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Section 13560
INSTRUMENTATION GENERAL REQUIREMENTS
Data Sheet
ara- IDescription IData
raph
General
Instruments and devices are
indicated on V PBID drawings
Instrument Deuce Schedule
V 1356oSO Schedules
and ink for each recorder One yeah supply of spare charts
ounted Instruments.
(Carlsbad Water)
(Recvclina Facilitv) 13560
-1-
Inits
Iml E [“C]
[“C]
(ReiB-li/27-95% Submittal) Std. Rev. 1.1, 03/31/2000
r /See Section 13562 for Flow Ili. Yea 1 Instruments.
Quantity of Programming Devices 1 total for each brand of instrument
. "
cNo I
lrequired for Flow Instruments
Software required for Flow
Copies of Diagnostidlnterface
I I
1 total for each brand of isntrument I Instruments
and Level Instruments
See Section 13563 for Pressure (i yes
c NO
required for Pressure and Level
Quantity of Programming Devices
Copies of Diagnostidlnterface
1 total for each brand of instrument
Instruments
Software required for Pressure and
1 total for each brand of instrument
ILevel Instruments
Instruments. 6 yes See Section 13564 for Analytical I
r NO
IQuantity of Programming Devices 11 total for each brand of instrument /required for Analytical Instruments I I /Copies of Diagnostidlnterface 11 total for each brand of instrument I lSo&are required for Analvtical / I I
/Instruments I lsee Section 13565 for IC Vme Miscellaneous Instruments .- nr.1
c NO
required for Miscellaneous
Quantity Of Programming Devices
Copies of Diagnostidlnterface
1 total for each brand of instrument
Instruments
Software required for Miscellaneous 1 total for each brand of instrument
Instruments
Instrument Installation
Requirements (PR 3-1)
rewired
Analog Control Description System r yes
li. No
/When "Yes" is selected, describe. 1
(Carlsbad Water)
(Recycling Facility)
(Rev 8-12/27-95% Submittal)
13560 -2-
Std. Rev. 1.1. 03/31/2000
Section 13560
INSTRUMENTATION GENERAL REQUIREMENTS
PART 1 - GENERAL
1-1, SCOPE. This section covers the furnishing of instrumentation equipment
required for the Plant Control System as indicated on the drawings and as
required.
Principal components of the instrumentation systems shall be as indicated on the
P81D drawings; as indicated on the instrument device schedule drawings; as
indicated on the instrument device schedules attached to this Section 13560, or
to Sections 13561 through 13565, as required.
1-1.01. Control Svstem. Section 13500 shall apply to all systems described in
this section. All applicable requirements defined in Section 13500 shall apply to
equipment and services provided under Section 13560.
1-1.02. Terminoloay. When the phrase "as required" is stated in this
section it shall mean "as required in the attached Data Sheet".
1-2. GENERAL. CONTRACTOR shall select the equipment furnished under this
section for its superior quality and the intended performance. The
CONTRACTOR shall install all equipment in accordance with the manufacturer's
instructions. Equipment and materials used shall be subject to review and shall
comply with the following requirements.
1-2.01. General EauiPment Reauirements. When required, the General
Equipment Requirements shall apply to all equipment provided under this
section.
1-2.02. Drawinss. Supplementing this section, the drawings indicate locations
and arrangement of instruments and enclosures, provide mounting details, and
may show device schedules and other information regarding the connection and
interaction with other equipment.
1-2.03. Governinq Standards. Governing Standards for instruments shall be as
indicated in Section 13500.
1-2.04. Corrosive Fluids. All parts, which are exposed to corrosive conditions,
shall be made from corrosion resistant materials. CONTRACTOR shall submit
certification that the instrument manufacture approves the selection of materials
of primary elements which are in contact with the specified process fluid to be
inert to the effects of the process liquid;
(Carlsbad Water)
(Rev 8-12727-95% Submittal)
(Recycling Facility) 13560 -3-
Std. Rev. 1.1, 03/31/2000
1-2.05. Elevation and Temperature. All instruments shall be designed to Operate
within a range of elevation and temperature as required.
1-2.06. Power and Instrument Siqnals. Unless otherwise indicated, electric
power supply to the instrumentation equipment will be unregulated 120 volts ac.
Unless otherwise indicated, all transmitted electronic analog instrument signals
shall be 4-20 mA dc and shall be linear with the measured variable.
1-2.07. ADDurtenances. Signal converters, signal boosters, amplifiers, special
power supplies, special cable, special grounding, and isolation devices shall be
furnished as needed for proper performance of the equipment.
1-2.08. lnterchanqeabilitv and ADpearance. To the extent possible, instruments
used for similar types of functions and services shall be of the same brand and
model line. Similar components of different instruments shall be the products of
the same manufacturer to facilitate maintenance and stocking of repair parts.
Whenever possible, identical units shall be furnished.
1-2.09. Proarammina Devices. A programming or system-configuring device
shall be provided for systems that contain any equipment that requires such a
device for routine calibration, maintenance, and troubleshooting. The program-
ming device shall be complete, newly purchased for this project, and shall be in
like-new condition when turned over to OWNER at completion of startup.
1-2.10. Device Taq Numberinq System. All devices shall be provided with
permanent identification tags. The tag numbers shall be as close as practical to
the tag numbers used on the project drawings and device schedules. All field-
mounted transmitters and devices shall have stamped stainless steel
identification tags. Panel, subpanel, and rack-mounted devices shall have
laminated phenolic identification tags securely fastened to the device. Hand-
lettered or tape labels will not be acceptable.
1-3. SUBMITTALS. Submittals shall be as required in Section 13500
1-4. DELIVERY, STORAGE, AND SHIPPING. Delivery, storage and shipping
shall be as required in Section 13500.
1-5. SPARE PARTS. Spare parts shall be provided as required
2-1. INDIVIDUAL DEVICE SPECIFICATIONS. Individual instruments and
related devices shall be provided as specified in one or more of the following
sections, as required:
13561 Panel Mounted Instruments
13562 Flow Instruments
(Carlsbad Water) 13560
(Recycling Facility) -4-
(Rev 8-12/27-95% Submittal) Std. Rev. 1.1, 03/31/2000
13563 Pressure and Level Instruments
13564 Analytical Instruments
13565 Miscellaneous Instruments
PART 3 - EXECUTION
3-1. INSTRUMENTATION INSTALLATION REQUIREMENTS. Additional
instrumentation installation requirements are outlined in Section 13500.
Instruments shall be installed and calibrated in accordance with the following
requirements.
3-1.01. Field Calibration, After each instrument has been installed, a technical
representative of CONTRACTOR shall calibrate each instrument and shall
provide a written calibration report for each instrument, indicating the results and
final settings. The adjustments of calibrated instruments shall be sealed or
marked, insofar as possible, to discourage tampering. Instrument calibration
shall be done before checkout of the system operation. A typical instrument
calibration report is attached to the end of each section.
3-1.02. Svstems Check. A technical representative of CONTRACTOR shall
participate in the checkout of instrumentation systems. Systems check
requirements shall be as specified in Section 13500.
3-1.03. Installation Test Equipment. Unless specified otherwise, all test
equipment for the calibration and checking of system components shall be
provided by CONTRACTOR for the duration of the testing work and this test
equipment will remain the property of CONTRACTOR.
3-1.04. Mountinq of field Instruments. Instruments shall be mounted so that
they can be easily read and serviced and so that all appurtenant devices can be
easily operated. Installation details for some instruments are indicated on the
drawings.
3-2. CUSTOMER TRAINING. Instrumentation training is covered in Section
13500.
