeable panels) without the use of heavy lifting equipment. 2-5. CONSTRUCTION. 2-5.01. Filter Internal Eguiument. Equipment shall be furnished in modules, each including a bottom hopper cone, feed inlet piping, feed distribution radials, airlift pipe, silica sand filter media, internal sand washer, sand distribution cone, reject compartment with weirs, reject piping, airlift piping, compressed air control panel, compressed air piping and controls between the panels and the filters, support channels for reject troughs and grating, access grating over each cell, and drain piping. The system arrangement shall be as indicated on the drawings and shall permit access from the top of each module for maintenance of components. All feed, reject, and drain piping, and airlift and compressed air piping supplied with the filters shall meet the requirements of the miscellaneous piping section. 2-5.02. Compressed Air EQUiDment. The compressed air system shall include two air compressors, remote receiver, oil removal filter, air dryer, controls, and all accessories and appurtenances specified herein, indicated on the drawings, or otherwise required for a complete, properly operating installation. Air piping and valves not a part of the compressed air equipment package are covered in the miscellaneous piping and miscellaneous valves sections, respectively. The system arrangement shall be as indicated on the drawings and shall permit access from the front and sides of each package for maintenance of components. (Carlsbad Water) (Recycling Facility) 11250 -1 1- 2-5.02.01. ComDressors. The compressors shall be of the single stage, rotary screw type in a low sound enclosure with 10 micron inlet filter silencer suitable for indoor use. Each compressor shall be provided with vacuum degassed duplex taper roller bearings with coolant dam; OUOL with upper range mod control, with automatic control selection; automatic start-stop control; coolant; 8-point shutdown annunciator panel; aftercooler; and separator. The aftercooler and separator shall be premounted and prepiped within the compressor package. Compressors shall be lngersol Rand "Model EP-25SE" or equal. Each compressor and all its accessories and appurtenances shall be completely enclosed within an acoustic enclosure. The enclosures shall be sheet metal with acoustic lining designed to reduce noise levels below 80 dB at one meter. The enclosure shall provide easy access to all maintenance items within the enclosure. 2-5.02.02. Receiver. The receiver shall be a vertical tank of all welded construction with semiellipsoidal heads and leg supports for mounting on a concrete base. The receiver shall be designed and constructed in accordance with the ASME Code for Unfired Pressure Vessels and shall bear the code stamp. The receiver shall be provided with a liquid-filled pressure gage and petcock, safety valve, and solenoid automatic drain trap. 2-5.02.03. Air Drver. The air dryer shall be of the cycling refrigeration type and shall produce a 33EF to 39EF pressure dew point at the heat exchanger exit when operating continuously at the design conditions. The dryer shall include a heat sink and thermostat to cycle the refrigeration system to match the load with the demand. The dryer shall be complete with a solenoid automatic drain trap. Electrical supply to the equipment shall be 120 volt, 60 Hz, single phase. The dryer shall be Zeks "Model IOOHSE" or equal 2-5.02.04. Oil-Removal Filter. The oil-removal filter shall be of the coalescing type and shall remove 99.9 percent of the solids and liquids 0.1 micron or larger in size with replaceable filter elements. The filter shall be furnished with a dif- ferential pressure indicator to signify the need of service or replacement of the elements. The filter shall be furnished with a solenoid automatic drain trap. The maximum pressure drop across the filter shall be 1 psi over the expected IO-year element life. The air filter shall be Zeks "Model 125HDF" or equal. (Carlsbad Water) (Recycling Facility) 11250 -12- 2-5.02.05, Control Equipment. Each compressor shall be equipped with automatic start-stop control, 8-point shutdown annunciator panel, and motor starter. Each compressor shall have a dry-contact output signal, for "running" and "alarm" to be connected to the plant control system. Each motor starter shall be premounted and prewired with a control voltage transformer requiring a single-point connection from the Contractor-supplied fused disconnect switch. The motor starter shall be sized as required by equipment manufacturer. Each motor starter and protective device shall be rated 42,000 AIC. A sequencer shall be provided for field mounting and wiring. The sequencer shall automatically cycle the lead unit to the lag unit and vice versa every 24 hours. 2-5.02.06. Electric Motors. Each compressor shall be provided with a 25 hp open dripproof electric drive motor conforming to the requirements of the General Equipment Stipulations. Motors shall have a 1.2 service factor and be rated 460 volts, 60 Hz, 3 phase. 2-5.03. Airflow Control Panels. An airflow control panel shall be provided for each filter cell. Each panel shall contain an air filter and pressure regulator. Each panel shall contain separate air tubing, control valve, airflow meter, and pressure gauge for each module within the cell. The control panel shall be NEMA Type 4X stainless steel. Each panel shall be located as indicated on the drawings or as directed by the Engineer. 2-5.04. Aluminum Grating and SUDDO~~S. Aluminum grating and supports shall be furnished over each filter basin as shown on the drawings, in accordance with the miscellaneous metals section and as specified herein. Grating over the influent channel and rapid mix basin shall be supplied by others. Unless otherwise noted, all materials and work shall conform to applicable provisions of the Aluminum Association "Standard for Aluminum Structures". All members shall be Aluminum Association standard structural shapes. Fabrication work shall be in accordance with current industry practice. 2-5.04.01. Grating. All grating shall be aluminum, Depth of bearing bars for grating shall be as recommended by the filter manufacturer to meet the specified loading and deflection criteria. Except as modified herein, the manufacture, fabrication, and installation of grating shall comply with recommendations in the "Metal Bar Grating Manual" of the National Association of Architectural Metal Manufacturers. (Carlsbad Water) (Recycling Facility) 11250 -13- Grating shall be designed for a design uniform live load of 250 psf, with a maximum dead plus live load deflection not to exceed the lesser Of 1/300 of the span or 114 inch. Aluminum grating shall be the mechanically locked type, with cross bars deformed or swaged to prevent turning. Bearing bars shall be at least 3/16 inch thick flat stock or equivalent I-bars, with center-to-center spacing of 1-3/16 inches. Grating panels shall be arranged so that removable panel and sample hatch openings are centered on a joint between panels. Bands extending the full depth of the grating shall be provided around removable panel and sample hatch openings, around removable panels and sample hatches, and in other locations indicated on the drawings. Ends of bearing bars in grating floor panels shall be provided with full-depth bands. Bands shall be 3/16 inch thick. Bands shall be welded to each bearing bar and the first, the last, and every fourth intermediate bar. Cross bars shall be cut off flush with the outside face of side bars. Each sample hatch shall be equipped with a hinged joint and lifting handle. Hinges shall be welded in place and shall be recessed such that the top of the hinge is flush with the top of the grating. Lifting handles shall be constructed to provide the ability to raise and lower the handles. In the lowest position, each handle shall be recessed with the top of the handle flush with the top of the grating. In the highest position, each handle shall extend 2-1/2 inches above the grating. Each handle shall extend through the grating and shall be welded to a lifting plate below the grating of sufficient size and strength to open the hatch without damage to the grating bars. All angular, circular, re-entrant, and other cuts in aluminum grating shall be sawed or sheared. Grating shall be fabricated in panels that can be easily handled by plant personnel. Unless otherwise indicated on the drawings, the weight of individual panels shall not exceed 150 pounds. Panels shall be within i3/16 inch of authorized length and *1/8 inch of authorized width, and shall have a maximum difference in length of opposite diagonals of 1/4 inch. The spacing of bearing bars shall be within 1/32 inch of authorized spacing. Cross bars and edge bars of adjacent panels shall align. After installation, there shall be not more than 114 inch clearance between panels. All bearing bars shall be parallel. Bands and toeplates shall align within 1/8 inch tolerance, vertical and horizontal. All grating shall lie flat, with no tendency to rock when installed. Poorly fitting or damaged grating will be rejected. 2-5.05. Edqe Grinding. Sharp projections of cut or sheared edges which will be submerged in operation shall be ground to a radius by multiple passes of a power grinder. (Carlsbad Water) (Recycling Facility) 11250 -14- 2-5.06. Painting, 2-5.06.01. Filter EquiDment. There are no carbon steel filter components requiring painting. Painting of nonferrous metal or nonmetallic components will not be required. 2-5.06.02. Air ComDressor EauiDment. Unless otherwise specified, all components of the compressed air equipment system, including motors and the associated receiver, shall be shop primed and finish painted prior to shipment to the site. Unless otherwise specified, all iron and steel surfaces, except galvanized surfaces and stainless steel, shall be thoroughly cleaned, sanded, and shop primed with one or more coats of Cook "391-N-167 Barrier Coat", Kop-Coat "340 Gold Primer", Tnemec "37-77 Chem-Prime", or Valspar "13-R-28 Chromox Primer'' rust-inhibitive primer, followed by two or more finish coats of Cook "801 Series Gloss Enamel", Kop-Coat "Glamortex 501 Enamel", Tnemec "Series 2 Tneme-Gloss", or Valspar "12 Series Panorama" gloss alkyd enamel. Stainless steel, nonferrous, and nonmetallic surfaces shall not be painted. The total paint film thickness, including prime coat and finish coats, shall be not less than 5 mils. The color shall be safety green in accordance with ANSI 253.1. The compressor cabinet shall have manufacturer's standard finish 2-5.06.03. Aluminum. All surfaces of aluminum which will be in contact with concrete, mortar, or dissimilar metals shall be given a coat of epoxy enamel. PART 3 - EXECUTION 3-1. INSPECTION. The Contractor and the manufacturer's representative shall inspect all equipment prior to erection. Repair or replacement of defective or damaged items, as directed by the Engineer, shall be done at no additional cost to the Owner. 3-2. PREPARATION. Each filter cell shall be cleaned thoroughly before filter equipment is installed and shall be kept clean throughout placement operations. 3-3. INSTALLATION. Contractor is notified that filter equipment will need to be placed prior to completion of the building superstructure and roofing system. Contractor shall suitably protect the equipment during construction operations. The filter system and all accessories and devices shall be com- pletely installed, adjusted, and placed in operating condition under the (Carlsbad Water) (Recycling Facility) 11250 -1 5- direction of an experienced, competent, and authorized representative Of the filter equipment manufacturer. Before filter media is placed, the equipment installation shall be checked and approved by the manufacturer's field representative. The manufacturer's representative shall also inspect and test the operation of all mechanisms and operating devices. The Contractor shall install filter modules, reject supports, and other components in conformance with provisions of these specifications, as indicated on the drawings, and in accordance with the manufacturer's instructions. Filter media shall be placed after installation of filter equipment. Media shall be kept clean and free of trash and other debris throughout placement operations. Foreign objects which fall into media shall be immediately removed. The installation of filter media shall be under the direct supervision and Control of the manufacturer's field representative. The Contractor shall install the media in compliance with the recommendations and instructions of the filter system manufacturer. Aluminum grating shall not be damaged during handling and installation. Sampling hatches shall be anchored with hinged joints. All other grating shall be securely anchored in place. Removable grating panels shall be anchored with readily removable fasteners. Grating panels shall be fastened in place with saddle-clips or flange blocks as illustrated in the NAAMM "Metal Bar Grating Manual". Clips or flange blocks for aluminum grating shall be aluminum or stainless steel. Clips shall be fastened to supporting steel with Nelson stud-type bolts at least 114 inch in diameter. All fastener parts shall be galvanized or shall be of a corrosion-resistant alloy. 3-4. FIELD QUALITY CONTROL. Field testing shall conform to the require- ments of the field testing paragraphs under the Quality Assurance paragraph. At least one sieve analysis shall be made representing each truckload of media. Additional analyses shall be made whenever deemed necessary by the Engineer. 3-5. STARTUP. The Contractor shall have the manufacturer's representative check and verify that installation of the filter modules is in accordance with drawings and manufacturer's installation instructions. The Contractor shall have manufacturer's representative adjust all reject weir plates and air rates to each airlift. The Contractor shall start up and test in accordance with these specifications. (Carlsbad Water) (Recycling Facility) 11250 -16- Startup testing shall confirm the hydraulic capacity of the filter systems and shall be done using clean water in the presence of, and to the satisfaction of, the Engineer. All filter system components which do not perform satisfactorily will be promptly corrected at no cost to the Owner. 3-6. TRAINING. The Contractor shall have the manufacturer's representative instruct plant personnel on operation and maintenance of filters and compressed air control system and air compressors. The representative shall provide 24 hours of onsite instruction. End of Section (Carlsbad Water) (Recycling Facility) 11250 -17- Section 11330 MICROFILTRATION (MF) TREATMENT SYSTEM PART 1 -GENERAL 1.01 DESCRIPTION A. Description of Work: 1. This Section coves the microfiltration (MF) treatment system. The membrane filtration units will be supplied as a skid mountedkontainerized unit. The membrane filtration ancillary equipment will be supplied as a skid mounted equipment container. All piping within the membrane filtration system framework will be provided by the Microfiltration Equipment Manufacturer (MFEM). a. The Owner has placed a purchase order with an MFEM. A copy of the MFEM’s approved shop drawings and equipment information will be provided for the CONTRACTOR. 2. The MF system shall consist of inlet pumping, pre and post- treatment chemical addition, particulate straining, two CMF-S Model 84S10T MF units, the membrane cleaning system, the membrane backwash filtration system, compressed air system, interconnecting piping, valves, controls and instrumentation. 3. The MF system will treat a secondary treated, undisinfected municipal wastewater effluent that has received conventional primary and secondary treatment at the Encina Water Pollution Control Facility. 4. The CONTRACTOR’S Responsibilities include, but is not limited to the following: a. Offloading and placing the skid mounted containerized MF unit. b. Offloading and placing the MF accessory equipment container. c. Installation of all membrane filtration equipment provided by the MFEM. d. Submittal, purchase, and installation of equipment specified by the ENGINEER. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -1- e. Installation of yard piping. f. Installation of interconnecting piping and appurtenances between components of the MF system. g. Installation of electrical systems, field instrumentation, control panels, and operator interfaces. h. Corrective assistance during demonstration, field, and acceptance testing. B. Coordination 1. The MFEM will furnish the majority of equipment items associated with the MF system and will participate in the commissioning, startup, testing, and training of DISTRICT'S personnel in operation of the MF system as a whole. 2. The CONTRACTOR shall unpack, assemble, and install equipment items furnished by the MFEM as shown on the Drawings and as specified herein. In addition, the CONTRACTOR shall also furnish and install additional equipment items, interconnecting piping, valves, instruments, power and control wiring, and other appurtenances not furnished by the MFEM to provide a complete and operable system. 3. The MFEM will provide all information needed to coordinate the design of the membrane filtration system and the ancillary equipment not provided by the MFEM. 4. The CONTRACTOR, in association with the MFEM, shall be responsible for acceptance testing of individual items of equipment as defined in the individual equipment specifications. The CONTRACTOR shall also participate in the startup of the MF system as required herein. 1.02 SUBMITALS A. General 1. Shop drawing submittals shall be made in accordance with the requirements of Section 01 300, except as modified herein. 2. The CONTRACTOR shall: a. Provide manufacturers' catalog sheets for all components furnished by the CONTRACTOR. Include the selected model numbers and accessories clearly indicated. (CARLSBAD WATER) (RECYCLING. FACILITY) (1 00% Submittal) 11330 -2- B. 1.03 A. 6. b. Submit certified fabrication drawings of the equipment provided by the CONTRACTOR. c. Submit spare parts lists for all equipment provided by the CONTRACTOR. d. Submit operating and installation instructions for all equipment provided by the CONTRACTOR. Piping and Equipment Supports 1. The CONTRACTOR Shall: a. Identify by unique number and detail all proposed external equipment and pipe supports located outside pipe trenches. b. Provide detailed shop and assembly drawings, catalog information, and other details for the metal framing support system and appurtenances used in pipe trenches. PRODUCT DELIVERY STORAGE AND HANDLING Shop Drawings 1. Prior to the delivery of the Goods, the MFEM will submit to the CONTRACTOR and Owner a bill of materials for the contents of all shipments. This list will detail contents; size and weights of each item shipped. Upon receipt of the Goods, the bill of materials will be used to determine that the Goods are in conformance with the specifications. Transportation of Goods 1. The MFEM will make all arrangements for transportation and delivery of all MFEM supplied equipment and materials to the Point of Delivery. Shipments of materials will be delivered to the Point of Delivery only during regular working hours. 2. The MFEM will coordinate deliveries that 'occur between specified Contract Times to accommodate Work of CONTRACTORS and/or Owner, limitations of storage space, and availability of equipment and personnel for handling products. 3. A representative of the MFEM will be present when the MF equipment is delivered to the site, off-loaded, and unpacked by the CONTRACTOR, in order to provide technical guidance and certify proper delivery condition and handling methods. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -3- a. The MFEM representative will provide a letter certifying that all equipment has been delivered, off-loaded and unpacked in accordance with the recommendations of the manufacturer. 4. A representative of the MFEM will visit the site when all equipment to be provided under this Contract has been delivered, or at such other time as requested by the ENGINEER, to inventory the equipment and confirm identification of all individual items. 5. The CONTRACTOR shall provide equipment and personnel necessary to unload, handle and store products by methods designed to prevent soiling or damage and as directed by the MFEM. C. Protection of Goods 1. General: a. The MFEM will make all arrangements and provisions necessary for the protection of Goods to the Point of Delivery. The MFEM will coordinate with the DISTRICT and CONTRACTOR for Goods that require special protection, storage or handling. b. The CONTRACTOR shall not open MFEM’S containers until the time of installation, unless recommended by the manufacturer, or otherwise specified. 2. The CONTRACTOR shall be responsible for providing proper storage and storage facilities in accordance with the MFEM storage requirements. a. The MFEM will provide the CONTRACTOR with a list of pumps, motors, drives, electrical equipment, instrumentation equipment (controls, devices, panels, etc.), and other equipment having anti-friction or sleeve bearings for storage in weather tight storage facilities such as warehouses. b. At least thirty (30) days prior to delivery of the Goods, the MFEM will provide CONTRACTOR with a list of panels, microprocessor-based equipment, and other Goods and devices subject to damage or useful life decrease due to temperature below 40 degrees F. or above 120 degrees F, relative humidity above ninety (90) percent, or exposure to rain. c. The MFEM will provide the CONTRACTOR and Owner with a list of Goods which could be damaged by low or high (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -4 - temperature and require temperature-controlled storage space. d. The MFEM will provide the CONTRACTOR and Owner a list of Goods required to be protected from contamination by dust, dirt, and moisture. e. The MFEM will provide the CONTRACTOR and Owner with a list of Goods required to be maintained at specific humidity levels as recommended by manufacturer. f. Electrical equipment, controls, and instrumentation will be protected against moisture or water damage. The CONTRACTOR, as noted by the MFEM, shall connect space heaters provided in the equipment and operated at all times until equipment is placed in operation. g. The MFEM will provide specific storage and handling instruction for each loose-shipped item of equipment, instrumentation, materials and crates provided by the MFEM. 3. All packages containing panels, electronic devices, and other microprocessor-based equipment will be furnished with a desiccant, volatile corrosion inhibitor (VCI) blocks, a moisture indicator, and maximum-minimum indicating thermometer. The MFEM will provide a spare set of such protection equipment including a desiccant, a moisture indicator, and VCI blocks for each package containing panels, electronic devices, and other microprocessor-based equipment for replacement by the CONTRACTOR during the storage period. 4. If damage occurs to any items while stored on-site, the CONTRACTOR shall be responsible for any costs associated with damaged items. 1.04 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) 1. ASTM A 193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service. B. American National Standards Institute (ANSI): 1. ANSI B16.5 - Pipe Flanges and Flanged Fittings C. American Welding Society (AWS) (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11 330 -5- 1. AWS A5.9 - Specification for Bare Stainless Steel Welding Electrodes and Rods 2. AWS Dl .I - Structural Welding Code - Steel D. Steel Structure Painting Council (SSPC) 1. SP 10 - Joint Surface Preparation Standard Near-White Blast Cleaning E. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. 1.05 QUALITY ASSURANCE I QUALITY CONTROL (QA I QC) A. All equipment furnished under this specification shall be new and shall be the standard product of a manufacturer who is fully experienced, reputable, qualified and regularly engaged for at least 5 years in the manufacture of the equipment to be furnished. B. The CONTRACTOR shall assume responsibility for the satisfactory installation and operation of the MF system. Upon completion of system installation, manufacturers of equipment shall inspect the completed work and shall submit a certificate of proper installation. PART 2 - PRODUCTS 2.01 A. B. 2.02 A. B. 2.03 A. MF FEED PUMPS The MF feed pump station will provide pressurized feed to the automatic strainers and downstream MF units. The MF feed pumps will be furnished by the MFEM for installation by the CONTRACTOR. AUTOMATIC STRAINERS The automatic strainers will be used to provide pre-filtration ahead of the MF membrane units. The automatic strainers will be furnished by the MFEM for installation by the CONTRACTOR. CHEMICAL ADDITION SYSTEMS General: Chemical addition systems shall be provided to inject sodium hypochlorite into the MF feed and filtrate lines, and inject sodium hydroxide, Memclean C, and citric acid solution into the MF cleaning feed line for the CIP process. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -6- B. The sodium hypochlorite addition system shall include a bulk storage tank and accessories, chemical metering pump and accessories, in-line mixers, interconnecting piping, valves, instrumentation and controls. 1. The CONTRACTOR shall furnish and install the sodium hypochlorite bulk storage tank. a. Requirements for the sodium hypochlorite bulk storage tank are included in Section 131 9OP. 2. The CONTRACTOR shall furnish and install the sodium hypochlorite chemical metering pumps with accessories, equipment numbers MP-1100-(2), as well as system interconnecting piping, valves, and instrumentation. a. Requirements for the sodium hypochlorite chemical metering pump and accessories are included in Section 11727. 3. CONTRACTOR shall furnish and install the sodium hypochlorite injection quill sized to inject chemical at or near the centerline of the recirculation piping to the tank. The quill shall be constructed of Type 316 stainless steel and shall incorporate an integral injection ball check valve. The quill and integral valve shall be as manufactured by Neptune Chemical Pump Company or equal. 4. The CONTRACTOR shall furnish and install the in-line static mixer (equipment number "0903) along with related instrumentation and accessories. a. Requirements for the sodium hypochlorite in-line mixer are included in Section 11 530. C. The citric acid injection system will include a mixing tank, tank mixer, chemical metering pump and accessories, interconnecting piping, valves, instrumentation and controls. 1. The citric acid mix tank with accessories, equipment number T- 0933 will be furnished by the MFEM for installation by the CONTRACTOR. 2. The citric acid tank mixer, equipment number "0933 will be furnished by the MFEM for installation by the CONTRACTOR. 3. Chemical metering pump with accessories, equipment number MP- 0939 will be provided within the skid mounted containerized equipment unit by the MFEM. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -7 - 4. The citric acid injection quill, equipment number, "0939-1 will be furnished by the MFEM for installation by the CONTRACTOR D. The sodium hydroxide injection system will include a sodium hydroxide carboy chemical metering pump and accessories, interconnecting piping, valves, instrumentation and controls. 1, The sodium hydroxide carboy with accessories, equipment number T-0941 will be furnished by the MFEM for installation by the CONTRACTOR. 2. Chemical metering pump with accessories, equipment numbers MP-0941 will be included with the skid mounted equipment container provided by the MFEM. 3. The sodium hydroxide injection quill, equipment number, "0941-1 will be furnished by the MFEM for installation by the CONTRACTOR. E. General: Memclean C is a surfactant used with sodium hydroxide for the membrane system clean-in-place process. 1. The Memclean C injection system will include a Memclean C carboy chemical metering pump and accessories, interconnecting piping, valves, instrumentation and controls. a. The Memclean C carboy with accessories, equipment number T-0940 will be furnished by the MFEM for installation by the CONTRACTOR. b. Chemical metering pump with accessories, equipment numbers MP-0940 will be included with the skid mounted equipment container provided by the MFEM. c. The Memclean C injection quill, equipment number, "0940-1 will be furnished by the MFEM for installation by the CONTRACTOR. 2.04 MF MEMBRANE SYSTEM A. General: The following subsystems and components are included in the MF membrane system: 1. Two (2) CMF-S MF units, equipment numbers MF-0912-(2) consisting of the following: 84S10T microfiltration modules; module support frame (two units per frame): skid mounted piping, valves, and instrumentation; electrical control panels; and pneumatic panel, (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -8- 2. Interconnecting feed, filtrate (effluent), waste, process air, and control air piping manifolds. 3. All required components for installation, including but not necessarily limited to, appropriate anchor bolts, skid mounted piping supports, hardware, sutface preparation, and shop and field painting. B. The CMFS units will be skid-mounted inside a container assembly connected on common pipe manifolds as shown on the Drawings. C. The MFEM will arrange for the delivery of the containers to the site. The CONTRACTOR shall be responsible for: 1. Unloading the units from the shipping containers, 2. storing the equipment prior to assembly and installation, 3. completing final unit assembly, 4. and setting the units on the equipment pad. D. All piping external to the CMFS containerized units shall be furnished and installed by the CONTRACTOR. E. The Owner will provide the services of a qualified representative of the MFEM to instruct CONTRACTOR’S personnel in the proper unloading, storage, assembly and erection procedures. F. The unit mounted electrical and pneumatic panels will be furnished pre- wired, and all power and control wiring within the CMF unit framework will be provided by the MFEM. All external power and control wiring is the responsibility of the CONTRACTOR. 1. The CONTRACTOR is responsible for control wiring of the feed pH and conductivity meters to the. containerized MF unit control panel. G. CONTRACTOR shall be responsible for connecting the containerized MF unit overflow to the plant drain system. H. Valves 1. Membrane system manual valves listed in the table below will be provided by the MFEM. BER SIZE [INCHES] TYPE (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -9 - a. Other manual valves associated with this system, not listed above, shall be provided by the CONTRACTOR. 2.05 COMPRESSED AIR SYSTEM A. Compressed Air System 1. The compressed air system shall consist of two separate subsystems: a process air blower system and control air compressor system. The MFEM will provide the control air system and process air blower system as part of the skid-mounted ancillary equipment container. a. The process air blower system shall consist of the following: two aeration blowers with inlet filter assemblies; interconnecting piping, valves, instrumentation and controls. 1) The process air blower system will supply air for the membrane process aeration system. b. The control air system will consist of the following: two air compressors with integral dryers and outlet filters; two supply air filter assemblies: one air receiver with accessories; one control air regulator assembly; one process air regulator assembly; interconnecting piping, valves, instrumentation and controls. 1) The compressed air system will supply control air for the pneumatically operated valves furnished with the MF system. 2.06 MEMBRANE CLEANING SYSTEM A. Membrane Cleaning System 1. The cleaning system shall include a CIP solution tank and accessories, citric acid dose system, Memclean C dose system, sodium hydroxide dose system; interconnecting piping, valves, instrumentation and controls. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11 330 ~ 10 - B. C. 2.07 A. B. a. The CIP tank, equipment number T-0925, will be mounted within the skid mounted MF containerized unit, provided by the MFEM, and share a common wall with the backwash supply tank. b. Membrane cleaning system manual valves listed in the table below will be provided by the MFEM. c. All other manual valves associated with the cleaning system not listed in the table above shall be furnished and installed by the CONTRACTOR. See Section 15100 for valve requirements and Valve Schedule. CONTRACTOR shall be responsible for connecting the CIP waste line from the containerized MF unit to the plant drain system. Instrumentation and Controls 1. Cleaning of individual MF units shall be manually initiated but automatically controlled thereafter through the PLC. Cleaning solutions shall be made up of RO permeate and the appropriate cleaning chemicals. Tank charging shall be conducted automatically through the PLC. 2. For instrument component specifications, see Section 13560 and other related sections. MEMBRANE BACKWASH SYSTEM The backwash system shall consist of a storage tank, interconnecting piping, valves, instrumentation and controls. The backwash tank, equipment number T-0920, will be mounted within the skid mounted MF containerized unit, provided by the MFEM, and share a common wall with the CIP tank. 1. Backpulse system manual valves listed in the table below will be provided by the MFEM. TAG NUMBER SIZE [INCHES] TYPE V-0920-2 BFV3 8 (CARLSBAD WATER) (RECYCLING FACILITY) (1 00% Submittal) 11330 - 11 - C. D. 2.08 A. B. C. 2.09 A. 2.10 A. a. All other manual valves associated with the cleaning system not listed in the table above shall be furnished and installed by the CONTRACTOR. See Section 15100 for valve requirements and Schedule. CONTRACTOR shall be responsible for connecting the backwash waste line from the unit container to the plant drain system. Instrumentation and Controls 1. The backwash cycle shall be automatically initiated and controlled through the PLC. Backwash cycles shall be initiated on an elapsed time of filtration basis. The design backwash cycle interval shall be 22 minutes. 2. For instrument component specifications, see Section 13560 and other related sections. MF FILTRATE STORAGE TANK (BREAK TANK) General: The MF filtrate storage tank is used to provide intermediate storage and equalization of flow between the MF and RO systems. The filtrate storage tank, equipment number T-0919, shall be furnished and installed by the CONTRACTOR in accordance with the Contract Documents. The MF filtrate storage tank is specified in Section 13190. The CONTRACTOR is responsible for connection of the MF system filtrate line from the containerized MF unit to the filtrate storage tank. INTERCONNECTING PIPING AND VALVES The CONTRACTOR is responsible for all piping and valves as required to provide a complete and operable system. All pipe and valves shall be provided in accordance with applicable sections under Division 15. The CONTRACTOR is advised that some manual and automated valves shown on the Drawings will be furnished by the MFEM for installation by the CONTRACTOR. See the valve schedule attached to Section 15100 for identification of all MFEM supplied valves. INSTRUMENTATION AND CONTROLS General 1. The MF system will be controlled by a PLC based control system. The system will consist of a master PLC housed in panel PLC-1. (CARLSBAD WATER) (RECYCLING FACILITY) (1 00% Submittal) 11330 - 12- An operator graphical interface (OIT-MF) shall be provided to communicate with the system. 2. The unit mounted panel and PLC-1 will be located in the MF process area. The MF System Workstation will be located in the Control Room. 3. The MF control system will be required to communicate with the plant supervisory control system for monitoring and control. B. Scope 1. The MFEM will provide PLC-1, the master PLC, and other local control panels not provided by equipment vendors. The MFEM will also provide the MF System Workstation (OIT-MF) specifically configured to operate the system. 2. The CONTRACTOR shall furnish all hardware and software associated with the plant supervisory control system. The CONTRACTOR shall also be responsible for all software programming associated with the plant overall supervisory control system. 3. The CONTRACTOR shall be responsible for installation of all control system hardware. In addition, the CONTRACTOR shall provide all interconnecting field wiring. This includes internal data link wiring for the MF system and between PLC-1 and the supervisory control system interface; plant wide data highway cable; all instrumentation and control system power and signal wiring; and all other connections shown on the Drawings or otherwise required to provide a complete and functional system. 4. The CONTRACTOR shall be responsible for all field instrumentation not provided by the MFEM. 5. Requirements a. See Division 13 for Instrumentation and Control requirements. b. All wiring shall be installed in accordance with the applicable requirements of Division 16. C. The MFEM will provide the following control panels: (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -13- D, 2.1 1 A. TAG NUMBER 1 NAMt . .. - P-091 I-(2) Air Compressor Panel(s) Integral Plant Pneumatic Control Integral .. - Panel CP-0939 CIP Dose Pump Panel 1 Non-Freestanding The CONTRACTOR shall supply all other control panels not listed above as specified in the Contract Documents. 1. For general control system and panel mounting requirements, see Division 13. 2. All wiring shall be installed in accordance with the applicable requirements of Division 16. MISCELLANEOUS COMPONENTS Anchor Bolts: Anchor bolts shall be Type 316 stainless steel and at least 112-inch in diameter. The MFEM will provide all required anchor bolts for system components furnished by him, excluding anchorage components for non-freestanding panel support systems furnished by the CONTRACTOR. PART 3 - EXECUTION 3.01 A. B. C. 3.02 A. SHIPMENT, HANDLING, AND STORAGE The equipment specified herein, shall be factory assembled and ready for installation and connection to the piping as shown on the drawings. The parts and assemblies that are shipped unassembled shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. See Section 01015 for additional requirements. INSTALLATION General: 1. The CONTRACTOR is responsible for all installation and shall comply with the installation instructions provided by the MFEM including any and all requirements prescribed by the MFEM or its (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11 330 -14- manufacturers for the proper handling, placement, connection, and wiring of the MF System. 2. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer's printed instructions, and approved shop drawings. 3. The CONTRACTOR shall be responsible for making any adjustments and/or modifications to the installation process that may become necessary to ensure that all equipment is properly installed. 4. The MFEM will: a. Submit to the CONTRACTOR five (5) copies of the approved shop drawings to be used during the Installation of the Goods. b. Provide written instructions to the CONTRACTOR that detail the installation procedures and proper procedures for unloading, handling, installing and wiring of all supplied membrane filtration equipment. The MFEM's written instructions will be submitted 14 days prior to the scheduled delivety of equipment. c. Instruct the CONTRACTOR in the proper installation procedures for the membrane filtration equipment including all associated ancillary components. B. Connections: 1. The CONTRACTOR shall furnish and install the interconnecting piping between the MF unit container and the MF accessory container. CONTRACTOR is responsible for all interconnections of the Membrane System including, but not limited to: a. CIP Waste Line connection b. Membrane Unit Overflow connection c. Raw Water Feed connection d. Filtrate connection e. Filter to Waste connection f. All drain piping (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -15- g. All utility piping 2. CONTRACTOR is responsible for confirming with the MFEM the size and type of connection for each line included in the MF system. C. Valves 1. In horizontal pipe runs centered less that 4’-6” above the operating floor, orient valve stems as close to vertical as permitted by adjacent piping. 2. In horizontal pipe runs centered between 4-6” and 6’-6” above the operation floor, orient the valve stems as close to horizontal as permitted by adjacent piping. 3. In vertical pipe runs, orient the valve stems in the most accessible position for operation from the operating floor. D. Instrumentation and Control Components 1. Instrument Mounting: Mount each instrument as specified herein and in accordance with manufacturer’s printed instructions. Provided block valves for all instrument taps unless otherwise noted or shown. 