End of Section
(Carlsbad Water)
(Recycling Facility)
(Rev B-12/27-95% Submittal)
13560
-5-
Std. Rev. 1.1, 03/31/2000
NAME B SERVICE:
INSTRUMENT
TAG OR LOOP NO.:
INPUTIOUTPUT RANGE:
ACTUAL DESIRED
INPUT OUTPUT OUTPUT
PROPORTIONAL BAND:
RESET:
1) COMMENTS:
DATE OF CALIBRATION:
CALIBRATED BY:
Black & Veatch INSTRUMENT CALIBRATION Figure 1-13560
~~ ~ ~
REPORT
T
l" r
1
"I
1
Section 13561
PANEL MOUNTED INSTRUMENTS
Data Sheet
[Para- lDescription bata
graph
Annunciators
Annunciator(s) Required c Yes
c No
Annunciator window size required. c 1 by 3-114 inch [25 by 831
c 1-112 by 3-1/4 inch [38 by 83 mm]
c 3 by 3-114 inch [75 by 83 mm]
required.
Annunciator operating sequence c ISA Sequence A
C ISA Sequence M (manual reset)
c ISA Sequence F2A (first out)
Audible alarm device and
accessories required. r Repeating chime
Adjustable wlume hom
Auxiliary contacts for alarm
r Automatic acknowledge relay
r Resettable common alarm relay
r
r Other
(When "Other" is selected, indicate I
alternative.
Annunciator point requiring isolated
auxiliary contact outputs. c Yes
c No
Adjustable time delay required. C yes
c No
Auxiliary relay required. c Yes
r No
trotaiiiers
trotalizer(s) Required r Yes
@ No
nit
(Carlsbad Water)
(Recycling Facility)
13561
-1-
r NO
Digital Panel Indicators
Digital Panel Indicator(s) Required C Yes
No
Electronic Bar Graph Indicators
Electronic Bar Graph lndicator(s) C Yes
Required G No
Absolute alarm with set point
required.
r Yes
r NO
Edgewise Panel Indicators
Edgewise Panel Indicator($
Required
C Yes
GNO
~~ Manual Loading Stations
Manual Loading Station@) C Yes
Required
Ratio Stations
Ratio Station@) Required r Yes
G No
G No
Electronic Indicating Control
Stations
Electronic Indicating Control r Yes
Station(s) Required
'A DIN Single-Loop Control
Stations
X DIN Single-Loop Control
Station(s) Required r Yes
No
'A DIN ManuallAuto Backup
G No
Stations
'A DIN ManuaVAuto Backup
Station(s) Required r Yes
G Nn . _- I
Case Recorden
Large Case Recorder(s) Ir Yes I (Required No
(Carlsbad Water)
(Recycling Facility)
13561
-2-
7 day chart speed
Integrator and totalizer
Clocks
Clock(s) Required r Yes
No
Clock type and options rewed. r Circular panel clock
r Dkgital clock with 12 hour display
r Dlsplay clock with 24 hour display
(Carlsbad Water)
(Recycling Facility)
13561
-3-
bwitches, Lights. and Push I
-. uttons
Devices Required p Selector Switches
p Indicating Lights
p Push Buttons
Panel Interior Mounted Devices
Devices required. r Integrators
p Power supplies
I7 Relays
r Intrinsically safe relays
I7 Electronic signal boosterlisolators
r Electronic signal selectors
r Electronic signal summers
r Fixed deadband signal monitors
Adjustable deadband signal monitors
r Strip heaters
r Other
When "Other" is selected indicate
alternative.
Common power supply for all
instruments in a filter system. r Yes
Other Items Required Weatherproof Horn
. - . . . - .
No
(Carlsbad Water)
(Recycling Facility) 13561
-4-
Section 13561
PANEL MOUNTED INSTRUMENTS
PART 1 - GENERAL
1-1, SCOPE. This section covers the furnishing of all panel-mounted instruments
and accessories required for the Plant Control System as indicated on the
drawings and as required.
Equipment and services provided under this section shall be subject to the
General Instrumentation Requirements specified in Section 13500 and Section
13560. This section shall be used and referenced only in conjunction with
Section 13560. Supplementing Section 13560, instrument data, special
requirements, and options are indicated on the drawings or the Instrument
Device Schedule, as required.
When multiple analytical instruments of a particular type are indicated on the
Data Sheet, and each requires different selectable features, the required features
are described in the drawings or the Instrument Device Schedule.
1-1.01. Terminoloqy. When the phrase "as required" is stated in this
section it shall mean "as required in the attached Data Sheet ".
1-2. DESIGN CRITERIA. The instruments shall be installed to measure, monitor,
or display the specified process at the ranges and service conditions indicated on
the drawings or as indicated in the Instrument Device Schedule.
1-3. SUBMITTALS. Submittals shall be made in accordance with the
requirements of Section 13500.
1-4. SHIPMENT, PROTECTION, AND STORAGE. Equipment provided under
this section shall be shipped, protected, and stored in accordance with the
requirements of Section 13560. Identification of packaging shall be as described
in Section 13560.
PART 2 - PRODUCTS
2-1. GENERAL. The following paragraphs provide minimum device
requirements. The drawings or Instrument Device Schedule shall be used to
determine any additional instrument options, requirements, or service conditions
(Carlsbad Water)
(Recycling Facility) 13561
-5-
2-1.01 Proarammina Device. For systems that require a dedicated programming
device for calibration, maintenance, or troubleshooting, one such programming
device shall be provided for each OWNER facility (quantity required shall be as
indicated in the Section 13560 general data sheet). The programming device
shall include appropriate operation manuals and shall be included in the training
requirements. For systems that allow the programming device functions to be
implemented in software, running on a laptop computer, the software shall be
provided instead of the programming device.
2-1.02 Confiauration SoftwarelSerial Interface. Devices indicated as requiring a
serial interface shall be provided with all accessories required to properly
communicate over the serial link. As a minimum, an appropriate cable shall be
provided to allow the transmitter serial interface to be connected to a personal
computer. One licensed copy of the diagnostidinterface software shall be
provided for each Owner facility (quantity required shall be as indicated in the
Section 13560 general data sheet). Software shall be capable of running under
Microsoft's Windows 98, Windows Me, Windows 2000, and Windows NT 4.0
operating system. If the software furnished performs the same functions as the
programming device, specified elsewhere, then the programming device shall not
be furnished.
2-2. PANEL FRONT MOUNTED DEVICES.
2-2.01. Annunciators. Not Used.
2-2.02. Totalizers. Not Used.
2-2.03. Diaital Panel Indicators. Not Used
2-2.04. Electronic Bar Graph Indicators. Not Used.
2-2.05. Edaewise Panel Indicators. Not Used
2-2.06. Manual Loadinq Stations. Not Used.
2-2.07. Ratio Stations. Not Used
2-2.08. Electronic lndicatina Control Stations. Not Used
2-2.09. 114 DIN Sinale-Loop Control Stations. Not Used.
2-2.10. 114 DIN ManuaVAuto Backup Stations. Not Used
2-2.1 1. Larqe Case Recorders. Not Used
(Carlsbad Water)
(Recyclmg Facility)
13561
-6-
2-2.12. Strip Chart Recorders. Not Used.
2-2.13. Pressure Gauoes. Not Used.
2-2.14. Diaital and Panel Clocks. Not Used
2-2.15. Weatherproof Horn. Weatherproof alarm horns shall have NEMA 4
housings, and adjustable volume of 78 to 103 dB. Alarm horns shall be
Edwards, Federal Signal, or equal.
2-2.16. Switches, Liohts. and Push Buttons.