2. Mounting Locations: a. Provide clear space for front and rear access to interior and/or panel mounted components. b. Orient displays for simultaneous viewing of process variable and process line. c. Provide clear floor space for approach and observation. 3. Instrumentation Tubing: a. Tubing shall be 316 stainless steel seamless. The use of plastic tubing will not be allowed. b. Differential pressure transmitters shall be connected with 1/2- inch O.D. by 0.049-inch wall tubing. All other tubing shall be 1/4-inch O.D. by 0.035-inch wall tubing. c. Tubing runs shall be neatly installed on horizontal and vertical alignment. All bends, where possible, shall be 90 degree angles. Multiple runs of tubing shall be properly supported (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 - 16 - E. 3.03 A. B. C. D, with standard commercial spacers such that the tubing runs are in the same plane and uniformly spaced. The maximum distance between supports shall be five feet. d. Tubing runs to differential pressure transmitters shall continuously slope upward to the pressure taps on the process piping. High points in these tube runs will not be allowed. e. All tubing fittings shall be stainless steel double ferrule type, Swagelok or equal. f. Pipe threads shall be used only where absolutely necessary. Pipe thread joints shall be made up with Teflon tape and Leak Lock sealant from Highside Chemicals, or equal. Wiring: Refer to Division 16, Electrical. STARTUP AND COMMISSIONING The MFEM will prepare a “Detailed Plan of Commissioning Activities” that will be used as a guideline for commissioning of the Goods provided by the MFEM. The ”Detailed Plan of Commissioning Activities” will identify the commissioning requirements for all tagged components that have been supplied by the MFEM. 1, The “Detailed Plan of Commissioning Activities” will be coordinated with the activities of the Installation CONTRACTOR, the ENGINEER and the DISTRICT. The CONTRACTOR is responsible for preparing a startup and commissioning schedule, which incorporates the MFEM’s “Detailed Plan of Commissioning”. The MFEM will schedule his on-site activities with commissioning and startup schedules developed by the CONTRACTOR. The MFEM will be responsible for providing labor, materials, equipment, and incidentals necessary to perform the MF system commissioning. The CONTRACTOR is responsible for ensuring the installation is complete to a level that will allow the MFEM to complete commissioning activities as described in the commissioning plan, without exceeding the MFEM scheduled number of days. 1. If the CONTRACTOR installation is not complete to allow commissioning by the MFEM within the MFEM contracted days, the CONTRACTOR will be responsible for additional costs incurred by the MFEM. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -17- E. F. G H. 3.04 A. 3.05 A. 3.06 A. 2. The MFEM will be responsible for initial operation of the MF control system and will make any required changes or adjustments necessary to perform the functions intended. 3. The MFEM will perform checkout and startup of the system components. No system or subsystem shall be started-up for continuous operation unless all Goods, including instrumentation and monitoring systems, of that system or subsystem have been tested and proven to be operable as intended by the Contract Documents. As a part of the commissioning, the MFEM will start-up and operate all support systems provided by MFEM, including but not limited to chemical feed systems, instrumentation, air compression equipment, and electric controls. This testing will demonstrate that there are no water or air leaks in the System, that the piping has been installed and connected properly, that the electrical system is operating correctly, and that the instrumentation has been properly calibrated. The MFEM will furnish all labor, materials, instruments, and incidental and expendable equipment required for commissioning I placing the equipment into operation. The MFEM will conduct a membrane integrity test on each Unit PAINTING Field painting of MF system components shall be in accordance with the requirements of Division 09. OPERATIONS AND MAINTENANCE MANUAL The CONTRACTOR shall submit operations and maintenance manuals for equipment not furnished by the MFEM in accordance with the Contract Documents. FIELD SERVICES Services Provided by MFEM 1. The MFEM will provide assistance to the DISTRICT, ENGINEER, and CONTRACTOR during the design, construction, commissioning and acceptance testing of the Goods. 2. A representative of the MFEM will be present on-site to provide guidance when the MF units are delivered. (CARLSBAD WATER) (RECYCLING FACILITY) (1 00% Submittal) 11330 -18- 3. A representative of the MFEM will visit the site when all equipment to be provided under this Contract has been delivered. 4. The MFEM will provide necessary inspections to insure proper installation of system components. 5. The MFEM will instruct the CONTRACTOR in the proper installation procedures for the membrane filtration equipment including all associated ancillary components. The training will be conducted on-site by an authorized, experienced, employee of the MFEM. 6. The MFEM will be present on site to witness and supervise the proper placement and positioning of the MF skid mounted containerized unit, ancillary equipment container and all significant ancillary equipment, including, but not limited to tanks, pumps, compressors, blowers, and VFD’s. An MFEM representative will also be present to supervise the assembly installation of the associated anchor bolts. 7. The MFEM will inspect, with the CONTRACTOR and ENGINEER, the System and list any equipment that has not been properly installed, detailing the outstanding installation issues on a “punch list” and noting the party who shall be responsible for each correction. 8. Throughout the acceptance testing period, a representative of the MFEM will be present on site during normal working hours and available via means of a pager or cellular communication during non-working hours in case of an emergency. 9. The MFEM will provide Operations Assistance to the DISTRICT for the MF equipment during the correction period. B. Field Testing 1. Coordination a. The CONTRACTOR shall submit functional and performance test schedules and plan for equipment, at least 14-days prior to start of related testing. b. The MFEM will schedule his on-site activities with schedules developed by the CONTRACTOR. 2. Functional Testing a. General (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11 330 - 19- 1) The CONTRACTOR shall conduct an initial functional test on installed components of the MF system to demonstrate their proper installation and operation under the supervision of the MFEM. 2) The CONTRACTOR will perform functional loop tests on all installed equipment to demonstrate their proper installation and operation under the supervision of the MFEM. 3) The CONTRACTOR will submit a report documenting each test in a format acceptable to the ENGINEER. b. Chemical Metering Pumps: Inspect for proper alignment, quiet operation, and acceptable vibration levels. c. All Other Pumps: 1) Alignment: Test complete pump assemblies for correct rotation, proper alignment and connection, and quiet operation. 2) Vibration Test: a) Test with units installed and in normal operation, and discharging to the connected piping systems at rates between the low discharge head and high discharge head conditions specified, and with the actual foundations provided. Pumps shall not develop at any frequency or in any plane, peak to peak vibration amplitudes in excess of 3 mils. b) If units exhibit vibration in excess of the limits specified, adjust or modify as necessary. Units which cannot be adjusted or modified to conform as specified shall be replaced. 3) Operating Temperatures: Monitor bearing areas on pump and motor for abnormally high temperature. d. Tanks 1) Fill all storage tanks to the overflow for 24-hours to ensure no there is no leakage due to tank damage or defect. 2) Any leaks observed shall be repaired to the satisfaction of the ENGINEER. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 -20- e. Piping and Valves 1) Conduct hydrostatic or pneumatic pressure and leakage tests on all newly installed pipelines, as appropriate. 2) Conduct tests in accordance with the requirements of Section 02704. Test pressure shall be as specified in the applicable piping section. f. Instrumentation and Control System 1) The CONTRACTOR shall provide loop/component inspections and tests to track terminations and calibrations. 2) MFEM will be present to confirm completion of required terminations and calibrations, and will verify communications between system components on a loop-by-loop basis. 3. Performance Testing a. General 1) Prior to complete system startup, components of the MF system shall undergo individual performance tests to demonstrate and confirm that the equipment and/or sub- system meets performance requirements specified herein. Performance testing shall be conducted as part of the pre-operational testing specified in Section 01650. 2) Performance testing shall be conducted by the CONTRACTOR. 3) The CONTRACTOR will submit a report documenting each test in a format acceptable to the ENGINEER. b. MF Membrane System 1) The MFEM will conduct a performance testing on the complete MF train with membrane module pressure vessels installed for a period of up to 72-hours of cumulative operation, during which the MF system will be operated and adjustments made to demonstrate that the equipment and controls operate as a functional system as intended. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11 330 - 21 - (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) The major acceptance criteria for the 72-hour performance tests shall be that the train and ancillary systems operate as intended without major mechanical or electrical problems and with minimal operator attention. Observed deficiencies in operation of the system will be corrected to the satisfaction of the ENGINEER at no cost to the Owner. Significant Interruption: May include any of the following events: Failure of MFEM to maintain qualified onsite startup personnel as scheduled. Failure of any equipment item or treatment subsystem furnished by MFEM to meet specified performance requirements for more than 2 consecutive hours. Failure of any critical equipment unit, system, or subsystem that is not satisfactorily corrected within 5 hours after failure. Failure of non-critical unit, system, or subsystem that is not satisfactorily corrected within 8 hours after failure. As may be determined by ENGINEER. The following events will not be considered cause for significant interruption: a) Loss of feedwater delivered to the MF system for reasons beyond the control of the MFEM or CONTRACTOR. b) Loss of power to the plant for reasons beyond the control of the MFEM or CONTRACTOR. c) Inability of the product water distribution system to accept water produced by the MF system. d) As may be determined by the ENGINEER. Following successful completion of the 72-hour performance test, the MFEM will prepare a report documenting system results which includes daily operating and performance data for each day of the test. 11 330 -22- Submittal of the report and subsequent approval by the ENGINEER shall be required prior to final acceptance of the system. 6) Minimum prerequisites prior to initiation of the 72-hour performance test include the following: a) Successful completion of functional and performance testing of all MF system individual equipment items. b) Successful completion of functional and performance tests for portions of the control system required to operate the MF equipment. C. Acceptance Testing 1. 2. 3. 4. 5. 6. 7. The CONTRACTOR shall be responsible for acceptance testing of individual items of equipment as defined in the individual equipment specifications. The CONTRACTOR is also responsible for the coordination and participation in the commissioning and startup of the Interim MF System as required herein. The MFEM will coordinate all acceptance testing activities with the CONTRACTOR. Upon receipt of the written “notice of substantial completion”, the MFEM will perform an acceptance test on the System. The MFEM will furnish all materials, instruments, and incidental and expendable equipment required for acceptance testing, except where otherwise specified. The CONTRACTOR and MFEM shall notify the Owner at least 48 hours prior to beginning the acceptance testing. The Owner or authorized representative will be present to witness the acceptance testing. Final Acceptance: a. ENGINEER will accept equipment and systems as complete and ready for continuous operation only after successful testing and startup is completed and documented, test and startup reports submitted, and manufacturers’ services completed for training of Owner‘s personnel. (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11 330 -23- End Of Section (CARLSBAD WATER) (RECYCLING FACILITY) (100% Submittal) 11330 - 24 - SECTION 1 1340 REVERSE OSMOSIS (RO) TREATMENT SYSTEM GENERAL 1.01 A. B. 1.02 A. B. DESCRIPTION Scope: This section covers the reverse osmosis (RO) treatment system. The RO system shall consist of transfer pumping, pretreatment chemical addition systems, cartridge filtration, two (2) 240 gpm (nominal permeate capacity) RO membrane trains complete with membrane feed pumps, the membrane clean-in-place (CIP) system, the membrane flushing system, product water decarbonator, interconnecting piping, valves controls and instrumentation. Requirements: The CONTRACTOR shall procure the services of a qualified reverse osmosis equipment manufacturer (ROEM) to provide detailed design and construction phase services for the RO system. The ROEM shall furnish all labor, materials, equipment and incidentals necessary to fabricate, ship to the site, install, startup, performance test, and demonstration test the RO system as shown on the Drawings and as specified herein. QUALITY ASSURANCE General: All equipment furnished under this specification shall be new and shall be the standard product of a manufacturer who is fully experienced, reputable, qualified and regularly engaged for at least 5 years in the manufacture of the equipment to be furnished, unless otherwise allowed herein. Reference Standards: Where reference is made to one of the following standards, the revision in effect at the time of bid opening shall apply. 1. ' American Society for Testing and Materials (ASTM) a. ASTM A 36 - Standard Specification for Carbon Structural Steel b. ASTM A 276 - Standard Specification for Stainless Steel Bars and Shapes c. ASTM A 500 '- Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -1 - d. ASTM A 193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service. e. ASTM A 380 - Standard Specification for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems f. ASTM A 967 - Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts 2. American National Standards Institute (ANSI): a. ANSI B16.5 - Pipe Flanges and Flanged Fittings b. ANSI B16.9 - Wrought Steel Butt Welding Fittings 3. American Society of Mechanical Engineers (ASME) a. ASME Boiler and Pressure Vessel Code 4. American Welding Society (AWS) a. AWS A5.9 - Specification for Bare Stainless Steel Welding Electrodes and Rods b. AWS D1.l - Structural Welding Code - Steel 5. Steel Structure Painting Council (SSPC) a. SP 10 - Joint Surface Preparation Standard Near-White Blast Cleaning C. Certification: The CONTRACTOR shall assume responsibility for the satisfactory installation and operation of the RO system. Upon completion of system installation, manufacturers of equipment shall inspect the completed work and shall submit a certificate of proper installation. The CONTRACTOR shall furnish to the Owner all certification and warranty obtained from the ROEM for the system provided. D. Single System Supplier: Major components of the RO treatment system shall be furnished by a single qualified ROEM. The CONTRACTOR shall assign the responsibility for the design, procurement, fabrication, and proper operation of the RO system to the ROEM, who shall be listed on the "EquipmentlMaterial Source Information to Accompany Proposal" form in the Contract Documents. The minimum scope of work (Carlsbad Water) (Recycling Facility) (100% Submittal) 11 340 -2- performed by the ROEM shall conform to the division of work described herein. 1, ROEM Qualifications: a. The ROEM shall be a corporation, or joint venture or partnership with experience in the design, construction, and startup of RO systems and shall have been in business for at least three years. The ROEM shall hold a valid contractor's license in accordance with state and local laws. The ROEM's license number shall be listed where required on the BID FORM. b. The ROEM shall have designed, fabricated and installed at least three (3) RO systems which have a permeate capacity of 480 gpm or greater each. The minimum scope of design and fabrication for each of the three required systems shall include the pretreatment chemical addition system(s), the cartridge filters, the membrane feed pumps, the membrane elements in pressure vessels mounted on support frames, the concentrate control valves, inteconnecting pipe and manifolding between system components, and the instrumentation and control system hardware associated with system components. In addition, the ROEM shall have developed or participated in the development of control software for each of the referenced RO systems. c. The reference systems shall have been in operation for a minimum of one year at the time of bid submittal. Project references shall be submitted with the CONTRACTOR'S bid proposal for the three RO systems claimed by the ROEM on the forms attached to this Section. These references shall include project location, RO permeate capacity, date of contract, date of initial operation, current status, and Owner's contact (name, address, and telephone number). It shall be the responsibility of the ROEM to provide current and correct project information and contacts. The Owner reserves the right to receive, upon request, a complete set of designlconstruction documents prepared by the ROEM to verify compliance with minimum design and fabrication requirements specified herein, for any of the referenced plants. Failure of the ROEM to provide verifiable qualifications meeting the criteria listed'herein will result in rejection of the proposed ROEM and the CONTRACTOR will be required to submit an alternate ROEM for approval. (Carlsbad Water) (100% Submittal) (Recycling Facility) 11340 -3- d. Any ROEM acting as a corporation can utilize only the ROEM's qualifying experience. Experience of subcontractors to the corporation cannot be used to meet the project experience requirements. ROEM's which are joint ventures or partnerships, can utilize their respective experience, but experience of their subcontractors cannot be used to meet the project experience requirements. The experience of team members or employees while working at other organizations cannot be used to meet the Corporation, joint venture, or partnership experience requirements. e. The ROEM shall assign a qualified employee as project manager for this project. The project manager shall be responsible for the technical, financial and contractual performance of the ROEM. The project manager shall have a minimum of 5 years of experience as a project manager with a minimum of at least one project that includes the design, construction, installation, and startup of a RO system. The proposed project manager shall be submitted with the experience documentation. f. The ROEM shall demonstrate the existence of service capabilities located in the United States that can be called upon to provide continuing service following completion of the project and beyond specified contractual defective work correction periods. Upon notification of service needs, a response by the ROEM within two business days is required. The ROEM shall indicate the service organization that will respond and the location of that service organization with the experience documentation. E. Equipment Factory Testing and Inspections: 1. Membrane Elements: Each membrane element shall be factory tested by the manufacturer and certified test data for each membrane element shall be supplied to the Owner's Representative prior to shipment. The test data shall be accepted by the Owner's Representative in writing prior to shipment, a. The elements shall be tested under the manufacturer's standard published test conditions as detailed below, for a period of 30 minutes prior to data collection: i Standard Test Conditions I Manufacturer Model No. Recovery [Percent] pH [mglL NaCI] [psig] Concentration Pressure 11 340 -4 - (Carlsbad Water) (Recycling Facility) (100% Submittal) DowIFilmtec FR, BW30-400- 225 2,000 8 15 . . .- I I I I KochlFluid TFC8822HR Systems -400 225 2,000 7.5 15 b. The feedwater shall contain no foreign substance, such as large dye molecules, that will mask performance of the element. c. The elements shall meet the performance requirements detailed below. d. Certified test data shall be provided for each element and shall consist of the element serial number, the feed flow, recovery, productivity, rejection, and differential pressure. The Owner reserves the right to have a representative observe factory testing at any time during regular testing by the element manufacturer. In addition, the Owner reserves the right to request retesting by the manufacturer of a random choice (by the Owner's representative) of five (5) percent of the elements at no additional cost to the Owner. On retest, should any of the elements fail to meet the performance specified above, the Owner's Representative reserves the right to require the element manufacturer to retest up to 100% of the elements at no additional cost to the Owner or reject the proposed shipment, at the sole discretion of the Owner. 2. Pressure Vessels: a. Each vessel shall be tested at the manufacturer's facility for compliance with requirements set forth herein. All testing shall be conducted on finished assemblies with the actual vessel heads installed. (Carlsbad Water) (Recycling Facility) (1 00% Submittal) 11 340 -5- b. A certified copy of the production test data for each pressure vessel shall be submitted to the Owner's Representative prior to shipment. A code stamp is required. 3. Pressure Vessel Racks: a. Support frames shall be inspected at the ROEM or fabricator's facility by the Owner or his designated representative. b. The first inspection shall be conducted following welding of the racks, but prior to application of coating. The ROEM must receive written acceptance of the racks from the Owner's Representative prior to painting. Deviation from the Drawings, as well as excessive weld porosity, splatter, slag, voids, rough edges, and like anomalies shall be grounds for rejection and rework. c. A second inspection shall be conducted following painting. Coverage voids, holidays, rough areas, drips and other indications of poor workmanship shall be grounds for rejection and rework. The manufacturer must receive written acceptance of the finished support racks prior to shipment to the site. 1.03 ENVIRONMENTAL CONDITIONS A. B. Ambient Environment: The equipment furnished under this section will be installed at the locations shown on the Drawings. The ambient temperatures are expected to range between 40 degrees F and 100 degrees F with relative humidity that varies from 10 to 100 percent. Feedwater Quality: Anticipated quality of the tertiary plant f effluent pretreated by microfiltration for treatment in the RO system is provided below: (Carlsbad Water) (Recycling Facility) (lOOo/, Submittal) 11340 -6- 1.04 SUBMITALS A. General: Shop drawing submittals shall be made in accordance with the requirements of Section 01300, except as modified herein. 1. Provide manufacturers’ catalog sheets for all components with the selected model numbers and accessories clearly indicated. 2. Submit certified fabrication drawings of the equipment. 3. Submit spare parts list. 4. Submit operating and installation instructions. B. Drawings: The ROEM shall coordinate production and submit each of the following drawings for approval by the Owner’s Representative, including calculations for equipment anchorage and supports as required herein. All drawings shall be produced electronically in AutoCAD v.14 format, or higher. Hardcopy submittals shall be plotted on white bond with 118-inch (minimum) black lettering, D-size (22 inches by 34 inches) sheets unless otherwise noted or approved by the Owner. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -7- 1. Pressure Vessel Support Frames: a. Show complete fabrication details, identify all components, welds, and methods of construction. b. Include a list of materials, with all components clearly identified. c. Include an assembly drawing, showing the arrangement of frames within each train. 2. Piping and Equipment Supports: a. Identify by unique number and detail all proposed external equipment and pipe supports located outside pipe trenches. b. Provide detailed shop and assembly drawings, catalog information and other details for the metal framing support system and appurtenances used in pipe trenches. 3. RO System Assembly Drawings: a. Show locations of all RO system components, identified by project tag number where appropriate. b. Show and identify electrical and instrumentation conduit stub- up locations. List size, identify wires and circuits. c. Provide plan and elevation views of all major components and subsystems, detailing precise orientation of equipment, piping, fittings and valves (including valve actuators). 4. Piping Fabrication and Assembly Drawings a. Provide detailed pipe fabrication drawings for all RO system stainless steel piping. Identify all components in a list of materials. Detail each unique spool, identifying all dimensions, welds, and methods of construction. b. For all RO system piping (including chemical feed systems), provide double-line scaled drawings showing all fittings, valves, in-line devices, chemical injectors, and supports. Identify each support and cross-reference to applicable mechanical details or manufacturei's catalog number. Identify all in-line equipment and valves by project equipment number, Clearly show and identify all interfaces with sub-grade portions of piping external to the RO system. (Carlsbad Water) (100% Submittal) (Recycling Facility) 11340 -8- C. 5. Panel Construction Drawings: Provide construction drawings for all RO system panels as specified in Section 13570. 6. Panel Wiring Diagrams: Provide panel wiring diagrams for all RO system panels as specified in Division 13. 7. Loop Diagrams: Provide a complete set of control loop diagrams for all assigned RO system control loops as specified in Section 13500. Equipment: The ROEM shall submit technical information for approval prior to procurement on all items of equipment, showing all dimensions, materials of construction, performance ratings, set points, component parts, construction details, weight, factory finish system, mechanical and electrical drawings. Additional requirements for specific items of equipment shall be as follows: 1. RO Membrane Elements: a. b. C. d. e. Include element construction details (e.g., active membrane surface area, feed brine spacer thickness, etc.), standard performance parameters, installation instructions, interconnection instructions, storage and handling requirements. Provide standard commercial part numbers for the interconnector O-rings and u-cup brine seals. Provide standard operating and maintenance data, including recommended cleaning solutions and long and short term storage protocols. Provide a train performance projection endorsed by the membrane manufacturer documenting compliance with system operating and performance requirements specified herein. Submit certified production test data for each element. 2. Pressure Vessels: a. Submit certified production test data for each vessel, including heads. b. Provide orifice plug and port velocity calculations. 1.05 WARRANTIES (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -9- A. B. General: The CONTRACTOR shall warrant all components of the RO system supplied against defects in materials and workmanship for a period of twelve (12) months. The warranty period shall commence on successful completion of the system performance test or a period of no greater than six (6) months from the date of delivery. If any component part of the system should fail due to defects in materials or workmanship during the warranty period, it shall be restored to service at no expense to the Owner. Membrane Elements: The CONTRACTOR shall furnish a separate warranty for the RO membrane elements. 1. The membrane elements supplied under these specifications shall be warranted by the manufacturer to be free of liens and encumbrances, and against defects in materials or workmanship for a period of twelve (12) months. If any membrane elements should fail due to a defect in material or workmanship during the warranty period the element shall be either repaired or replaced at no cost to the Owner. The warranty period shall commence on successful completion of the 48-hour Performance test. 2. The manufacturer shall also warrant the performance of the membrane elements for a period of three (3) years from completion of the 48 hour performance test. The manufacturer shall guarantee the membrane elements during that three (3) year period in accordance with the performance requirements specified herein and the following prorated replacement conditions if the elements fail to meet the warranted performance: a. The elements shall at all times during the three year period have a minimum flow of 80 percent of the minimum product flow specified on the membrane manufacturer's specification sheet for the elements furnished when tested at standard conditions as defined herein. b. During the same three (3) year period the element salt passage shall not exceed two (2.0) times the maximum salt passage specified on the membrane manufacturer's specification sheet for the elements furnished when tested at standard conditions as defined herein. 3. The warranty conditions specified above shall be valid under the following conditions: a. The RO system has been operated as designed in terms of product water recovery, array configuration, and feedwater pH. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -10- b. C. d. e. The feedwater has not contained chemicals that chemically or physically destroy the elements. The elements are periodically cleaned with an effective cleaning solution to remove colloidal matter inherent in brackish groundwater. The elements are cleaned using standard cleaning solutions prior to performance testing for warranty purposes. The elements have not been irreversibly fouled by biological matter or sparingly soluble substances in the feedwater. 4. Should element flow decrease below 80 percent of the specified flow or element salt passage increase above 2.0 times specified salt passage the membrane element manufacturer shall replace the elements at the current market price per element, less a credit of 1/36 of the purchase price for each unused month of the warranty period. The manufacturer shall guarantee that future replacement elements will be sold to the Owner at a price not to exceed $650 per 40-inch element (or equivalent) at any time within three years from acceptance of the RO system. PART 2 - PRODUCTS 2.01 A. B. GENERAL Scope: The system provided under this Specification shall be complete and operable in all respects including, but not limited to, connections to other facilities, lubricants, component and system tests, calibration, alignment, and adjustments as necessaty to place the system in operation to perform its intended function. RO System Components: Drawings PI-I2 through PI-21 are the piping and instrumentation diagrams (P&IDs) for the main RO treatment system. Drawing PI-8 shows the RO transfer pumping system, while the RO flush and cleaning systems are shown on Drawings PI-I8 and PI-19. Drawings PI-20 and PI-21 show the sulfuric acid and threshold inhibitor chemical feed systems associated with the RO system, while Drawings PI-I and PI-2 are legend sheets which describe the symbols and abbreviations used on the P&IDs. 1. Drawing PI-8 shows the RO transfer pumps. Filtered water from the MF pretreatment system will be pumped from the MF Break Tank. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 11 - 2. Drawing PI-I2 shows the low pressure RO feedwater line (MFE) from the transfer pumps entering the RO system. Sulfuric acid and a threshold inhibitor shall be added to the RO feedwater before being routed to one (1) full capacity cartridge filter housing. A bypass line and valve shall be provided around the cartridge filter to allow temporary continued operation during filter changeout. Connecting pipe flanges shall be provided to allow the installation of second parallel cartridge filter in the future. The cartridge filter is not intended for heavy duty filtration service but will be used to protect the high pressure pumps and RO membrane elements from potential upsets in the pretreatment system. The rate of acid feed shall be controlled by feedwater pH and feedwater flow while the rate of threshold inhibitor addition shall be controlled by the feedwater flow. Process instruments and transmitters for the RO feedwater line shall be centralized on a local panel. Following chemical conditioning and cartridge filtration, RO feedwater shall be piped to the RO membrane feed pumps for Train Nos. 1 and 2. 3. Drawings PI-I4 shows the RO membrane train, consisting of a high pressure pump complete with a variable frequency drive (VFD), membrane elements in pressure vessels supported on frames, and a local train panel incorporating transmitters, instruments and motor operated valve controls associated with the train. On leaving the cartridge filters the RO feedwater shall be pressurized to the required operating pressure in the high pressure pump. The pump flow and discharge pressure shall be controlled by the RO system PLC which shall adjust the pump speed and concentrate valve setting. Pump discharge pressure (speed) shall be set by permeate flow while the concentrate valve position shall be set by RO system recovery and concentrate flow. 4. The pressurized feed shall be routed to the membrane elements in pressure vessels in each train. RO system recovery shall be set at 80 percent and the array of each of the trains shall be 7:3 with seven spiral wound 8-inch diameter by 40-inch length membrane elements in each pressure vessel. The pressurized feed shall be routed to the first bank, consisting of 7 pressure vessels in parallel, The concentrate from the first bank pressure vessels shall be routed to the second bank, consisting of 3 pressure vessels in parallel. The concentrate from the second bank pressure vessels shall be manifolded and routed through the recovery (concentrate) control valve to waste. The permeate from the 10 pressure vessels in each train shall be manifolded and routed to the decarbonation system. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -12- 5. Drawing PI-17 shows the decarbonator and product water transfer pumps. RO product water from each train shall be fed to the top of the decarbonator tower. The tower shall be filled with plastic packing material to provide a large surface area for mass transfer. Incoming water shall be sprayed over the packing, and contacted with a counter-current air stream fed by forced air blowers located at the bottom of the tower. The product transfer pumps shall take suction from the sump at the base of the decarbonator. The pumps shall be equipped with VFDs, with speed controlled to maintain a constant level in the decarbonator sump. 6. Drawing PI-I8 shows the RO flush system. The system shall consist of a tank, pump, interconnecting piping, valves, instrumentation and controls. The flush tank shall be filled with RO permeate. The fill system shall operate continuously with a small overflow to the decarbonation product pipeline in order to maintain a fresh supply in the tank. On shutdown of the train, the flush pump shall start automatically and flush stored permeate through the train pressure vessels to displace residual concentrate. 7. Drawing PI-I9 shows the RO clean-in-place (CIP) system. The system shall consist of a tank fitted with a flanged immersion heater, a recirculation pump, cleaning chemical dosing system, instrumentation, interconnecting piping and valves. The CIP system shall be operated manually from a local control panel. The tank will be charged with cleaning chemicals and diluted with RO permeate, then recirculated through a line on the pump discharge to mix the contents and bring them to the required temperature. Once within specified limits, the solution will be valved to the appropriate bank within the train and recirculated through the pressure vessels and cleaning feedlreturn headers. Tank charging shall be accomplished by feeding dry chemical directly to the tank using a top mounted bag loader and a caustic addition system to adjust pH. The system shall incorporate a five valve manifold at the cleaning skid to allow feeding of cleaning solution to either cleaning feedlreturn header, as well as direct routing back to the tank or discharge to the common waste collection line. It shall also include an isolated recirculation leg to allow flushing of cleaning solution from the main feedheturn headers without entering the pressure vessels of any train. Permeate created during the cleaning cycle shall be collected and routed back to the tank through the permeate cleaning return header. Tank overflow, drain, and cleaning solution waste flows shall be routed to waste. An industrial water service connection shall be provided adjacent to the tank to allow for using this water when permeate is not available. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -13- 8. Drawing PI-20 shows the sulfuric acid addition system. The sulfuric acid system shall consist of a bulk storage tank, chemical injection pumps, instrumentation, local control panels, interconnecting piping and valves. The tank shall be located in a diked containment area. From the bulk tank the sulfuric acid shall be pumped into the RO feedwater by the chemical injection pumps. 9. Drawing PI-21 shows the threshold inhibitor addition system. The threshold inhibitor addition system shall consist of a bulk storage tank, delivery drum, transfer pump, mixer, addition pumps, instrumentation, local control panels, interconnecting piping and valves. Concentrated inhibitor will be transferred from the delivery drum to the bulk storage tank for dilution and mixing. The addition pumps shall be used to inject the inhibitor into the RO feedwater from the bulk tank. 10. The RO system shall be controlled by a programmable logic controller (PLC), which will monitor system process variables and provide the control functionality indicated on the P&IDs and specified herein. The PLC shall be located in a central Plant Supervisory control panel (PLC-2) located in the control room. PLC-2 shall integrate control of all RO system components, including components of the system not furnished by the ROEM. Operator control of the system shall be executed locally through panel face mounted interface on PLC-2, and remotely through the main plant HMI system located in the control room. The ROEM shall work with the CONTRACTOR to integrate control of the RO treatment system with the plant wide control system. 11. All of the equipment discussed above and shown on the P&IDs as well as the RO system control philosophy and control system configuration are described in detail in the Specifications. This detailed information does not relieve the ROEM of his responsibility to provide a well designed and fully operable RO system as described in this specification. The ROEM shall assume all responsibility for the design of the system provided. C. Equipment Numbers: By definition, component equipment numbers referenced herein and listed in parentheses include numbered items up through and including the number (e.g., P-1600-(2) represents equipment numbers P-1600-1 and P-1600-2). 2.02 RO FEED TRANSFER PUMPING SYSTEM A. General: A transfer pumping system shall be installed to provide low pressure feedwater to the RO system. The system shall consist of two (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -14- B. 2.03 A. B. C. 2.04 A. B. of three pumps taking suction from the MF Break Tank, interconnecting piping, valves, instrumentation and controls. Requirements: Requirements for the RO transfer pumps, equipment numbers P-1600-(3), are included in Section 11 115. PRETREATMENT CHEMICAL ADDITION SYSTEMS General: Pretreatment chemical addition systems shall be provided to inject sulfuric acid and threshold inhibitor into the RO feedwater. Sulfuric Acid Additions System: The sulfuric acid feed system shall include a bulk storage tank, chemical metering pumps and accessories, interconnecting piping, valves, instrumentation and controls. 