2-2.16.01. Selector Switches. Selector switches shall be heavy-duty, oil-tight
NEMA 4 type with gloved-hand or wing lever operators. Position legends shall
be engraved on the switch faceplate. Switches for electric circuits shall have
silver butting or sliding contacts, rated 10 amperes continuous at 120 V ac.
Contact configuration shall be as indicated on the drawings or as required for the
application. Switches used in electronic signal circuits shall have contacts
suitable for that duty. Switches shall be Cutler-Hammer "Type T", General
Electric "CR, or Micro Switch "Type PT".
2-2.16.02. lndicatina Liahts. Indicating lights shall be heavyduty, oil-tight NEMA
4 type, with low voltage LEDs. A built-in transformer shall be used for ac service.
Legends shall be engraved on the lens or on a legend faceplate. Lights shall be
push-to-test type. Indicating lights shall be Cutler Hammer "Type T", General
Electric "CR, or Micro Switch "Type PT".
2-2.16.03. Push Buttons. Push buttons shall be heavy-duty, oil-tight NEMA 4
type. Legends shall be engraved on the push-button faceplate. Contacts shall
be rated 10 amperes continuous at 120 V ac. Push buttons shall be Cutler-
Hammer "Type T", General Electric "CR", or Micro Switch "Type PT".
2-3. PANEL INTERIOR MOUNTED DEVICES
2-3.01. Inteorators. Not Used.
2-3.02. Power SuDplies. Regulated dc power supplies for instrument loops shall
be designed and arranged so that loss of one supply does not affect more than
one instrument loop or system. Power supplies shall be suitable for an input
voltage variation of *IO percent, and the supply output shall be fused or
shortcircuit protected. Output voltage regulation shall be as required by the
instrumentation equipment supplied. Multiloop or multisystem power supplies will
be acceptable if backup power supply units are provided which will automatically
supply the load upon failure of the primary supply. The backup supply systems
shall be designed so either the primary or the backup supply can be removed,
(Carlsbad Water)
(Recycling Facility) 13561
-1 -
repaired, and returned to service without disrupting the instrument system
operation. The power distribution from multiloop supplies shall be selectively
fused so a fault in one instrument loop will be isolated from the other loops being
fed from the same supply. Fuses shall be clearly labeled and shall be located for
easy access. Multiloop supply systems shall be oversized for an additional
10 percent future load. Failure of a multiloop supply shall be indicated on the
respective instrument panel or enclosure.
2-3.03. Relavs. Relays indicated to be provided in panels, enclosures, or
systems furnished under this section shall be of the plug-in socket base type with
dustproof plastic enclosures unless noted otherwise. Relays shall be UL
recognized and shall have not less than double-pole, double-throw contacts.
Control circuit relays shall have silver cadmium oxide contacts rated 10 amperes
at 120 V ac. Electronic switchingduty relays shall have gold-plated or gold alloy
contacts suitable for use with low-level signals. Relays used for computer input,
alarm input, or indicating light service shall have contacts rated at least
3 amperes. Time delay relays shall have dials or switch settings engraved in
seconds and shall have timing repeatability of +2 percent of setting. Latching
and special purpose relays shall be as required for the specific application.
Unless otherwise indicated, all relays shall have an integral pilot light that
illuminates to indicate an energized condition. Relays shall be Eagle Signal
"Series 22, 80; IDEC "Series RR; Potter 8 Brumfield "Series KRP, CB; or
Struthers-Dunn "Series A3. A4".
2-3.04. Intrinsicallv Safe Relavs. Not Used.
2-3.05. Electronic Siqnal Booster/lsolators. Electronic signal boosters and
isolators shall have all solid-state circuitry and complete electrical isolation
between the power supply and the input and output signals. Accuracy shall be
k0.15 percent of span. Isolators shall be manufactured by Acromag, Moore,
Phoenix Contact or R.I.S.
2-3.06. Electronic Siqnal Selectors. Not Used
2-3.07. Electronic Signal Summers. Not Used.
2-3.08. Fixed Deadband Siqnal Monitors. Not Used
2-3.09. Adjustable Deadband Siqnal Monitors. Not Used.
2-3.10. Strip Heaters. Not Used
PART 3 - EXECUTION
(Carlsbad Water)
(Recycling Facility)
13561
-0-
3-1 FIELD SERVICES. Manufacturer's field services shall be provided for field
calibration, startup, and training as specified in Section 13560.
End Of Section
(Carlsbad Water)
(Recycling Facility) 13561
-9-
Section 13562
FLOW INSTRUMENTS
Data Sheet
ransmitter(s) Required
r Hazardous area
I? Multiple Instruments
Pulse output from converter
requlred.
r Yes
No
r Multiple instruments
Totalizer required on signal
converter.
r Yes
No
r Multiple instruments
type.
When "Yes" is selected, indicate c Non-reset 7 digit
r Manual reset 6 digit
r Multiple instruments
(Carlsbad Water)
(Recycling Facility)
13562
-1-
Flowmeter(s) Required
r Multiple instruments
r Multiple instruments
(Carlsbad Water)
(Recycling Facility)
13562
-2-
(Single Path)
In-Line Ultrasonic Flowmeter(s) r Yes (Single-Path) Required
Select temperature range c +32 to +13o"F [O to +WC]
G No
c -20 to +14o"F 1-28 to +6o"C]
Tranducers removable without c Yes
depressurizing or dewatering. r No
c Multipie instruments
In-Line Ultrasonic Flowmeters
'Multi-Path)
In-Line Ultrasonic Flowmeters r Yes
(Multi-Path) Required G No
transminer.
AC power receptacle required on C Yes
r No
r Multiple instruments
Elements
Averaging Pitot Type Flow
Averaging Pitot-Type Flow
Elements Required
r Y~S
rz No
Element support mount required. C yes
No
Thermal Dispersion Flowmeters
Thermal Dispersion Flowmeten C Yes
Required No
inch [25mm] MNPT mounting C Yes
onnection required. /r No
Multiple instruments
required. Isolation valve and packing gland C Yes
C No
C Multiple instruments
Transmitter mounting requirements. C On sensing element assembly
IC Remote within 30 feet I I I )r Multiple instruments I II Enclosure type r NEMA ~ype 4
C For hazardous area
r Multiple instruments
/Propeller Flowmeters
(Carlsbad Water) (Recycling Facility) 13562
-3-
Propeller Flowmeters Required r Yes
G No
Suitable for use with potable water. r Yes
r No
C Multiple instruments
Rate of flow indicator required. C Yes
rNo
r Multiple instruments
Signal converter required. r Yes
r No
C Multide instruments
ignal converter required.
t Positive Displacement Flow Meter
Paddle Wheel Type Flow Meter I
(Carlsbad Water)
(Recycling Facility) 13562
-4-
Section 13562
FLOW INSTRUMENTS
PART 1 - GENERAL
1-1. SCOPE. This section covers the furnishing of all flow instruments and
accessories required for the Plant Control System as indicated on the drawings
and as required.
Equipment and services provided under this section shall be subject to the
General Instrumentation Requirements specified in Section 13500 and Section
13560. This section shall be used and referenced only in conjunction with
Section 13560. Supplementing Section 13560, instrument data, special
requirements, and options are indicated on the drawings or the Instrument
Device Schedule, as required.
When multiple flow instruments of a particular type are indicated on the Data
Sheet, and each requires different selectable features, the required features are
described on the drawings or in the Instrument Device Schedule.
1-1.01. Terminoloqy. When the phrase "as required" is stated in this
section it shall mean "as required in the attached Data Sheet".
1-2. DESIGN CRITERIA. Each device shall be a pre-assembled, packaged unit.