1. Sulfuric acid bulk storage tank, equipment number T-I 171, is specified in Section 131 92. 2. Chemical metering pumps with accessories, equipment numbers MP-1173, as well as general system piping requirements are specified in Section 11727. Threshold Inhibitor Addition System: The threshold inhibitor feed system shall include a transfer-storage and dilution system, chemical metering pumps and accessories, interconnecting piping, valves, instrumentation and controls. 1. Threshold inhibitor bulk storage and dilution tank, equipment number T- 1177, is specified in Section 13190P. 2. The tank mixer, equipment number "1177, is specified in Section 1 1247. 3. Chemical metering pumps with accessories, equipment number MP-1178-(2), as well as transfer pump, equipment number P-1177, and general system piping requirements are specified in Section 1 1727. CARTRIDGE FILTRATION General: A single cartridge filter shall be installed to provide pre-filtration ahead of the RO system. The system shall include the filter vessel, cylindrically wound filter elements, interconnecting piping, valves, instrumentation and controls. Requirements: Requirements for the cartridge filter, equipment number M-1602, are specified in Section 11403. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 15 - 2.05 RO MEMBRANE TRAIN A. General: Each RO membrane train shall include the membrane feed pump, pressure vessel racks, pressure vessels, membrane elements, interconnecting piping manifolds, valves, instrumentation and controls. Train configuration shall conform generally to the arrangement shown in Appendix A attached to this section. B. Membrane Feed Pump: 1. One (1) membrane feed pump for each train shall be provided to boost pressure into the RO membrane system. 2. Requirements for the membrane feed pumps, equipment numbers P-1604-(2), are specified in Section 11213. C. Pressure Vessel Racks: 1. Frame Construction: a. The pressure vessel support frames and miscellaneous brackets shall be fabricated from ASTM A36 hot rolled steel structural members and ASTM-ASOO, Grade B welded steel structural tubing. b. The method of fabrication shall be continuous fillet and bevel welds. The strength of these welds shall meet or exceed the strength of the structural shape or tubing material. All welding operators shall be qualified in accordance with the current AWS requirements. All exterior welds shall be ground flush and smooth prior to sandblasting. Stitch and spot welding will not be accepted. Bolt holes, mounting holes, etc. shall be drilled prior to painting wherever possible. c. The configuration of the pressure vessel support shall be "T" type frames with positions for five vessels on each side of the center upright. There shall be three uprights on each frame with sufficient cross bracing to give optimum lateral strength. d. There shall be a single stand alone frame supporting the 10 pressure vessels in the train. Within the frame, the vessel horizontal center line distance shall not exceed 18-inches and the vertical center line distance shall not exceed 12-inches. e. Support brackets for vertical skid manifolds shall be welded to the frames. Provide two supports for each header, one in the top section and one in the bottom section. Include support (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 16- assemblies for vertical feed and concentrate headers located outside the frame as shown on the Drawings. 2. Painting: a. Prior to painting, all steel components of the installation shall be sandblasted to an SSPC-SP 10-63T condition. This specification refers to "near white blast cleaning". b. DuPont epoxy gray base primer No. 25P shall be applied immediately after blasting. The resulting dry thickness shall be 0.003 to 0.005 inches. c. DuPont lmron polyurethane No. 333 shall be applied after proper cure of the primer coat according to recommendations of the paint manufacturer. The resulting finish coat thickness shall be 0.0015 to 0.002 inches. The painting shall be done in a professional manner such that the finish is smooth, glossy, and free of inclusions and holidays. The finish color shall be white in accordance with lmron number 67632. D. Pressure Vessels: Furnish and install the membrane pressure vessels for the RO trains as shown on the Drawings and specified herein. 1. The membrane pressure vessels shall be designed, constructed, qualification tested, quality control tested, and production tested in accordance with the latest edition of the ASME Boiler and Pressure Vessel Code, Section X - Fiberglass-Reinforced Plastic Pressure Vessels. 2. A total of 20 pressure vessels shall be provided for the entire RO system. 3. Manufacturers: a. Codeline Division of Pentair; b. Progressive Composite Technologies; c. Or equal 4. Vessel Construction: a. Pressure vessels shall have a diameter and length so as to contain a seven-element column of 8-inch diameter by 40-inch length spiral wound membrane elements. The feed and concentrate ports shall be located in the vessel sidewall. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 17 ~ b. C. d. e f. The shell of the vessel shall be fabricated of filament wound fiberglass reinforced plastic (FWFRP) using continuous glass roving impregnated with an elevated temperature cure epoxy resin system. Materials of construction shall be lot traceable to vessel serial number. All wetted components in continuous contact with the pressurized process water shall be made from plastic or metal proven to have long-term resistance to corrosion in the service intended, including solutions of sodium bisulfite used as a membrane preservative. All other materials of construction shall be of appropriate strength and corrosion resistance for the operating conditions. The materials of construction for each component part of the vessel shall be clearly and fully specified on the engineering drawing included with the submittal documentation for the vessels. Vessels shall have a maximum working pressure of not less than 450 psig at a temperature of not less than 120 OF with a minimum operating temperature not greater than 20 OF. Vessels shall be so designed as to allow membrane elements to be connected to the permeate port at both ends of the vessel so that permeate can be taken from either or both ends. Each feedlconcentrate port in the vessel sidewall shall incorporate a flush face elastomeric seal so that edge laminate surfaces are not exposed to the process fluid. The contour of the sealing surface shall conform to the curvature of the vessel wall to eliminate dead space. The ports themselves shall be constructed of high grade stainless steel and shall be designed to interface with a grooved end fitting; Victaulic or equivalent. 1) Maximum feedlconcentrate port size: 2-1l2 inches. 2) Maximum feedlconcentrate port velocity at design flow: 7 fIlS . 3) Maximum number of feedlconcentrate ports per vessel: 2 (each end, 4 total). Permeate ports shall be located in the vessel end caps. Each port shall be designed with an anti-rotation mechanism so that piping may be easily tightened without the use of special retention tools. 11340 -18- (Carlsbad Water) (Recycling Facility) (100% Submittal) h. k. 5. Acc a. b. C. The vessel heads shall incorporate a Seal gland. Seal glands shall seat flush with the vessel wall and the head to eliminate dead space. The seals shall be located at the high pressure face of the head and clearly exposed to the process fluid for continuous flushing of the seal. The primary means for head retention shall be a single piece retaining mechanism that provides redundancy in accordance with the ASME code and is constructed of stainless steel. Each head shall contain a secondary interlock that requires a specific sequence of manipulations to remove the end closure. The secondary interlock shall not require the use of separate components that may become separated from the vessel. The head retaining grooves shall be integrally molded into each end during the manufacturing process. Cutting of grooves into finished laminate is not allowed. The head section of the vessel shall be constructed with a larger bore diameter than the body of the vessel'to limit contact of the element brine seals with the head and port seal surfaces during element loading. Pressure vessels shall be painted white to match the support system color. Zessories Vessels shall be complete with end closures, mounting hardware and membrane element adapters. The element adapters furnished shall be appropriate for the brand of membrane element furnished for this project. However, the vessel shall be so designed as to allow other makes of membrane element to be easily accommodated by changing adapters. Five pressure vessel shims shall be provided for each pressure vessel (100 total). The shims shall be 0.2-inch thick, have machined surfaces and be manufactured from a plastic material suitable for this service. Elements shall be shimmed on the feed end of each vessel to minimize movement of the elements within the vessel. One complete set of permeate orifice plugs and blind plugs shall be supplied for operating the RO trains without membrane elements. Supply 25 drilled plugs and 25 plain plugs that fit the element adapter ports on the pressure 11340 -19- (Carlsbad Water) (Recycling Facility) (100% Submittal) vessels. The plugs (undrilled) shall be a product of the pressure vessel manufacturer to insure compatibility with end adapters furnished. Drilling of the plugs shall be calculated to mimic the anticipated performance of the train at startup once membrane elements are installed. The design initial operating pressure shall be as stipulated in the membrane manufacturer's performance projection submitted as required herein. The ROEM shall submit calculations documenting the determination of the orifice size for review by the Owner's consultant. E. Membrane Elements: 1. General: A total of 140 membrane elements shall be fabricated, tested, packaged, shipped to the project site and installed. 2. Manufacturers (without exception): a. Dow/Filmtec, Model BW30-400-FR2 b. KochlFluid Systems, Model TFC8822HR-400 c. Nitto Denko/Hydranautics, Model ESPA2 3. Element Construction a. The membrane elements shall be spiral wound with feed and reject flow through the element parallel to the product water tube of the element. Elements shall have a reinforced fiberglass outer wrap. The element serial number and direction of feedlreject flow shall be clearly marked on each element. b. The elements shall have nominal dimensions of eight inches in diameter and 40 inches in length. The active membrane area of the elements shall be 400 square feet, minimum. c. The membrane in the element shall be a composite membrane fabricated with a polyamide membrane barrier layer on a polysulfone porous support. d. The feedlreject spacer material shall have a nominal thickness of between 0.026 and 0.028 inches. e. Each element shall be furnished complete with element-to- element interconnector, interconnector O-rings, and u-cup brine seal. O-rings and brine seals shall be constructed of ethylene propylene rubber, and shall be standard products (Carlsbad Water) 11340 (Recycling Facility) -20- (1 00% Submittal) available from vendors other than the membrane manufacturer. f. The elements shall be fully compatible with the pressure vessels furnished. 4. Performance: Nominal membrane performance shall be as required under Article 1.02.E.1 hereinbefore. In addition, performance of the membrane as installed in the system shall meet other stipulated performance goals as specified in Article 3.05-C-4 herein. F. Interconnecting Pipe Manifolds: 1. General: a. Where shown on the Drawings and specified herein, train feed, inter-bank, and concentrate manifolds shall be Schedule 40S, Type 316L stainless steel in accordance with Section 15062-1. b. Where shown on the Drawings and specified herein, train permeate manifolds shall be Schedule 40S, Type 316L stainless steel in accordance with Section 15062-1 ; or Schedule 80 PVC in accordance with Section 15067. c. At the option of the ROEM, Schedule 10s stainless steel pipe assemblies may be substituted for Schedule 40S, provided that Schedule 40s nipples with machined grooves are welded to the assemblies at all locations requiring grooved pipe couplings. d. All grating penetrations, including those required for instrument sample taps, shall be made in the trenches at the ends of the trains. No penetrations of grating over trenches running alongside the train will be allowed. 2. Vertical FeedlConcentrate Manifolds: a. Connections from the pressure vessel feedlconcentrate ports to the pipe manifolds shall be via 90 degree ell weldments with grooved pipe couplings on both ends. The use of fabricated ells is not permitted. b. Connections to inter-bank, feed or concentrate headers in the trench shall be made with grooved pipe couplings. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -21 - c. Connections for pressure instrument taps shall be made via 1/2-inch FPT SST weld-0-lets, located so as to insure that the taps are above the location of the transmitters. 3. Vertical Permeate Manifolds: a. Permeate manifold connections to the pressure vessel permeate ports shall be made using Schedule 80 PVC U- bends, with a union at the connection to the vessel and a grooved pipe coupling at the connection to the manifold. Machined grooves in other PVC piping will not be allowed. b. The connection for the pressure switch tap shall be made via a 114-inch FPT SST weld-0-let in the manifold closest to the train instrument panel. 4. Feed, Inter-bank, and Concentrate Headers a. Piping shall be run at the ends or alongside the trains in piping trenches. All horizontal runs shall be located beneath the trench grating. b. Connections to vertical feedlconcentrate manifolds shall be via grooved fitting connections. c. Connections to the high pressure pump discharge interface@) shall be flanged, drilled ANSI Class 300 standard. d. The concentrate sample tap for the train instrument panel shall be made using a 1/2-inch FPT SST weld-0-let located in the low pressure portion of the concentrate header, downstream of the control valve. 5. Permeate Header a. Piping shall be run at the ends or alongside the trains in piping trenches. All horizontal runs shall be located beneath the trench grating. b. The main horizontal permeate header for each train shall be constructed of socket welded Schedule 80 PVC. c. Connections to stainless steel vertical permeate manifolds shall be via flanged connections located beneath the trench grating. 2.06 MEMBRANE CIP SYSTEM (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 22 - A. General: The RO membrane CIP system shall consist of one tank with accessories, pump, heater and controls, chemical dosing system, interconnecting piping, valves, instrumentation and controls. 6. Requirements: 1. The cleaning tank and related accessories (including the immersion heater), equipment number T-1625, are specified in Section 131 9OP. 2. The membrane cleaning pump, equipment number P-1629, is specified in Section 11 115. 3. Chemical Dosing System: a. A chemical dosing system shall be provided to allow injection of liquid chemicals, such as 25 percent sodium hydroxide, into the pump recirculation line as shown on the Drawings. b. The system shall include a dosing pump, carboy containment vessel, injection piping, and controls. The caustic storage carboy will be furnished separately. c. The dosing pump (equipment number MP-1631) shall operate on 120 VAC, single phase, 60 Hz power. It shall be an electromagnetic diaphragm type with manually adjustable stroke length and frequency. Maximum stroking speed shall be 100 strokes per minute. Operating capacity at maximum stoke length and speed shall be 20 gallons per hour. Electrical power consumption shall not exceed 87 watts. Pump head and check valves shall be Type 316 stainless steel. Pump diaphragm shall be Teflon faced elastomer and seal rings shall be Teflon. Pump inlet and outlet shall be 1/2- inch MNPT pipe fittings. Pump shall be furnished with suction and discharge polyethylene tubing. The Suction tubing shall come equipped with an integral foot valve for maintaining the pump prime. The metering pump shall be Series C as manufactured by Liquid Metronics Division (LMI) of Milton Roy, or equal. d. Provide a polyethylene security spill containment vessel with minimum volume of 122 gallons. The vessel shall have keyed entries to allow movement by forklift, and shall accommodate up to two standard 55 gallon drums. The vessel shall incorporate a hinged, lockable cover. The vessel shall be Part No. SPIOOIHA as manufactured by Chem-Tainer Industries, Inc., or equal. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11 340 -23- 2.07 A. B. 2.08 A. e. Provide a 1/2-inch 316 stainless steel injection line conforming to the requirements of Section 15062-1 with injection quills. The lines shall combine and terminate in a 1/2-inch FNPT coupling at an elevation of 3 feet above grade to SllOW easy connection of temporary piping from the injection pump. f. Provide one injection quill (equipment number "1631-2) sized to inject chemical at or near the centerline of the recirculation piping to the tank. The quill shall be constructed of Type 316 stainless steel and shall incorporate an integral injection ball check valve. The quill and integral valve shall be as manufactured by Neptune Chemical Pump Company or equal. 4. Interconnecting Piping Requirements a. Cleaning system piping shall be Schedule 80 PVC unless otherwise noted or shown in conformance with Section 15065. b. PVC Van Stone flanges with fabricated flange rings drilled ANSI Class 300 standard shall be incorporated for installation with ANSI Class 300 cleaning solution stage valves to permit direct connection of the valves to the cleaning solutions feedlreturn headers without the use of an additional spool piece. MEMBRANE FLUSHING SYSTEM General: The membrane flushing system is used to flush the RO train with permeate on extended shutdown (longer than 30 minutes). The system shall include the flush tank, flush pump, interconnecting piping, valves, instrumentation and controls. REQUIREMENTS: 1. The flush tank, equipment number T-1620, is specified in Section 131 90. 2. The flush pump, equipment number P-1621, is specified in Section 11115. DECARBOWTOR General: The decarbonation system is used to remove residual carbon dioxide from the RO permeate. The system shall include a single decarbonator with blower, interconnecting piping, valves, instrumentation and controls. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -24- B. 2.09 A. 2.10 A. 8. Requirements: The decarbonator and blower, equipment numbers T- 1660-1 and "1661-1, are specified in Section 11401. INTERCONNECTING PIPING AND VALVES The CONTRACTOR in association with the ROEM is responsible for all piping and valves as required to provide a complete and operating system. All pipe and valves shall be provided in accordance with applicable sections under Division 15. INSTRUMENTATION AND CONTROLS General: 1. The RO system will be controlled by a programmable logic controller (PLC) based control system. The system shall consist of a master PLC and related modules housed in PLC-2. 2. PLC-2 will be located in the plant control building scope: 1. The CONTRACTOR or his designated CONTRACTOR shall provide PLC-2. 2. The ROEM shall provide other local control panels not provided by equipment vendors. The ROEM shall also assist the CONTRACTOR in developing the PLC program and HMI screens and control interface for the RO system on the central plant workstations. 3. The CONTRACTOR shall furnish all hardware and software associated with the plant supervisory control system. The CONTRACTOR shall be responsible for all software programming associated with the PLC and plant overall supervisory control system. 