Upon delivery to the work site, each device or system shall be ready for
installation with only minor piping and electrical connections required by
CONTRACTOR.
Where possible, each instrument shall be factory calibrated to the calibration
ranges indicated on the drawings or in the Instrument Device Schedule.
Transmitters or similar measurement instruments shall be calibrated using
National Institute of Standards and Testing (NISI) approved bench calibration
procedures, when such procedures exist for the instrument type. For "smart"
devices, calibration data shall be stored digitally in each device, including the
instrument tag designation indicated on the drawings or Instrument Device
Schedule.
1-3. SUBMITTALS. Submittals shall be made in accordance with the
requirements of Section 13500.
1-4. SHIPMENT, PROTECTION, AND STORAGE. Equipment provided under
this section shall be shipped, protected, and stored in accordance with the
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requirements of Section 13500. Identification of packaging shall be as described
in Section 13500.
14.01. Cleaning. Instruments indicated to be utilized in oxygen, ozone, or
similar service shall be cleanetl for oxygen service, labeled appropriately, and
bagged or packaged as necessary to ensure the instrument will remain suitable
for insertion in the process during installation. Any special mounting or
installation requirements associated with such instruments shall be detailed on
tags attached to the instrument.
PART 2 - PRODUCTS
2-1. GENERAL. The following paragraphs provide minimum device
requirements. The drawings or Instrument Device Schedule shall be used to
determine any additional instrument options, requirements, or service conditions.
2-1.01, lnterconnectina Cable. For instruments where the primary element and
transmitter are physically separated, interconnecting cable from the element to
the transmitter shall be provided. The cable shall be the type approved by the
instrument manufacturer for the intended purpose of interfacing the element to
the transmitter. Length of cable shall be a minimum of three meters or as
indicated on the drawings or in the Instrument Device Schedule.
2-1.02. Proarammina Device. For instruments that require a dedicated
programming device for calibration, maintenance, or troubleshooting, one such
programming device shall be provided as indicated in the Section 13560. The
programming device shall include appropriate operation manuals and shall be
included in the training requirements. For systems that allow the programming
device functions to be implemented in software, running on a laptop computer,
the software shall be provided instead of the programming device.
2-1.03. Configuration Software/Serial Interface. Devices indicated as requiring a
serial interface shall be provided with all accessories required to properly
communicate over the serial link. As a minimum, an appropriate cable shall be
provided to allow the transmitter serial interface to be connected to a personal
computer. Software shall be capable of running under Microsoft's Windows 98,
Windows Me, Windows 2000, and Windows NT 4.0 operating systems. If the
software furnished performs the same functions as the programming device,
specified elsewhere, then the programming device shall not be furnished,
2-2. FLOW INSTRUMENTATION.
2-2.01. "Smart" Differential Pressure Flow Transmitters. Not Used.
2-2.02. Magnetic Flowmeters, Signal Converters, and Accessories
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2-2.02.01, Maanetic Flowmeter. The magnetic flowmeter shall be a completely
obstructionless, in-line flowmeter with no constrictions in the flow of fluid through
the meter. The meter shall consist of a metallic tube with flanged ends and with
grounding rings, Flange diameter and bolt drilling pattern shall comply with
ANWASME B16.5, Class 150. Flangeless wafer insert style meters may be
used for pipe sizes up to 6 inches [150 rnm], where compatible with adjacent
piping flanges. Meters shall be suitable for the maximum range of working
pressures of the adjacent piping. Self-cleaning bullet-nosed electrodes shall be
provided for all meters used for sludge metering. Electrode and liner materials
shall be fully compatible with the process fluid and shall comply with the
requirements specified in the instrument device schedules. Each meter shall be
factory calibrated, at a facility, which is traceable to NlST or other standard
acceptable to ENGINEER, and a copy of the calibration, report shall be
submitted as part of the operation and maintenance manual submittal.
The meter shall be capable of standing empty for extended periods of time
without damage to any components.
When required, the meter housing shall be of a splash-proof and drip-proof
design. Meters that are located in pipe trenches or below grade shall have
housings designed for accidental submergence. When submersible design is
required, the meter housing shall withstand submergence in 30 feet (9.1 m] of
water for 48 hours without damage.
When required, the meter shall be suitable for use in a Class I, Division 2,
hazardous area.
Meters shall be as manufactured by Foxboro. or Rosemount, without exception.
2-2.02.02. Maqnetic Flowmeter Siqnal Converters. Separately mounted,
microprocessor-based signal converters shall be provided for the magnetic
flowmeters. The signal converters shall include output damping, self-testing,
built-in calibration capability, and an "empty pipe zero" contact input. The overall
accuracy of the magnetic flowmeter transmitter and signal converter shall be
k0.5 percent of actual flow rate for full-scale settings of 3 to 30 fps [0.91 to
9.14 mls]. The meter manufacturer shall furnish the signal cable between the
converter and the magnetic flowmeter. The signal converter shall be housed in a
corrosion-resistant, weatherproof NEMA Type 4 housing and shall be suitable for
operation over an ambient temperature range of -30 to +140"F [-34 to +6O"C],
and relative humidity of 10 to 100 percent. The converter shall have an analog
output of 4-20 mA dc. Transmitters tagged on the drawings or specified to be of
the indicating type shall contain a local indicator with a minimum four digit LCD
type display, scaled to read in engineering units of flow.
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Magnetic flowmeter systems shall provide zero flow stabilrty by means of
automatic zero adjustment of a DC excited metering circuit. Converters shall be
capable of bi-directional flow measurement. Signal converters shall be of the
same brand as the magnetic flowmeters.
2-2.03. Open Channel Ultrasonic Flowmeters. Each ultrasonic flowmeter shall
be a microprocessor-based electronic unit consisting of a sensor assembly, a
signal converter/transmitter, and an interconnecting cable. The sensor shall be
encapsulated in a chemical- and corrosion-resistant material such as kynar or
CPVC, and shall be suitable for operation over a temperature range of -20 to
+150"F [-28 to +66"C], with a relative humidity of 10 to 100 percent. Sensors
shall be compatible with the process media being measured. The sensor shall
be mounted directly over the flume or weir channel and shall measure the fluid
level by means of reflected high frequency sound waves. Sensors mounted in
areas subject to freezing condensation shall be protected against icing with
special transducers or heaters. Sensors mounted in direct sunlight shall be
provided with sunshades.
The supplier shall coordinate the sensor mounting requirements and shall furnish
drawings, complete with dimensions and elevations, to ensure a proper and
satisfactory installation. When required, general installation requirements are
indicated on the drawings.
The ultrasonic flowmeter shall have automatic compensation for changes in air
temperature at the sensor location. If separate temperature sensing probes are
provided, they shall be mounted with or adjacent to the ultrasonic sensor, as
recommended by the manufacturer. The transmitter shall have a four-digit LCD
display scaled to read in engineering units of flow. Digit height shall be
approximately 0.5 inch t12.7 mm). The transmitter shall be designed to ignore
momentary level spikes, false targets, or momentary loss-of-echo. A loss-of-
echo condition shall be indicated on the transmitter unit and shall be available as
an alarm contact output. The transmitter output shall be an isolated 4-20 mA dc
signal linearly proportional to flow. The signal converter shall use a
microprocessor-based digital flow linearizer circuit that can be easily changed in
the field. Calibration parameters shall be stored in nonvolatile EEPROM
memory. Accuracy of the transmitted signal shall be *1 percent of the flow
range.
A sufficient length of sensor-to-transmitter signal cable shall be furnished with the
instrument to locate the sensor 25 to 200 feet [7.6 to 61 m] from the signal
converter.
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When outdoor installation is required, the signal converter electronics shall be
housed in a weatherproof, corrosion-resistant NEMA Type 4 enclosure suitable
for wall or pipestand mounting and for operating temperatures of -15 to +125"F
[-26 to +51"C], and a relative humidity of 10 to 100 percent. A thermostatically
controlled strip heater shall be provided in the signal converter enclosure.
The signal converter shall be of the ac-powered type.
The ultrasonic flow transmitter shall be Milltronics "HydroRanger Plus", Magnetrol
"Echotel3PI". or Panametrics "PC1 XMT868".
2-2.04. Open Channel Admittance Probe Flowmeters. Not Used
2-2.05. Doppler Ultrasonic Flowmeters. Not Used
2-2.06. In-Line Tvpe Ultrasonic Flowmeters (Single Path). Not Used
2-2.07. in-Line Tvpe Ultrasonic Flowmeters (Multi-Path). Not Used
2-2.08. Averaainq Pitot TvDe Flow Elements. Not Used.
2-2.09. Thermal Dispersion Flowmeters. Not Used.
2-2.10. Propeller Flowmeters. Not Used
2-2.1 1. Turbine Flowmeters. Not Used.
2-2.12. Orifice Plates. Not Used.
2-2.13. Differential Pressure Flow Indicators. Not Used.,
2-2.14. Gas Service Rotameters. Not Used.
2-2.15. Liquid Service Rotameters. Rotameters shall be guided float, direct
reading with an integral flow adjustment valve, suitable for panel mounting with
inlet and outlet fittings perpendicular to the meter body for rear entry. Scale
length shall be IO-inches with a flow range of 0 - 2 gpm. The meters shall have
clear acrylic bodies with Type 316 stainless steel float, guide, valve, and fittings.
Seals shall be EPDM. Process connections shall be 112-inch MNPT fittings. The
metering valve shall be needle type, 3-piece design, with CNC machined knob
and integral travel stop. Accuracy shall be 2 percent of full range. Rotamters
shall be King Instruments Model No. 7530; or equal.
2-2.16. Target Type Flow Switches. Not Used
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2-2.17. Thermal Dispersion Flow Switches. Flow detecting switches shall be of
the thermally actuated probe type with 3/4" threaded NPT process connection.
The sensing probes shall be constructed of Hastelloy-C or 316 stainless steel as
indicated on the device schedule. The switch shall be powered from 120 VAC
and shall have a NEMA type 4 housing. The switch actuating point shall be field
adjustable and shall be initially set as indicated on the Device Schedule. The
switch shall have a single-pole-double-throw relay contact output rated 2
amperes at 120 VAC. Flow switches shall be Fluid Components, Intl. "Model
FLT93L" or equal.
2-2.18. Positive Displacement Flow Meter. Positive displacement flow meter
systems shall be of the rotary piston type and produce a dc pulsed signal directly
proportional to and linear with the liquid flow rate. Each flow metering system
shall include a displacement type sensor with pre-filter, signal cable, and
transmitter. Meters, including transmitters and remote junction boxes, shall be
rated NEMA 4X.
The flow sensor shall be constructed of type 316 stainless steel with 3/8-inch
FNPT connections, and with a minimum of 2 carbon pistons with a rated
displacement of 10.5 cc per revolution. The meter shall have Teflon bearings
and Viton seals.
The flowmeter shall include a microprocessor-based signal converteritransmitter
with a 4-20 ma output signal. The converter shall have a 10-digit alphanumeric
display with tactile keypad for flowrate, percent of span, and totalizer.
The transmitter shall have programmable parameters for calibration and display
units and hsall be suitable for integral panel mounting remote from sensor.
Ambient temperature operating limits of 32 to 130 degrees f (0 to 55 degrees c).
Performance requirements:
Flow range: 10 cc/min (0.158 gph) to 1.5 gpm (90 gph)
Accuracy: 0.75 percent of flow rate for flows above 40 cdmin (0.632 gph)
Power supply: 120 vac, plus or minus 10 percent.
Factory testing:
Each flow metering system shall be hydraulically calibrated. A real-time computer
generated printout of the actual calibration data indicating apparent and actual
flows at 20%, 40%. 60%. 80% and 100% of the calibrated range shall be
submitted prior to shipment of the meters to the project site.
Manufacturer shall be Max machinery, inc., or equal.
2-2.19. Paddle Wheel Type Propeller Flow Meter. Paddle wheel flow meter
systems shall be of the rotorlpropeller type and produce a dc pulsed signal
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directly proportional to and linear with the liquid flow rate. Each flow metering
system shall include a sensor, signal cable, and transmitter.
Meters, including transmitters and remote junction boxes, shall be rated NEMA
4x.
Flow sensor: the flow sensor shall have the following:
Constructed of polypropylene with a titanium shaft and black PVDF rotor.
Furnished with a mounting saddle for installation in a IO-inch diameter schedule
80 pvc pipe.
Sensor mounting connection shall be 2-114” FNPT,
-
Viton seals.
Transmitter: the microprocessor-based signal converter/transmitter shall have
the following:
Convert dc pulse signal from the sensor to a standard 4-20 ma signal into a
minimum of 700 ohms.
A 2x16 character Icd display with tactile keypad.
Programmable parameters for calibration and display units.
Suitable for integral panel mounting remote from sensor.
Performance requirements:
Operating range: 1 to 20 Ws.
Linearity: 1 .O percent of full range.
Power supply: 24 vdc, unregulated, 50 - 60 hz.
Factory testing:
Each flow metering system shall be hydraulically calibrated. A real-time computer
generated printout of the actual calibration data indicating apparent and actual
flows at 20%, 40%, 60%. 80% and 100% of the calibrated range shall be
submitted prior to shipment of the meters to the project site.
Manufacturer shall be George Fischer. inc.. or equal
PART 3 - EXECUTION
3-1. FIELD SERVICES. Manufacturer’s field services shall be provided for
installation, field calibration, startup, and training as specified in Section 13560
Instruments shall not be shipped to the Work Site until two weeks prior to the
scheduled installation. The CONTRACTOR shall be responsible for coordinating
the installation schedule with the Installation Contractor. Each shipment shall
contain a listing of protective measures required to maintain sensor operation,
including a listing of any common construction or cleaning chemicals that may
affect instrument operation.
End of Section
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Section 13563
PRESSURE AND LEVEL INSTRUMENTS
Data Sheet
r Multiple instruments
Ultrasonic Level Transmitters
Ultrasonic Level Transmitters
Required C Yes
No
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r Multiple instruments
llnstallation requirements are lr Yes
Indicated on the drawings.
(Output characterized for. Ir Lewl
No
Volume
Ir Dual unit for differential sensing I r Multiple instruments
Four alarm contacts required. r Yes rNo
I- Multiple instruments
Ilndoor signal converter housings Ir Yes
required.