4. The CONTRACTOR shall be responsible for installation of all control system hardware. In addition, the CONTRACTOR shall provide all interconnecting field wiring. This includes all data link wiring for the RO system and between PLC-2 and the supervisory control system interface; plant wide data highway cable; all instrumentation and control system power and signal wiring; and all other connections shown on the Drawings or otherwise required to provide a complete and functional system. (Carlsbad Water) (Recycling Facility) (1 00% Submittal) 11 340 -25- 5. The CONTRACTOR is responsible for all field instrumentation for the system. Coordinate the division of scope with the ROEM prior to the bid. C. Requirements: 1. 2. 3. 4. 5. 6. For PLC and HMI functional requirements specific to the RO system, see Section 13550. For general control system requirements, see Section 13500. For control panels, see Section 13570. For instrumentation, panel, and accessory device requirements, see Section 13560 and related sections which follow. For PLCs, see Section 13530. All wiring shall be installed in accordance with the applicable requirements of Division 16. 2.1 1 MISCELLANEOUS COMPONENTS A. B. C. D. E. Anchor Bolts: Anchor bolts shall be Type 316 stainless steel and at least 1/2-inch in diameter. See Section 05550 for requirements. Lifting Lugs: All equipment items or component assemblies weighing in excess of 100 pounds shall be furnished with lifting lugs. Identification Tags: All equipment items, instrumentation, and valves shall be furnished with a securely mounted or attached Type 316 stainless steel plate bearing its assigned identification number as referenced on the Drawings andlor listed in the specifications. Plates shall be 16 gauge minimum. Identification numbers shall be die stamped with %-inch minimum characters. Miscellaneous Fasteners: Bolts, nuts, washers, flange backing rings, and other miscellaneous metal components not specifically addressed elsewhere in these specifications shall be Type 316 stainless steel. Spare Parts and Special Tools: Spare parts and special tools associated with the RO system shall be provided. Furnish the following, suitably packaged and identified: 1. One lot (20 minimum) each of pressure vessel seals, including feedlconcentrate port seals, product water tube adapter seals, head seals, and permeate port seals. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 26 - 2. Spare components for pressure vessels including 5 product water tube adapters; 5 head retaining rings; 5 feedkoncentrate port retaining rings; and 2 complete head assemblies. 3. One new and unused portable hand held conductivity analyzer, battery operated, capable of measuring and indicating sample conductivities from 0 to 20 mS, adjustable over four intermediate ranges. The meter shall have an integral polyethylene cell cup, digital LCD display, and automatic temperature compensation. The meter shall be Myron L DC4, or equal. 4. One complete set of special tools used to install, operate, and maintain each type of equipment furnished. 5. One of each type of specialty equipment used in the installation, calibration, disassembly and removal of installed equipment. This includes, but is not limited to, special lifting, clamping, hooking and securing tools and equipment. 6. Two pressure vessel retaining ring removal tools, and two pressure vessel head removal tools. PART 3 - EXECUTION 3.01 A. B. 3.02 A. B. SHIPMENT, HANDLING, AND STORAGE General: The equipment specified herein, shall be factory assembled and ready for installation and connection to the piping as shown on the drawings. The parts and assemblies that are shipped unassembled, shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Requirements: Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. See Section 01400. INSTALLATION General: The CONTRACTOR shall be responsible for the proper installation of all RO system equipment. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer's printed instructions, and approved shop drawings. Pressure Vessel Racks: 1. Use slings to set finished racks individually on the support pad. Avoid damage to the finished coating system. (Carlsbad Water) 11340 (Recycling Facility) -27 - (100% Submittal) 2. Pressure vessels may be loaded (empty) on the individual racks at the option of the CONTRACTOR. 3. Once set and aligned, anchor the racks to the concrete support pads in accordance with details shown on the Drawings with suitable deferred anchorage components of Type 316 stainless steel construction meeting the requirements of Section 05550. C. Pressure Vessels: 1, Anchor each vessel to the support rack angle supports with straps at three points. 2. Prepare a vessel mounting chart indicating the vessel serial number at each position within the train and submit to the Owner's Representative. 3. Install shims on the feed end of each vessel during loading of the membrane elements, to prevent movement of the elements within the pressure vessels. Do not load elements in the vessels prior to completion of system performance tests specified hereinafter. 4. Prior to installing the vessel heads, insure that there is a product water tube adapter installed in lead element at each end. If performing orifice testing, an orifice plug and blind plug should be installed at the opposite ends in place of the adapters. If loading membrane elements, the opposite end of the adapter should seat firmly in the vessel head. D. Membrane Elements: 1. Assemble elements for loading into each vessel in a row. Prior to loading, record the serial number of each element and its position within the pressure vessel. On completion of loading the train, submit the element loading chart to the Owner's Representative. 2. Prior to loading elements, install the u-cup brine seals on the feed end of each element in the proper orientation. Install O-rings on the element interconnectors furnished by the membrane manufacturer. 3. Brine seals and O-rings shall be sparingly lubricated with a lubricant furnished or approved by the membrane manufacturer. Do not use excessive amounts of lubricant which may plug the elements. 4. Load elements into the pressure vessels from the feed end of each vessel. Loading or pushing elements in the opposite direction of feedlconcentrate flow is not permitted. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 -26 - E. F. G H. 3.03 A. 3.04 A. B. 3.05 A. B. Vertical Pipe Manifolds: Align all vertical headers on the train assembly such that the top caps are at the same elevation and ell connections are at a uniform slope between headers. Valves: See Section 151 00 Instrumentation and Control Components: See Section 13560 and related sections. Wiring: Refer to Division 16, Electrical. PAINTING General: Paint all RO system assemblies in accordance with the requirements specified herein and Section 09900. OPERATIONS AND MAINTENANCE MANUAL General: The CONTRACTOR in association with the ROEM shall provide an integrated operations and maintenance manual for the facility incorporating requirements for the RO treatment system. Requirements: See Section 01300. FIELD SERVICES General: 1. A qualified representative of each of the equipment manufacturers shall be present at the job site or classroom designated by the Owner’s Representative for the services hereinunder described, travel time excluded: a. Provide representatives of equipment manufacturers for installation assistance, inspection, and certification of their equipment. b. Provide representatives of the pressure vessel manufacturer to inspect and correct visible weeping or chronic head seal leaks in any of the installed pressure vessels. c. Provide representatives of the membrane manufacturer to provide initial loading instruction and witness initial membrane performance tests following installation. d. Provide representatives for training and operations assistance. Training: (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 29 - 1. The ROEM and CONTRACTOR shall provide training in accordance with Section 01400. C. Field Testing: 1. Testing and Startup Responsibilities a. b. C. d. e. f. Perform all Work for equipment functional and performance tests specified herein. Complete all Work associated with the unit and related processes before testing, including related manufacturer's representative services. Provide all related operating and maintenance manuals, and spare parts and special tools as specified before testing any unit or system. Furnish qualified manufacturer's representatives when required to assist in testing. Utilize an approved Manufacturer's Certificate of Proper Installation Form, supplemented as necessary, to document all functional and performance procedures, results, problems, and conclusions. Schedule and attend pretest (functional and performance) meetings related to test schedule, plan of test, materials, chemicals, and liquids required, facilities' operations interface, Owner and CONTRACTOR involvement. 2. Functional Testing a. General: Conduct an initial functional test on installed components of the RO system to demonstrate their proper installation and operation. Submit report documenting each test in a format acceptable to the Construction Manager. b. Piping and Valves: 1) Conduct hydrostatic pressure and leakage tests on all piping. 2) Water shall be used for the hydrostatic test fluid. 3) The Owner's Representative will monitor the tests. Test pressure shall be as specified in the individual piping (Carlsbad Water) (Recycling Facility) (1 00% Submittal) 11 340 - 30 - sections included in Division 15, and shall be conducted in accordance with the requirements of Section 02704. Examine all joints and connections for leaks The piping system shall show no visual evidence of weeping or leaking. Any visible leakage shall be corrected and the line re- tested. Note that full hydrostatic testing of some of the RO system piping (e.g., vertical feedlconcentrate manifolds) will have to be conducted during performance testing of the train, when orifice plugs are installed in the pressure vessel permeate ports. c. Instrumentation and Control System: Conduct an operational readiness test for the RO control system prior to initiating system performance tests. See requirements in Section 13500. 3. Performance Testing a. General: 1) Prior to complete system startup, components of the RO system shall undergo individual performance tests to demonstrate and confirm that the equipment andlor sub- system meets performance requirements specified herein. 2) Include a compliance report documenting each test in a format acceptable to the Owner’s Representative in the startup file for each item of equipment. b. RO Membrane System: 3) (Carlsbad Water) (Recycling Facility) (100% Submittal) Coordinate performance testing of the RO system with the Owner’s Representative. Performance testing of the reverse osmosis system shall be conducted under the supervision and direction of the ROEM. The test@) shall be performed with orifice plugs in the pressure vessel permeate end caps and blind plugs in 11 340 - 31 - the opposite end caps. The ROEM shall be responsible for furnishing, installation and removal of all orifice and blind plugs used for testing. Testing shall be conducted on the train for a period of up to 48-hours of cumulative operation, during which the RO system will be operated and adjustments made to demonstrate that the equipment and controls operate as a functional system as intended. The major acceptance criteria for the 48-hour performance tests shall be that the train, along with associated feed delivery, chemical feed, product transfer, and other ancillary systems operate as intended without major mechanical or electrical problems and with minimal operator attention. Observed deficiencies in operation of any component shall be corrected to the satisfaction of the Owner’s Representative. 7) Following successful completion of the 48-hour performance test for the RO train, the ROEM will be allowed to begin loading membrane elements into the pressure vessels of the train, as specified herein. 8) Minimum prerequisites prior to initiation of reverse osmosis system performance testing include the following: Completion of final control systems check out and demonstration activities as specified in Section 01650. Completion of performance testing of the microfiltration system and RO transfer pump station, and pretreatment chemical addition systems. Completion of functional testing of individual RO system equipment items, as specified herein. Completion of functional testing for ancillary equipment items and subsystems required for distribution of RO waste streams generated during testing. 4. RO System 7-day Performance Demonstration Test a. General (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 32 - 1) Conduct a 7-day demonstration test on the complete RO system to demonstrate its competent operation in accordance with the intent of these Contract Documents. 2) Complete 48-hour performance tests on the RO train as specified herein prior to initiation of the test. 3) After the plant is operating, but prior to initiation of the 7-Day demonstration test, complete the testing of those items of equipment, systems, and subsystems which could not be or were not adequately or successfully tested prior to plant startup. This shall include verification of proper membrane element installation by conducting a conductivity profile on the pressure vessels of the RO train while the train is operating. The ROEM'S personnel shall conduct the profiles by sampling permeate from the sample valves on each pressure vessel within a given train. Those vessels not meeting pre- established conductivity criteria shall be opened up by the ROEM and examined for proper installation of end connectors and element interconnectors, damaged O-rings, mis-aligned brine seals, and other like causes. Any observed deficiencies shall be corrected by the ROEM and the vessel re-tested. 4) Successful checkout of the RO train within the RO system and performance testing of related ancillary systems shall constitute grounds for Substantial Completion of the RO system and allow it to proceed to the 7-day test. b. Testing The test shall be considered complete when, in the opinion of the Owner's Representative, the complete treatment system has operated in the manner intended at plant design capacity for 7 continuous days without significant interruption. This period is in addition to any training, functional, or performance test periods specified elsewhere. A significant interruption will require the test then in progress to be stopped and restarted after corrections are made. Significant Interruption: May include any of the following events: a) Failure of ROEM to maintain qualified onsite startup personnel as scheduled. b) Failure of any equipment item or treatment subsystem furnished by CONTRACTOR or ROEM to meet specified performance requirements for more than 2 consecutive hours. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 33 - C) Failure of any critical equipment unit, system, or subsystem that is not satisfactorily corrected within 5 hours after failure. d) Failure of a non-critical unit, system, or subsystem that is not satisfactorily corrected within 8 hours after failure. e) As may be determined by Owner’s Representative. 3) The following events will not be considered cause for significant interruption: a) Loss of feedwater delivered to the RO system for reasons beyond the control of the CONTRACTOR. b) Loss of power to the plant for reasons beyond the control of the CONTRACTOR. c) Inability of the product water distribution system to accept water produced by the RO system. d) As may be determined by the Owner’s Representative. 4) Minimum prerequisites prior to initiation of the 7-Day demonstration test include the following: a) Successful completion of 48-hour performance tests for the reverse osmosis trains. b) Completion of membrane element loading and checkout for the reverse osmosis trains. c) Completion of initial startup operations, including successful completion of performance testing on remaining equipment items as specified herein. c. Report: At the end of the 7-day test, the ROEM’S representative shall prepare a test report which shall include daily operating and normalized performance data for each day of the test. d. Final Acceptance: The Owner‘s Representative will accept equipment and systems as complete and ready for continuous operation only after successful testing and startup is completed and documented, test and startup reports submitted, and manufacturers’ services completed for training of Owner’s personnel. The major acceptance criteria shall be as follows: e. Each RO Train shall produce a minimum of 240 gpm of RO permeate at 85 percent recovery on a feed with a TDS not exceeding 1,200 mg/L. During the acceptance test the permeate TDS shall not exceed 50 mg/L (based on testing of periodic grab samples from the (Carlsbad Water) 11 340 (Recycling Facility) - 34 - (100% Submittal) train). In addition, it will be expected that the plant will operate as intended without major mechanical or electrical problems and with minimal operator attention. 3.06 SUPPLEMENTAL INFORMATION A. Supplements listed below are attached following "End Of Section" and are a part of this specification 1. Appendix A - Mechanical Arrangement Drawing 2. Appendix B - ROEM Experience Documentation Forms End Of Section (Carlsbad Water) (Recycling Facility) (100% Submittal) 11340 - 35 - h "---' i ROEM QUALIFICATIONS (Must be Submitted with Bid Proposal) Note: ROEM must provide the following information validating qualifications and experience for two (2) Reverse Osmosis Projects as defined in Section 11340. (Carlsbad Water) (Recycling Facility) (100% Submittal) 1 1340 - 37 - APPENDIX B PROPOSED PROJECT MANAGER 1. IDENYIFIED RO SERVICE ORGANIZATION (Carlsbad Water) (Recycling Facility) (1 00% Submittal) 11 340 - 38 - APPENDIX B SECTION 11401 FORCED DRAFT DECARBONATOR PART 1 -GENERAL 1.01 DESCRIPTION A. Description of Work: The Contractor shall furnish all labor, materials, equipment and incidentals required, install, shop test, field test, and complete for operation the forced draft decarbonator system shown on the Drawings and specified herein. All necessary and desirable accessory equipment and auxiliaries whether specifically called out in this specification or not shall be furnished and installed as required for an installation incorporating the highest standards for this type of service. Also included shall be supervisory services during installation and field testing of each unit and instructing the regular operating personnel in the proper care, operation, and maintenance of the equipment. B. Type: Forced draft. Used to remove residual carbon dioxide from the RO system permeate in order to help stabilize the plant finished product water. C. Equipment List: Decarbonator Blower 1.02 QUALITY ASSURANCE T-1660-1 "1661-1 A. Performance and Design Requirements: One decarbonator shall be furnished and installed to remove carbon dioxide from the RO permeate. The decarbonator shall consist of a tower, packing, blower, anchor bolts, and all accessories required for a complete system. The complete decarbonator system shall be furnished under a single system supplier. B. Operating Requirements: 1. Fluid Characteristics: a. Name: RO permeate b. pH: 5.2 c. Temperature: 77 "F d. Carbon Dioxide: 100 mg/L (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -1 - e. Alkalinity: 8.5 mglL as CaC03 f. Total Hardness: 1.76 mglL as CaC03 g. Total Dissolved Solids: 32 mglL 2. Design Requirements: a. b. C. d. e. f. 9. h. I. j. Influent Flow Rate (initial): Design Flow Rate (ultimate): Liquid Loading Rate: AirlLiquid Ratio: Depth of Packing: Effluent C02: Distributor Type: Distributor Backpressure: Tower Diameter: Sump Capacity: 200 - 480 gpm 960 gpm 25 gpmh? (maximum) 3.0 scfmlgpm 8.0 feet (minimum) 8.0 mglL (maximum) Weir Style 2 feet (maximum) 7 feet 2,875 gallons (minimum) C. Seismic Consideration: 1. The anchoring of the decarbonator tower and blower shall be designed in accordance with the requirements for Seismic Zone 4 of UBC andlor SEAC. Each piece of equipment shall be anchored to resist a minimum lateral seismic force of 43 percent of the operating weight of the equipment. This force shall be considered acting at the center of gravity of the piece under consideration. D. Equipment Factory Testing and Inspections: 1. General a. Conduct tests on actual equipment to be furnished to the job site. b. Notify the Construction Manager two weeks prior to equipment functional and performance tests. c. Furnish certified test reports which include test data sheets, performance test logs, and equipment performance curves, as (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -2- 1.03 A. 1.04 A. applicable. Indicate separately equipment guaranteed operating points identified in the specifications, including efficiency. 2. Functional Tests a. Test blower with actual job motor: 1) Test blower for acceptable dynamic balance of components. Measured vibration levels shall be less than 90 percent of the allowable limit specified in the applicable ACMA standard. 2) Test for sound pressure level. Conduct test on combined blower and motor assembly as a single unit. 3. Performance Tests a. Operate the blower and motor under simulated operating conditions for a continuous three hour period. Record the following parameters on test logs: 1) Capacity over the full operating range of the blower. 2) Total head over the full operating range of the pump. 3) Horsepower requirements over the full operating range of the blower. 4) Driving motor voltage, amperage, and kilowatts measured for each phase. ENVIRONMENTAL CONDITIONS The equipment furnished under this section will be installed at the locations shown. The motors will be outdoors. The ambient temperatures are expected to range between 35 degrees F and 100 degrees F with relative humidity that varies from 10 to 100 percent. SUBMITTALS Scope: Shop drawings submittals shall be made in accordance with the requirements of Section 01300, except as modified herein. 1. Submit mass transfer data for C02 - H20 stripping. 2. Submit tower and accessory information in accordance with requirements in Section 13190, Fiberglass Storage Tanks. (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -3- 3. 4. 5. 6. 7. a. Provide fabrication drawings and descriptive literature for ductwork, duct supports, and appurtenances for the duct system. Submit data curves showing performance parameters over the full operating range of the blower, annotated for the point of operation in the system. Submit electrical wiring diagrams and other data as required for complete blower installation. Provide manufacturers data and drawings describing the equipment in sufficient detail, including parts lists and materials of construction, to indicate full conformance with the detailed specifications. Provide detailed drawings showing the dimensions and weight of the blower unit and the motor. Submit operation and maintenance data including installation instructions. 1.05 STANDBY COMPONENTS A. One (1) Blower drive belt B. One (1) Set of all tank gaskets PART 2 - PRODUCTS 2.01 GENERAL A. Scope: Furnish one decarbonator with integral blower and accessories. B. Manufacturers (System Suppliers): 1. 'Paramount Fabricators; 2. DEI Systems; 3. Deloach Industries; 4. Or Equal. 2.02 EQUIPMENT AND COMPONENTS A. General: The decarbonator tower shall be constructed of FRP. Fabricate in accordance with Section 13190 Fiberglass Storage Tanks. B. Tower Accessories: (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -4 - 1, Packing, Demister and Distributor SupportS: a. Structural members for support of internal components associated with packing supports, the dernister, and liquid distributor laterals shall be provided integral with the tank. b. Main structural members shall be constructed of FRP. Bolted connections and other fasteners shall be Type 316 stainless steel. 2. Flanged Nozzles and Manways: a. b. C. d. Provide flanged nozzles and manways as shown on the Drawings. Nozzle connections shall be mounted flush with the interior of the vessel, unless otherwise shown or indicated. All nozzles shall be gusseted, with four plate or conical type gussets. All flanges shall be ANSI Class 150 with EPDM gaskets and Type 316 stainless steel bolts. Manway covers shall be of opaque fiberglass 3. Special Nozzle Requirements: a. Liquid Inlet: 1) The inlet shall be of the diameter indicated on the Drawings, with flanged nozzles on the interior and exterior of the tower. 2) The process influent header shall be connected to the exterior flange, while the interior flange shall 'permit installation and removal of the liquid distributor header. b. Decarbonator Outlet: The decarbonated product outlet from the tower shall be flanged on the exterior of the tower, with an internal pipe and siphon outlet extending into the tower. c. Decarbonator Drain: The decarbonator shall be provided with a siphon outlet on the drain to allow for full drain down of the decarbonator sump. d. Blower Inlet: (Carlsbad Water) (Recycling Facility) (1 -1 4-02) 11401 -5- 1) The blower inlet size and configuration shall be coordinated with the blower manufacturer and requirements of the duct system. 2) The invert of the nozzle shall be at least 4-inches above the maximum anticipated operating water level in the decarbonator sump. 3) The top of the nozzle shall be located at least 6-inches below the packing support grid to promote distribution of air across the packing. e. Air Outlet: 1) The air outlet shall consist of an integrally shaped pipe without flanges, of sufficient diameter to reduce exit air velocity below 25 ftls. 2) The outlet interior shall be fitted with a Type 316 stainless steel or thermoplastic screen material, to prevent the ingress of insects or debris. 3) The outlet base within the tower shall be fitted with a polypropylene mist arrester, minimum 6-inches thick. 4. Ladders, Walkways, and Railings: a. Provide an access ladder with safety cage, walkway, and railing for maintenance access. b. The ladder and walkway shall be positioned to allow access to the top manway, and shall allow for complete removal of all components of the liquid distributor. The walkway shall extend a minimum of 4 feet from the tower wall. c. The access ladder shall be constructed of fiberglass and shall be furnished with integral safety cage, as specified in the Fiberglass Reinforced Plastic (FRP) Tank specification. Ladder rungs shall have non-slip surfaces. Ladder supports shall be constructed integral with the tower of FRP or Type 316 stainless steel structural shapes. All fasteners shall be Type 316 stainless steel. d. The walkway shall be constructed of fiberglass structural members and grating. The walkway perimeter shall be bounded by a three-bar handrail system with a safety gate at the ladder. A continuous 4-inch toe-board shall be provided at (Carlsbad Water) (Recycling Facility) 11401 (1 -1 4-02) -6- . the interface with the grating. The grating shall have a non- slip top surface. Grating shall be designed for a maximum deflection of 0.25 inch at a minimum uniform load rating of 312 pounds per square foot and concentrated load rating of 786 pounds per foot of width. All fasteners shall be Type 316 stainless steel. 5. Supports for External Piping: a. The towers shall include supports for external vertical pipes and ducts. Coordinate locations with the field piping arrangement. b. Supports shall be fabricated integral with the tower, with Type 316 stainless steel hardware. 2.03 LIQUID DISTRIBUTOR A. General: The liquid distributor shall be composed of distribution laterals, weirs, and distribution ports. The system shall be designed to evenly distribute water over the complete cross-section of the tower at the point of impingement on the packing. B. Performance: A sufficient number of nozzles, baffles, or other flow distribution devices shall be employed to attain the required coverage while meeting the specified maximum distributor operating pressure requirement over the listed initial and projected ultimate flow conditions. Components shall be arranged to ensure even water distribution on the packing and spray patterns shall overlap to ensure that no dry spots will occur on the surface of the packing. C. Construction: The distribution system laterals shall be constructed of Schedule 80 PVC or ABS pipe and fittings. Other miscellaneous components shall be constructed of FRP. Provide at least two feet between the distributor and the top of packing to facilitate water distribution and provide access for maintenance from the upper manway. Construction and assembly shall be such that the entire distributor system can be removed through the tower upper manway. 2.04 TOWER PACKING AND ACCESSORIES A. Packing Media: 1. Packing shall be provided to promote transfer of carbon dioxide from the liquid stream to the countercurrent air stream. (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -7 - 2. Packing media shall consist of spherical injection molded thermoplastic balls with a symmetrical network of ribs, struts and drip rods. Characteristics shall be as follows: a. Material: Polypropylene b. Nominal Diameter: 3.5-inches c. Geometric Surface Area: 38 ft2m3 d. Packing Factor: 12 unitsm e. Void Space: 95 percent f. Weight: 3.3 lbsl ft3 3. The system shall be designed for gravity loading of packing from the upper manway without damage to the packing or distributor. 4. Packing shall be Plastic Jaeger Tri-Packs, Product Bulletin 600, or equal. B. Packing Support Grid: 1. Provide a lower support grid for the packing constructed of fiberglass structural members and FRP or polypropylene grating. 2. Grid openings shall be sized to prevent passage of packing media, and shall have a minimum open area of 80 percent of the tower cross-section. 3. The system shall be designed to support the wetted media and appurtenances under normal operating conditions. 4. Structural supports shall be constructed integral with the tower. External fasteners shall be Type 316 stainless steel. C. Demister: 1. The air outlet interior shall be fitted with a mist arrester as specified hereinbefore. Characteristics shall be as follows: a. Performance: 1) Droplets > 10 microns: 90 percent removal 2) Droplets > 40 microns: 99 percent removal. b. Thickness: (Carlsbad Water) (Recycling Facility) 11401 -8- (1-14-02) D 2.05 A. 6. C. D 1) Minimum: 4-inches. 2) Maximum: 12-inches. C. Materials: Polypropylene. d. Weight: 4.9 lbslf?. 2. The mist eliminator pad shall be capable of removal through the top tower manway. 3. The demister shall be Style T-271 as manufactured by Munters or equal. Bed Limiter: 1. The towers shall be equipped with a grid assembly to limit movement of packing. 2. The grid assembly shall be constructed of polypropylene or PVC. Fasteners shall be Type 316 stainless steel. 3. The entire assembly shall be constructed so that it may be installed andlor removed through the top tower manway. AIR SUPPLY BLOWER AND APPURTENANCES General: The blower shall be complete with an electric motor, shafting, enclosure, inlet air filter, bearings, anchor bolts, and all other accessories required for a complete installation. Blower Manufacturers: 1. New York Blower Company; 2. Hartzell Fan Inc.; 3. Or equal. Service Conditions: 1. Ambient Air Temperature: a. Wet Bulb: 37 to 100 OF. b. Dry Bulb: 70 "F. Performance and Design Requirements, (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -9- 1. Guaranteed Performance Requirements: a. Rated Capacity: 2,880 scfm (minimum). b. Discharge Pressure: As determined by the system supplier. c. Maximum Speed: 2,115 rpm. 2. Blower/Motor Coordination: The blower shall be matched to the motor, such that blower operation does not exceed the motor rating at any point on the operating curve, without consideration of motor service factor. 3. Blower Type: Centrifugal, Class I, belt driven, single width, single inlet. E. Materials: 1. All primary components shall be of heavy gauge, welded steel construction. 2. Painting: See Section 09900, Painting. F. Blower Construction: 1. 2. 3. 4. 5. 6. 7. 8. 9. Standards: Blowers shall bear the seal of the Air Movement and Control Association (AMCA) and comply with the AMCA Certified Ratings Program. Blowers shall be statically and dynamically balanced at the factory. Inlet Cone: Spun steel or die formed. Airfoil Wheel: The wheel shall be attached to a spun steel rim and hub plate, solid shaft with center drilled ends to accept tachometer. Bearings: Self-aligning grease-packed pillow block type with L-IO life of 40,000 hours. Bearings lubrication shall be manufacturer's standard. Motor and Fan Sheaves: Multiple belt cast iron type. Enclosure: Provide a weatherproof motor cover and belt guard, and a 3/4-inch threaded drain connection on the bottom. of the fan scroll. Coupling: Non-reverse type. Accessories: (Carlsbad Water) (Recycling Facility) ( 1-1 4-02) 11401 - 10 - a. Inlet Filter: Provide a 1/2-inch grid, stainless steel, removable screen followed by a HVAC washable dust filter on the blower inlet. b. Blower Support: Provide open spring vibration isolators selected for the weight and natural frequency of blower. G. Drive Motors: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Type: AC induction type, 3 phase, premium efficiency, constant speed. Standard Compliance: Motors shall meet requirements for severe duty, IEEE 841, latest revision. Mounting: Horizontal Size: 2.0 hp, minimum. Voltage: 480-volt, 3-phase, 60-Hz. Base Speed: 3600 rpm synchronous. Service Factor: 1.15. Enclosure: TEFC Insulation: NEMA Class F, non-hygroscopic, rated at 180 "C. Ratings: NEMA Class 6 temperature rise of 100 "C pver 40 "C ambient. Time Rating: Continuous. Accessories: a. Space Heater: Provide small resistance heater unit mounted in motor, energized during motor shutdown, to prevent condensation in motor windings, rated 120 VAC. b. Conduit Boxes: Minimum size two times NEMA standard. Provide separate boxes for motor leads and space heater wiring. c. See electric drawings for any thermal protection requirements 2.06 DUCTWORK (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 - 11 - A, B. General: Ducting between the blower outlet and tower inlet shall be constructed of 316 (316L if welded) stainless steel, in the sizes and shapes required to suit the installation and provide good distribution of air into the tower. Blowers will be located at grade on housekeeping pads with the outlet duct routed to the tower inlet. Ducting shall slope up away from the tower from the point of connection to minimize the flow of water back into the blower. Ductwork Accessories: 1, The connection between the fan casing and the duct shall be made with flexible, fire retardant fabric suitable to the service, with 2-inch minimum separation between the casing and duct. The fabric shall be coated or otherwise protected against damage by UV radiation. 2. Instrument Tap: Provide a 112-inch FNPT half coupling on the duct for connection of the discharge pressure tap. PART 3 -EXECUTION 3.01 A. B. 3.02 A. INSTALLATION General: The Contractor shall be responsible for the proper installation of all system components. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer's printed instructions, and approved shop drawings. REQUIREMENTS: 1. Follow the manufacturer's printed installation instructions and recommendations. 2. Do not place sensitive components directly on the ground. Properly support using wooden blocks. 3. Place equipment on concrete base at least 3-inches wider and longer than the base plate. 4. Install anchor bolts plumb and at the proper location. 5. Correct conditions causing excessive blower, motor, or connector noise, chatter, or vibration after installation. FIELD TESTING Testing and Startup Responsibilities: (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -12- 1. 2. 3. 4. 5. 6. 7. A qualified representative of each of the equipment manufacturers, as required, shall be present at the job site or classroom designated by the Owner for the services herein described, travel time excluded: a. Provide representatives of equipment manufacturers for installation assistance, inspection, and certification of their equipment. b. Provide specialist to conduct blower vibration and noise evaluations. c. Provide representatives for training and operations assistance. Perform all Work for equipment functional and performance tests specified herein. Complete all Work associated with the unit and related processes before testing, including related manufacturer's representative services. Provide all related operating and maintenance manuals, and spare parts and special tools as specified before testing any unit or system. Furnish qualified manufacturer's representatives when required to assist in testing. Utilize an approved Manufacturer's Certificate of Proper Installation Form, supplemented as necessary, to document all functional and performance procedures, results, problems, and conclusions. Schedule and attend pretest (functional and performance) meetings related to test schedule, plan of test, materials, chemicals, and liquids required, facilities' operations interface, Owner, and Contractor involvement. B. Functional Testing: 1. General: Conduct an initial functional test on the decarbonator and blower to demonstrate the proper installation and operation. Submit report documenting each test in a format acceptable to the Owner's Representative. 2. Alignment: Test complete blower assembly for correct rotation, proper alignment and connection, and quiet operation. 3. Vibration Test: (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 -13- a. Provide a third party contractor to conduct vibration analyses on the blower and motor assembly. b. Operate the installed blower at the intended operating point. c. The blower shall not develop at any frequency or in any plane, peak to peak vibration amplitudes in excess of 3 mils, or within manufacturer's tolerances, or more specific tolerances specified for individual equipment items herein-whichever is more stringent. d. The natural frequency of the complete assembly must be avoided by 5225 percent by any exciting frequency of the assembly at the operating speed. e. A certificate of compliance shall be placed in the startup file for the decarbonation system. f. Units failing to meet the requirements specified shall be adjusted or modified in order to comply. Units which cannot be adjusted or modified to conform as specified shall be replaced, unless otherwise agreed in writing by the Owner's Representative. 4. Operating Temperatures: a. Monitor bearing areas on blower and motor for abnormally high temperature. b. Place a certificate of compliance in the startup file for each equipment item. C. Performance Testing: 1. General: a. Prior to complete system startup, the decarbonator shall undergo an individual performance test to demonstrate and confirm that the equipment meets the performance requirements specified herein. b. Include a compliance report documenting each test in a format acceptable to the Owner's Representative in the startup file for each item of equipment. 2. Operate the decarbonator over a period of at least three hours. (Carlsbad Water) (Recycling Facility) (1 -14-02) 11401 - 14 - 3. 4. 5. 6. 7. a. Sample the decarbonated product water and confirm compliance with specified carbon dioxide removal efficiency. Measure and record initial (clean) blower discharge pressure. Check each power lead to the motor for proper current balance. Compare performance test results to the manufacturer's equivalent shop test data. Field test results differing substantially from manufacturer's shop data shall be investigated, the units adjusted, and re-tested. Units failing to meet requirements of the specifications shall be replaced with conforming units. 3.03 TRAINING A. The services of a qualified representative of the decarbonator system manufacturer shall be furnished to instruct the plant personnel in its operation and maintenance. 1. Instruction of plant personnel shall be in accordance with Section 01400. 2. A minimum of two hours training shall be provided. End Of Section (Carlsbad Water) (Recycling Facility) (1-14-02) 11401 - 15- SECTION 11403 CARTRIDGE FILTERS PART 1 - GENERAL 1.01 A. B. 1.02 A. B. 1.03 A. SCOPE OF WORK This section covers the one (1) cartridge filter to be installed in the reverse osmosis system upstream of the membrane feed pumps. The cartridge filter shall remove debris, suspended solids, dirt, and other particulate matter before it enters the membrane feed system. The Contractor shall furnish all labor, materials, equipment and incidentals necessary to install the cartridge filters as shown on the Drawings and as specified herein. RELATED WORK Factory testing requirements included herein and in Section 01650. Field functional and performance testing requirements are included in Section 01650. SUBMITTALS Shop drawings submittals shall be made in accordance with the requirements of Section 01300, except as modified herein. 1. Provide Manufacturers catalog sheets with the selected model numbers and accessories clearly indicated. 