Outdoor signal converter housings
required. r yes
Admittance Probe Level
Transmitters
Admittance Probe Level C Yes Transmitter Required
Probe type. r Flexible weighted probe
r NO
r NO
No
I1 (r Rigid coated probe I r Multiple instruments
Probe mounting detail indicated on
drawings.
r Yes
r DC ow two-wire signal line. Transmitter powered by.
r No
I I Ir 120 v ac I r Multiple instruments
Indicator required on signal
converter. r Yes r NO r Multiple instruments
Bubbler System
Bubbler System Required C Yes
No
Fixed-Mount Float Type Level
Switches
quired for hazardous area. pecial type of sensor housing r Yes r NO
-
-
-
-
-
-
-
-
-
-
-
- -
-
-
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. "
Switches
Weighted Float Type Level
Switches Required
Weighted Float Type Level c Yes
Adjustable Deadband Float Type
Level Switch
Adjustable Deadband Float Type r Yes
Level Switches Required
Level Switches
ElectrodelConductance Relay
ElectrodelConductance Relay C Yes
Level Switch Required
s No
@ No
C Nn
IElectrode type. (c Flexible weighted probe I I IC Rigid coated probe I
C Multiple instruments
Electrode holder type. C 4 inch flange
I )r Wall bracket I
C Multiple instruments
elay housing. C Instrument panel
I IC Explosionproof enclosure I r Multiple instruments
\Flange-Mounted DiSDlaCement I
FloatType Level Switches
Flange-Mounted Displacement c Yes
Float Type Level Switches
Required. No
Switch housing. r Weatherproof
I )r Multiple Instruments I
Pressure Switches
Pressure Switches Required C Yes
c No
nubbers Requlred r Yes
IC No
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Ii" nubbers Required C Yes
15 No
Diaphragm Seais Required 5 Yes
r NO
Other Level instruments Required Indirect Magnetic Flag Type Level
Transmitters
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Section 13563
PRESSURE AND LEVEL INSTRUMENTS
PART 1 - GENERAL
1-1. SCOPE. This section covers the furnishing of pressure and level sensing
instruments and accessories required for the Plant Control System as indicated
on the drawings and as required.
Equipment and services provided under this section shall be subject to the
General Instrumentation Requirements specified in Section 13500 and Section
13560. This section shall be used and referenced only in conjunction with
Section 13560. Supplementing Section 13560, instrument data, special
requirements, and options are indicated on the drawings or the Instrument
Device Schedule, as required.
When multiple pressure and level instruments of a particular type are indicated
on the Data Sheet, and each requires different selectable features, the required
features are described on the drawings or in the Instrument Device Schedule.
1-1.01. Terminoloqy. When the phrase "as required" is stated in this
section it shall mean "as required in the Data Sheet".
1-2. DESIGN CRITERIA. Each device shall be a pre-assembled, packaged unit.
Upon delivery to the work site, each device or system shall be ready for
installation with only minor piping and electrical connections required by
CONTRACTOR.
Where possible. each instrument shall be factory calibrated to the calibration
ranges indicated in the drawings or in the Instrument Device Schedule.
Transmitters or similar measurement instruments shall be calibrated using
National Institute of Standards and Technology (NIST) approved bench
calibration procedures, when such procedures exist for the instrument type. For
"smart" devices, calibration data shall be stored digitally in each device, including
the instrument tag designation indicated on the drawings and/or Instrument
Device Schedule.
1-3. SUBMITTALS. Submittals shall be made in accordance with the
requirements of Section 13500.
1-4. SHIPMENT, PROTECTION, AND STORAGE. Equipment provided under
this section shall be shipped, protected, and stored in accordance with the
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13563 -5-
requirements of Section 13560. Identification of packaging shall be as described
in Section 13560.
1-4.01. Cleaning. Instruments indicated to be utilized in oxygen, ozone, or
similar service shall be cleaned for oxygen service. labeled appropriately. and
bagged or packaged as necessary to ensure the instrument will remain suitable
for insehion in the process during installation. Any special mounting or
installation requirements associated with such instruments shall be detailed on
tags attached to the instrument.
PART 2 - PRODUCTS
2-1. GENERAL. The following paragraphs provide minimum device
requirements. The drawings or instrument device schedule shall be used to
determine any additional instrument options, requirements, or service conditions.
2-1.01, lnterconnectinq Cable. For systems where the primary element and
transmitter are physically separated, interconnecting cable from the element to
the transmitter shall be provided. The cable shall be the type approved by the
instrument manufacturer for the intended purpose of interfacing the element to
the transmitter. Length of cable shall be a minimum of three meters or as
indicated in the drawings or Instrument Device Schedule.
2-1.02. Proqramminq Device. For systems that require a dedicated
programming device for calibration, maintenance, or troubleshooting, one such
programming device shall be provided as indicated in the Section 13560. The
programming device shall include appropriate operation manuals and shall be
included in the training requirements. For systems that allow the programming
device functions to be implemented in software. running on a laptop computer,
the software shall be provided instead of the programming device.
2-1.03. Confiwration SoftwarelSerial Interface. Devices indicated as requiring a
serial interface shall be provided with all accessories required to properly
communicate over the serial link. As a minimum, an appropriate cable shall be
provided to allow the transmitter serial interface to be connected to a personal
computer. One licensed copy of the diagnostidinterface software shall be
provided. Software shall be capable of running under Microsoft's Windows 2000,
Windows 98/Me. and Windows NT 4.0 operating system. If the software
furnished performs the same functions as the programming device, specified
elsewhere, then the programming device shall not be furnished.
2-2. PRESSURE AND LEVEL INSTRUMENTATION
2-2.01. "Smart" Pressure and Pressure Sensina Level Transmitters.
Transmitters shall have "smart" electronic circuitry and shall be of the two-wire
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type. Process fluid shall be isolated from the sensing elements by AIS1 Type 316
stainless steel, Hastelloy-C or cobalt-chromium-nickel alloy diaphragms, and a
silicone oil fluid fill. Transmitters shall have self-diagnostics and electronically
adjustable span, zero, and damping. Transmitters shall be enclosed in a NEMA
Type4X housing and shall be suitable for operation at temperatures from 0" to
180°F [-17" to +82"C], and relative humidity of 5 to 100 percent. All parts shall
be stainless steel, or other corrosion-resistant materials. Transmitters shall have
over-range protection to maximum line pressure. Accuracy of the transmitter
shall be 0.10 percent of span, and transmitter output shall be 4-20 mA dc without
the need for external load adjustment. Transmitters shall not be damaged by
reverse polarity. Transmitters shall have an elevated or suppressed zero as
required by the application. For calibrated spans of less than 8 psig [55 kPa
gauge] a differential pressure type transmitter with side vents shall be utilized.
Transmitters shall be provided with brackets for wall and pipe-stand mounting.
Transmitters shall be factory calibrated to the required range and provided with
the manufacturer's standard hand-held communications/calibration device. One
device shall be furnished for all transmitters provided by a single manufacturer.
Transmitters tagged on the drawings or specified to be indicating type shall be
furnished with LCD type digital indicators.
Transmitters shall be ABB 600T Series, Foxboro "Model IGPlO-D or Rosemount
Model 3051C.
2-2.02. "Smart" Differential Pressure Transmitters. Transmitters shall have
"smart" electronic circuitry and shall be of the two-wire type. Process fluid shall
be isolated from the sensing elements by AIS1 Type 316 stainless steel,
Hastelloy-C or cobalt-chromium-nickel alloy diaphragms, and a silicone oil fluid
fill. Transmitters shall be enclosed in a NEMA Type4X housing and shall be
suitable for operation at temperatures from 0" to 180°F [-17" to +82"C], with
relative humidity of 5 to 100 percent. All parts shall be stainless steel, or other
corrosion-resistant materials. Vents shall be provided on the sides of the
diaphragm housing body. Transmitters shall have positive over-range protection.
Accuracy of the transmitters shall be 0.10 percent of span, and the effect on
accuracy caused by static pressure changes shall be negligible. Transmitter
output shall be 4-20 mA dc without the need for external load adjustment.
Transmitters shall not be damaged by reverse polarity. Each transmitter shall be
provided with a stainless steel, three-valve manifold with PTFE seals and a
mounting bracket as required. Manifolds shall have test ports on the instrument
side of the valves and shall be Anderson-Greenwood "M4T".