2. Submit certified fabrication drawings of the equipment. 3. Submit spare parts list. 4. Submit operating and installation instructions. 5. The cartridge filter and installation provided under this Section shall be designed in accordance with the provisions of the latest edition of the Uniform Building Code (UBC) to withstand seismic Zone 4 loads in addition to other loads. Include consideration of wind loads based on 100 mph. Design calculations shall be prepared by a California licensed professional structural engineer and submitted to the Engineer for approval. Submittals shall be certified that designs are in conformance with the UBC and that all applicable loads, including seismic, have been included. The calculations shall include consideration of all Drimarv comDonents as well as (Carlsbad Water) (Recycling Facility) (100% Submittal) 11403 -1 - 1.04 A. B. C. D. 1.05 A. B. accessories and modifications to those components (e.g., cutouts, supports for pipes, lifting lugs, etc.). Equipment support and anchorage calculations shall be prepared and submitted with drawing submittals. REFERENCE STANDARDS American Society of Mechanical Engineers (ASME) 1. ASME Boiler and Pressure Vessel Code, Section Vlll American Society for Testing and Materials (ASTM) 1, ASTM AI82 - Standard Specification for Forged or Rolled Alloy- Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High- Temperature Service 2. ASTM A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service 3. ASTM A240 - Standard Specification for Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels American National Standards Institute (ANSI) 1. ANSI 616.5 - Pipe Flanges and Flanged Fittings 2. ANSI B36.19 - Stainless Steel Pipe Where reference is made to one of the above standards, the revision in effect at the time of bid opening shallapply. QUALITY ASSURANCE All equipment furnished under this specification shall be new and shall be the standard product of a manufacturer who is fully experienced, reputable, qualified and regularly engaged for at least 5 years in the manufacture of the equipment to be furnished. The Contractor shall assume responsibility for the satisfactory installation and operation of the cartridge filter as specified. Upon completion of the cartridge filter installation, the manufacturer shall inspect and shall submit a certificate of proper installation. PART 2 - PRODUCTS 2.01 GENERAL (Carlsbad Water) (Recycling Facility) (100% Submittal) 11403 -2- A. The manufacturer shall provide one (1) horizontal cartridge filter assembly complete with top inlet, horizontal outlet, internal filter support assemblies, bottom outlet drain connection, full load of filter cartridges, and all other accessories for a complete and fully functional filtering system. B. Equipment Numbers: "1602. C. Cartridge Filter Manufacturer: 1. Commercial Filters Division of Parker Hannifin Corporation: a. Housing: Model MP40H-4-6FKl b. Filter Cartridges: Model MI 5R-40-A 2. Filterite: a. Housing: Model 48MSOH4-6FD-316L b. Filter Cartridges: Model U20AW40UECl U 3. Or equal. 2.02 HOUSINGS A. Configuration: Horizontal, with the influent connection located on top of the vessel and filtrate connection located at one end. B. Size: To accommodate 40 cartridge filter elements as specified below in a horizontal configuration. C. Design Pressure: 150 psig. D. Construction: 1. Code Compliance: Vessel construction shall comply with requirements of the ASME Boiler and Pressure Vessel Code, Section VIII, Code U Stamp. 2. Materials: Welded components shall be constructed of Type 316L stainless steel. All other components (including cover lift and bolting) shall be Type 316 stainless steel. Vessel cover seal shall be ethylene propylene rubber. The housing exterior shall be glass bead blasted after fabrication. Interior and exterior surfaces shall be passivated. (Carlsbad Water) (100% Submittal) (Recycling Facility) 11403 -3- 3. Head Assembly: The vessel head shall be swing out to permit loading of filter cartridges. When disengaged, the head shall be supported with an integrally mounted mechanical cover lift assembly. The head and vessel body shall include guides to facilitate alignment of the head. The head shall be sealed to the vessel with permanently attached swing bolts and hex head nuts. The cover shall have EPDM O-ring closure seal. E. Process Connections: 1. 2. 3. 4. 5. Raw Water Inlet: 6-inch, flanged, ANSI Class 150. Filtered Water Outlet:g-inch, flanged, ANSI Class 150. Drain Outlets: Three (3) drain connections as follows: One each for raw water and filtered water zones, 2-inch NPT, located on the bottom of the vessel, one 2-inch NPT located on the bottom raw water inlet for draining the inlet. Vent Outlets: One each for raw and filtered water zones, 112-inch NPT, located on top of the vessel. Gauge Outlets: One each for raw and filtered water zones, 112-inch NPT, located on the side of the vessel. F. Sealing Assembly: 1. The filter housing shall be designed with an intermediate separator plate drilled to support the individual cartridge element or provided with individual sealing of cartridge elements (e.g. Accu-Seal or Uni- Seal type). 2.03 FILTER ELEMENTS A. Type: Cylindrical wound depth. B. Flow Configuration: Outside to inside. C. Size: 1. Length: 40-inches. 2. Outside Diameter: 2.5-inches. 3. Inside Diameter: 1 -inch. D. Rating: 20 microns. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11403 -4- E. F. 2.04 A. 8. 2.05 A. Materials: All food grade polypropylene. Number: Supply 40 filter cartridges to load the filter housing. SPARE PARTS: Filter Elements: Supply one spare load of 40 replacement cartridges. Cover Seals: Provide one (1) spare seal. ANCHORAGE: The cartridge filter furnished and installed under this Section shall be securely supported and anchored. All anchor bolts shall be Type 316 stainless steel. The Contractor shall coordinate requirements for cast-in- place anchorage devices with the corresponding equipment pad. PART 3 - EXECUTION 3.01 A. B. 3.02 A. 8. 3.03 SHIPMENT, HANDLING, AND STORAGE The equipment specified herein, shall be factory assembled and ready for installation and connection to the piping as shown on the drawings. The parts and assemblies that are shipped unassembled, shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. INSTALLATION The Contractor shall be responsible for the proper installation of the Cartridge Filter. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer’s printed instructions, and approved shop drawings. The cartridge filter shall be installed on a concrete equipment pads and grouted underneath per the details on the Drawings. TRAINING 1. The Contractor shall provide training in accordance with Section 01400. (Carlsbad Water) (Recycling Facility) (100% Submittal) 11403 -5- (Carlsbad Water) (Recycling Facility) (I 00% Submittal) End Of Section 11403 -6- Section 11 51 1 CHEMICAL INJECTION UNIT PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing and installation of a submersible rapid mixer, equipment No. M-1001-1. Principal items furnished and installed hereunder shall include the following: Rapid mixer Guide rail mounting system Pre-wired motor control panel 1-2. GENERAL A. B. C. D. E. F. Each chemical injection unit (CIU) shall be of a submersible design and shall be able to transport the chemical to be induced from the source to the point of application at or above the minimum vacuum required to operate the chemical feed equipment. The CIU shall be located as indicated on Drawings P-7 per the manufacturer's recommendations. The CIU shall be capable of inducing the liquid chemical into the waterlwastewater stream at a velocity of approximately 60' per second without prediluting by means of a venturi injector before contact with the eye of the propeller. The CIU shall be capable of dispersing the chemical within an axial discharge pattern created by the airfoil designed propeller. The CIU shall be designed for the maximum feed rate of 250 gal/day of 12.5% sodium hypochlorite. The manufacturer shall coordinate the length of the power cable, hoist chain , mounting system, vacuum tubing and all other pertinent items with the elevations as shown on the drawings. Manufacturer warrants its products to be free from defects in material and workmanship for a period of twelve months from date of start-up or eighteen months from date of shipment, whichever occurs first. (Carlsbad Water) (Recycling Facility) 11511 -1- 1-3. SUBMITTALS. Submit assembly drawings, installation drawings, electrical schematics, wiring diagrams, control panel layout diagrams, operation and maintenance manuals, shop testing reports, and detailed specifications and data covering materials of construction, equipment, parts, motors, arrangement details, in accordance with the submittals Section 01300. 1-4. QUALITY ASSURANCE. A. The manufacturer shall be experienced in the design and fabrication of the ClUs specified. B. Tests: Shop operate, test and adjust each CIU to ensure proper assembly and operation. C. Verification of Performance: The CIU manufacturer shall submit results of factory tests of equipment. Testing shall include motor amp draw and maximum vacuum produced. PART 2 - PRODUCTS 2-1. SERVICE CONDITIONS. All equipment shall be designed for continuous, 24-hour submerged operation feeding and mixing the chemicals listed in Part 1. 2-2. RAPID MIXER. All chemical induction unit components, accessories, and spare parts shall be provided by the same manufacturer. The chemical induction unit shall be a Water Champ Model # SWCSF, as manufactured USFilter Stranco Products. A. Components: 1. Piping Connection: Piping connection on the CIU shall be made of Grade 2 (unalloyed) titanium to eliminate the danger of pipe stress or over-tightening of vacuum tubing by service personnel. The propeller is to be an exposed four bladed airfoil design made of Grade 2 (unalloyed) titanium. The motor and CIU shall have an integral designed shaft constructed of Grade 2 (unalloyed) titanium. The vacuum enhancer shall be a chemically resistant material suitable for the application as recommended by the CIU manufacturer. 2. Propeller: 3. Shaft: 4. Vacuum Enhancer: (Carlsbad Water) (Recycling Facility) 11511 -2- 5. Vacuum ChamberlHousing: The vacuum chamber shall be made of Grade 2 (unalloyed) titanium. 6. Wetted Parts: All wetted parts of the inductor system, or material coming in contact with non-diluted chemical, shall be made of Grade 2 (unalloyed) titanium. 7. Motor: a. The motor shall be all 316 stainless steel construction, 460 volt, 3 phase, 60 Hz, Class F insulation, with a hermetically sealed, externally water cooled enclosure. b. The motor shall have an integral designed titanium shaft with a mechanical seal using silicon carbide seal faces. c. The motor windings shall be hermetically sealed and resin- filled in an all welded 316 stainless steel shell for moisture resistance. d. Electrical cable connection shall be through a removable water-block lead connector that is field replaceable. e. The motor thrust bearing shall be designed for a minimum of 1500 Ibs. submersible motor protection system. The submersible motor protection system shall be: ii. Capable of automatically restarting the CIU after a recovery period. If after restart the same condition exists, the CIU shall be automatically shut down an additional two times with timed intervals between restarts. After third shut down occurs, the submersible motor protection system shall require a manual reset. status, high temperature, overload, underload, and alarm conditions. f. Each motor shall be provided with a microprocessor based I. Designed to shut the CIU down. iii. Designed to have a lighted display identifying motor The installation contractor shall provide adequate space within an electric enclosure to mount the motor protection system. a. Power Cables: a. The CIU shall be furnished complete with power cable. b. Cable shall have UL andlor CSA approved insulation. C. The cable shall be four conductor. 8. Accessories 1. Mounting System: The CIU manufacturer shall supply: (Carlsbad Water) (Recycling Facility) 11511 -3- a. Type 316 stainless steel guide rail system for each CIU as recommended by the CIU manufacturer of sufficient length to raise the entire CIU above the mounting elevation. recommended by the CIU manufacturer. Chain shall be rated for lifting at least two times the weight of the CIU. Its length shall be two times depth from the walkway to the elevation where the rapid mixer is normally mounted for service. b. Type 316 stainless steel chain for lifting the CIU as 2. Mounting Bolts: a. Provide Type 316 stainless steel mounting bolts of the size b. Washers and nuts shall be Type 316 stainless steel . a. Vacuum tubing shall be a 1%” diameter flexible PVC hose as recommended by the manufacturer. 3. Vacuum Hose Kit: suitable for the chemical service conditions specified and shall have OPW Kamlok or equal fittings on each end. b. Hose shall have smooth inside bore with helically wound reinforcement. c. Manufacturer shall provide both the hose shank couplers on all hose and the male adapters which will be connected to the chemical feed piping including a ball check valve or backpressure valve designed for the particular application. C. Spare Parts: 1. Qty. 1 - Vacuum Enhancer per CIU. 2. Qty. 1 -Vacuum hose less fttings per CIU. 3. Qty. 1 set - Quick disconnect seals per CIU D. Pre-Wired Motor Control Panel. Provide a control panel in accordance with the CIU manufacturer‘s standard specification. Each CIU shall be provided with a prewired control panel with a submersible motor protection system as recommended by the manufacturer. The control panel shall be sized to match the voltage and horsepower of the motor to be controlled. The control panel shall have a hand-off-automatic control switch, hour meter and status indicating pilot lights for run and stop. 1. Control Functions: a. Under normal operating conditions the control panel shall function to control the start and stop action of the CIU, either locally or remotely. overcurrent, undercurrent, high temperature, rapid cycling and shall respond by tripping the starter/contactor off line whenever a fault occurs. b. The control panel shall function to monitor the CIU for (Carlsbad Water) (Recycling Facility) 11511 -4- C. d. e. f. 9. h. Each motor shall be provided with a microprocessor based submersible motor protection system. The submersible motor protection system shall be: ii. Capable of automatically restarting the CIU after a recovery period. If after restart the same condition exists, the CIU shall be automatically shut down an additional two times with timed intervals between restarts. After third shut down occurs, the submersible motor protection system shall require a manual reset. status, high temperature, overload, underload, and alarm conditions. I. Designed to shut the CIU down. iii. Designed to have a lighted display identifying motor The control panel shall have a non-resetable hour meter of the mechanical type. Battery operated LCD type will not be acceptable. The hour meter shall record hours of operation while the motor is running up to 99,999.0 hours before automatically resetting to zero. The control panel shall be provided with a three phase fused, lockable disconnect switch. The disconnect operator shall indicate status and not allow the inner panel door to be opened while the switch is in the on position. The control panel shall provide a contact brought to field terminals for alarm condition to be monitored remotely. The control panel shall be provided with contacts brought to field terminals for remote alarm monitoring of run and stop status. The panel shall be provided with a surge arrestor which exceeds ANSlllEEE standard C62.11. 2 Construction Features. a. The non-metallic panel enclosure shall be fabricated to meet NEMA 4X standards. b. Doors shall have continuous heavy-duty piano hinge with stainless steel hinge pins. c. Doors shall have a foamed polyurethane gasket with tongue and groove labyrinth at all seal points. d. All operator usable functions shall be located behind the main door on a separate hinged control panel. The main door shall have a window large enough to view all operation functions and diagnostics. e. The main door shall have non-locking stainless steel latches. f. All non-operator maintained parts and devices shall be located directly behind the control panel on a metallic back panel. All parts shall have easy access. (Carlsbad Water) (Recycling Facility) 11511 -5- g. All exposed metallic hardware components of the panel shall have grounding bonds to the main field grounding connection. h. The enclosure shall have integral wall mounting flanges. I. All wiring shall be color coded and plainly marked at all terminations. Black wire for all live power conductors. White wire for all neutral conductors. Green wire for all ground conductors. Red wire for all control circuits. Yellow wire for all circuits not de-energized when the panel disconnect is opened. j. Wires shall be routed within wireway as much as possible. k. Terminal blocks shall be rail mountable type. All terminal blocks shall be consecutively numbered. I. Provide spare terminal blocks. m. No mounting or fastening hardware other than conduit penetration shall penetrate the enclosure other than that supplied by the enclosure manufacturer. maintenance personnel of potential live circuits even when the main disconnect is open. n. A warning label shall be provided in plain sight to alert 4. Electrical Specification. a. Supply power shall be 460 volt, 3 phase, 60 HZ. b. Disconnect shall be rated for 600 volt. c. Wiring shall be rated for 600 volt, 105 degrees C. d. Terminal blocks shall be rated for 600 volt on motor power e. Fuses shall be rated 600 volt. circuits and 300 volt for control circuits. 2-3. FABRICATION. Shop assemble each CIU as a completed assembly for testing. PART 3 - EXECUTION 3-1. INSTALLATION. Equipment and materials furnished under this section shall be installed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Control and power cables and vacuum hose shall be supported to avoid excessive tension and damage. End of Section (Carlsbad Water) (Recycling Facility) 11511 -6- SECTION 11530 IN-LINE STATIC MIXERS 1. SCOPE. This section covers two in line static mixers for installation in the GMF and MF feed pipelines. The in-line static mixers for the GMF and MF feed pipelines shall be 36 inches and 16 inches in diameter, respectively. Static mixers shall include housing flanges, elements, spacers, ports, and all other appurtenances. 2. GENERAL. The General Equipment Stipulations shall apply to all equipment furnished under this section. The static mixers shall be as manufactured by Komax Systems, Inc., or equal. 2.01, Lenqth Tolerance. The actual length of each static mixer shall be within 1/8 inch (plus or minus) of the specified length. 2.02. Shop Paintinq. Painting of stainless steel construction will not be required. Carbon steel flanges and housing shall be shop primed with Koppers "No. 10 Inhibitive Primer", Valspar "13-R-28 Chromox Primer", or Tnemec "77 Chem- Prime". Flange faces shall be coated with rust preventive compound, Houghton "Rust Veto 344" or Rust-Oleum "R-9. Carbon steel and plastic components shall be field painted in accordance with the painting specification. 3. PERFORMANCE AND DESIGN REQUIREMENTS. Each static mixer shall provide for injection and complete mixing of each chemical solution specified herein. Uniform blending of the primary water stream and additive chemicals shall be accomplished at the minimum and maximum flow rates. Static mixers shall be installed as indicated on the drawings. The static mixers shall each be designed for the following requirements: GMF Feed Pipeline Mixing efficiency at max, percent 85 Nominal diameter, in 36 Flow rate, cfs Min 6.19 Max 24.6 (Carlsbad Water) (Recycling Facility) 11530 -1- Interior pressure, psi Max operating Peak Water temperature, degrees C Max headloss at max flow, psi Max laying length, ft Chemical feed rates Aluminum sulfate (alum), gph Polymer, gph MF Feed Pipeline Mixing efficiency at max, percent Nominal diameter, in Flow rate, cfs Min Max Interior pressure, psi Max operating Peak Water temperature, degrees C Max headloss at max flow, psi Max laying length, ft Chemical feed rates Sodium hypochlorite, gph 35 70 20 min, 28 max 1.50 11 1 .O min, 3.8 rnax 0.1 min, 0.3 max 85 16 1.43 5.73 35 70 20 min, 28 max 1.50 6 3.2 min. 12.9 max (Carlsbad Water) (Recycling Facility) 11530 -2-