Transmitters shall be factory calibrated to the required range and provided with
the manufacturer's standard hand-held communicationslcalibration device. One
device shall be furnished for all transmitters provided by a single manufacturer.
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Transmitters tagged on the drawings or specified to be the indicating type shall
be furnished with LCD type digital indicators.
Transmitters shall be ABB 600T Series, Foxboro "Model IDP10-D " or
Rosemount Model 3051C.
2-2.03. Flanqe-Mounted "Smart" Pressure Sensincl Level Transmitters. Not
Used.
2-2.04. Ultrasonic Level Transmitters. Not Used I
2-2.05. Admittance Probe Level Transmitters. Not Used.
2-2.06. Bubbler Svstem Components. Not Used.
2-2.07. Fixed-Mount Float TvDe Level Switches. Switches shall be of the
floating ball type, with a nominal 5 inch [125 mm] diameter, Teflon coated
stainless steel float ball that contains a sealed switch assembly. The float shall
be supported with a flexible synthetic rubber hinge fastened to an adjustable
mounting bracket. The hinge shall also act as a housing for the lead wires from
the alarm switch. The lead wire shall be a waterproof cable of such length that
no splice or junction box is required in the wet well. Stainless steel mounting
accessories shall be furnished. The switch contacts shall be single-pole-double-
throw rated 4 amp [A] at 250 V ac. Switches shall be US. Filter - Consolidated
Electric "9G.
2-2.08. Weiqhted Float TvDe Level SwitchesNot Used
2-2.09. Adiustable Deadband Float Tvpe Level Switch. Not Used
2-2.10. ElectrodelConductance Relay Level Switch.Not Used
2-2.1 1. Flanae-Mounted DisDlacement Float Tvpe Level Switches. Not Used
2-2.12. Pressure Switches. Pressure switches shall be diaphragm actuated
type switches. Switches shall be field adjustable type, with trip point repeatability
better than 1 percent of actual pressure. Switches shall have over-range
protection to maximum process line pressure. Switches mounted inside panels
shall have NEMA Type1 housings. All other switches shall have weatherproof
housings. Switches shall be differential type where indicated in the Instrument
Device Schedule. Switch wetted parts shall be compatible with the process fluid.
Switches for sulfuric acid service shall have Alloy 20 port, PTFE O-ring, and
PTFE coated polyamide diaphragm. Switches for Sodium Hypochlorite service
shall have Hastelloy C port, Viton O-ring, and PTFE coated polyamide
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diaphragm. Where the process is not defined, the switch shall be provided with a
316 stainless steel port, EPDM O-ring and PTFE coated diaphragm.
Panel-mounted and surface-mounted switches shall be provided with 114 inch
[6 mm] NPT connections. All stem-mounted switches shall be provided with
112 inch [12 rnm] NPT connections.
All pressure switches shall be ranged in psi [kPa] and all vacuum switches in
inches [mm] of water. Unless otherwise indicated, switches shall have a fixed
deadband and shall be auto-reset type. As a minimum switches shall be SPDT,
rated 10 amp [A] at 120 V ac.
Unless otherwise indicated, each switch shall be provided with a threaded end,
ball-type shutoff valve. Shutoff valve materials shall be compatible with the
process fluid. Where the process is not specified, valves shall have AIS1
Type 316 stainless steel wetted parts and Teflon seals. Multi-port valves shall
have all unused ports plugged. Shutoff valve construction shall be as detailed in
Section 13565.
Where indicated in the drawings or the Instrument Device Schedule, a diaphragm
seal shall be provided for the respective switch. All process wetted parts shall be
compatible with the process fluid. Seals used for acid service shall have Alloy 20
housing and diaphragm. Seals used for Sodium Hypochlorite service shall have
Hastelloy C housing and diaphragm. Seals used for sludge or water service
shall have stainless steel housing and diaphragm. The upper housing shall be
contoured to fit and provide a seat and seal for the diaphragm and shall be
designed to permit removal of the switch with the system under pressure. The
lower housing shall be provided with a tapped and plugged 114 inch [6 mm] NPT
flushing connection. Each diaphragm seal and the switch served shall be factory
assembled, tilled with a suitable fluid, and calibrated as a unit.
Switches shall be installed at the locations indicated on the drawings, with
installation conforming to the installation details. All switches, snubbers, and
diaphragm seals shall be installed in the vertical, upright position. Thread sealer,
suitable for use with the associated process, shall be used in the assembly of
threaded connections. All connections shall be free from leaks. Lines shall be
purged of trapped air at switch locations prior to installation of the switch or
diaphragm seal.
Switches shall be manufactured by Ashcroft, Barksdale, Mercoid Controls, or
S.O.R.
2-2.13. Flood Level Switches. The flood detecting level switches shall be float
actuated and shall be suitable for wall or sump mounting as required. The switch
float mechanism shall actuate when the water level rises to 1 inch 125 mm] above
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the bottom of the housing. The switch contacts shall be hermetically sealed,
rated for 0.1 amp [A] at 120 V ac, and shall be field changeable from normally
open to normally closed. Flood switches shall be Consolidated "Model 101G", or
equal..
2-2.14. Submersible Pressure Sensing Level Transmitters. Not Used.
2-2.15. Ultrasonic Level Switches. Not Used
2-2.16. Pressure Gauges. Pressure gauges shall be of the indicating dial type,
with C-type phosphor bronze Bourdon tube; stainless steel rotary geared
movement; phenolic or polypropylene open front turret case; adjustable pointer;
stainless steel, phenolic, or polypropylene ring; and acrylic plastic or shatterproof
glass window.
Gauge dial shall be 4-112 inch [I 14 mm] size, with white background and black
markings. The units of measurement shall be indicated on the dial face.
Subdivisions of the scale shall conform to the requirements of the governing
standard. Pointer travel shall be not less than 200 degrees or more than
270 degrees of arc.
Panel-mounted and surface-mounted gauges shall be provided with 114 inch
[6 mm] NPT connections. All stem-mounted gauges shall be provided with
112 inch [I2 mm] NPT connections. Where indicated in the drawings or on the
Instrument Device Schedule, stem mounted gauges shall have an adjustable
viewing angle to allow the gauge to be positioned for optimum viewing.
All pressure gauges shall measure in psi [kPa] and all vacuum gauges in inches
[mm] water. All gauges shall have a suitable range to give mid-scale readings
under normal conditions. Gauge accuracy shall be 0.5 percent of scale range.
Unless indicated otherwise, each gauge shall be provided with a threaded end,
ball-type gauge valve. Gauge valve materials shall be compatible with the
measured process. Where the process is not defined, gauge valves shall have
AIS1 Type 316 stainless steel wetted parts and Teflon seals. Multi-port gauge
valves shall have all unused ports plugged. Gauge valve construction shall be as
detailed in Section 13565.
Where indicated on the drawings or in the Instrument Device Schedule, a
diaphragm seal shall be provided for the respective gauge. All process wetted
parts shall be compatible with the process fluid. Seals used for acid service shall
have Alloy 20 housing and diaphragm. Seals used for Sodium Hypochlorite
service shall have Hastelloy C housing and diaphragm. Seals used for sludge or
water service shall have stainless steel housing and diaphragm. The upper
housing for all deals shall be stainless steel and shall be contoured to fit and
provide a seat and seal for the diaphragm and shall be designed to permit
(Carlsbad Water) 13563
(Recycling Facility) -1 0-
(01-19-02)
removal of the gauge with the system under pressure. The lower housing shall
be provided with a tapped and plugged 114 inch [6 mm] NPT flushing connection.
Each diaphragm seal and the gauge served shall be factoly assembled, filled
with a suitable fluid, and calibrated as a unit.
Gauges shall be installed at the locations indicated on the drawings, with
installation conforming to the installation details. All gauges, snubbers, and
diaphragm seals shall be installed in the vertical, upright position. Thread sealer,
suitable for use with the associated process, shall be used in the assembly of
threaded connections. All connections shall be free from leaks. Lines shall be
purged of trapped air at gauge locations prior to installation of the gauge or
diaphragm seal.
Each gauge shall be provided with all required mounting hardware to securely
mount the unit according to the mounting requirements indicated in the drawings
or the Instrument Device Schedule.
Unless otherwise indicated, mounting and installation hardware shall be
Type 316L stainless steel.
Pressure gauges shall be Ashcroft "1279 or 1288 Duragauge",3D Instruments, or
equal.
2-2.17. Indirect Maqnetic FlaQ Type Level Transmitters. Indirect magnetic flag
(sight glass) type level transmitters shall be constructed as follows.
e Housing tube with 2 inch tank side and side oriented connections
having a diameter and drilling conforming to ANSI 816.5,
Class 150. The housing tube diameter shall be 2.5 inches.
e At manufacturer's option, the top of the housing tube maybe either
fixedlsealed or flanged joint with a blind flange. The use of a
threaded cap will not be acceptable. The bottom of the housing
tube shall end in a flanged joint with blind flange,
e Magnetic indicator actuation float,
0 Two color flipper flag type magnetic indicators for liquid depth.
0 Indicating scale graduated in inches
e High and low liquid level alarm switches as indicated on the
drawings and in the device schedules.
0 Continuous liquid level transmitter
(Carlsbad Water)
(Recycling Facility)
(01-19-02)
13563
-11-
Isolation valves for the tank side connections.
Appurtenances as required for a properly operating system.
Unless otherwise indicated, materials of construction shall generally be selected
by the manufacturer for suitability with the intended chemical service. See
additional requirements on the chemical tank spec data sheets. The level
indicator mounting and materials of construction shall be coordinated with the
supplier of the chemical tanks.
As the liquid level rises or falls, the colored magnetic flags shall automatically
flip to indicate liquid level within a resolution of 0.5 inch. The liquid level
measurement range shall be approximately the distance between the lower
tank connection point and the upper tank connection point defined in the tank
specifications. Level transmitters shall be provided where indicated on the
device schedules and P&ID drawings. Unless otherwise noted, all level
transmitter system electronics components shall be housed in an enclosure(s)
rated for Class 1, Division 1, Group B service. The transmitter shall be suitable
for operating at temperatures of +5 to +120"F. The power supply to the
transmitter shall be 24 volts dc and shall be loop powered. The transmitter
output shall be an isolated 4-20 mA dc signal into 0 to 600 ohms. Linearity shall
be proportional to the measured level range.
Separate level switch modules shall be provided for high and low level alarming,
where indicated on the device schedules and P&ID drawings. The switch points
shall be adjustable in the field. The switches shall be housed in an enclosure
rated for Class 1, Division 1, Group B service.
Flanged end Isolation valves shall be provided for each tank connection.
Mounting arrangement and fitting connections shall be coordinated with the
tank supplier for each specific application. Valves maybe either ball valves or
diaphragm valves. Materials of construction and trim materials shall be selected
for the specific chemical service. Nonmetallic level indicators may utilize
nonmetallic valves of the type manufactured by NibcolChemtrol, Hayward
Plastics, or equal. Isolation valves for acid storage tanks shall be fully plastic
lined, metal body, diaphragm or plug valves as manufactured by Dow. All valves
shall have a rated working pressure of at least 100 psi.
Level indicators shall be GEMS "SureSite". John C. Ernst Company "Model 049,
ISE-Magtech, Kenco, or Magnetrol. Being named does not relieve the
manufacturer from compliance with the specification provisions.
(Carlsbad Water)
(Recycling Facility) (01-19-02)
13563
-12-
PART 3 - EXECUTION
3-1. FIELD SERVICES. Manufacturer's field services shall be provided for
installation, field calibration, startup, and training as specified in Section 13560.
Instruments shall not be shipped to the Work Site until two weeks prior to the
scheduled installation. CONTRACTOR shall be responsible for coordinating the
installation schedule with the installation Contractor. Each shipment shall
contain a listing of protective measures required to maintain sensor operation,
including a listing of any common construction or cleaning chemicals that may
affect instrument operation.
End of Section
(Carisbad Water)
(Recycling Facility) (01-19-02)
13563
-1 3-
Section 13564
ANALYTICAL INSTRUMENTS
Data Sheet
r Multiple instruments
(Carlsbad Water)
(Recycling Facility)
13564
-1 -
5 Multiple instruments
pas Detection System
as Detectlon System Required r Yes
I 15 No
required.
Types of gas detection systems r Ammonia
r Carbon Monoxide
r Combustible Gas (methane)
r Combustible Gas (gasoline)
Chlorine Gas
r Hydrogen Sulfide
Oxygen Deficiency
Sulfur Dioxide
r Other
I- Multiple instruments
in Section 13564.
When "Othef is selected, describe
Combustible gas sensors unaffected by hydrogen sulfide. r Yes
No
Additional receiver-alarm module r 4-20 ma dc output requirements. r Additional relays
ype of sensor required. r Flow-through I
"
"
"
"
"
"
-
"
"
-
- -
-
erial communications output
r Multiple instruments
Streaming Current Analyzers
Streaming Current Analyzers
Required C Yes
No
erial communications output
f Multiple instruments
Suspended Solids Analyzers
Suspended Solids Analyzers
Required r Yes
No
I berial communications output Ir Yes
C Multiple instruments
(Carlsbad Water)
(Recycling facility)
13564
-2-
Sample pump with pressure and flow
1 kequired
r Multiple instruments
Dissolved Oxygen Analyze=
Dissolved Oxygen Analyzers Required r Yes
Type of analyzer required. r Zullig
c= No
C Membrane
C Multiple instruments
Serial communications output
required. r Yes
r No
C Multiple instruments
Dissolved Ozone Analyzers
Dissolved Ozone Analyzers Required C Yes
NO
Serial Communications Output Required r Yes
r No
r Multiple Instruments
Low Concentration Ozone
- pnalyzers
(Carlsbad Water)
(Recycling Facility) 13564
-3-
Low Concentration Ozone
Analyzers Required r Yes
G No
required.
Serial communications output r Yes
r NO
C Multiple instruments
High Concentration Ozone
Analyzers
High Concentration Ozone
Analyzers Required r Yes
Serial communications output
required. Yes
G No
r No
C Multiple instruments
Oxygen Purity Analyzers
Oxygen Purity Analyzer Required C Yes
(i NO
transmitter.
Three pole receptacle required on r yes
r NO
erial communications output r Yes
r NO
r Multiple instruments
Dewpoint Analyzers
Dewpoint Analyzers Required r Yes
No
required.
Serial communications output Yes
r No
C Multiple instruments
Hydrocarbon Analyzers
Hydrocarbon Analyzers Required r Yes
@ No
Serial communications output
required. C Yes
r No
C Multiple instruments
Nuclear Sludge Density Meters
Nuclear Sludge Density Meters Required C Yes
Serial communications output C Yes required.
NO
No
C MUltiDle instruments I I bonductivity Analyzers Yes
(Carlsbad Water) (Recycling Facility) 13564
-4-
)Sample Pumm P-1002, Chlorine Contact Basin . P-1201. Thickener influent . P-1202. Thickener Effluent
(Carlsbad Water)
(Recycling Facility) 13564
-5-
Section 13564
ANALYTICAL INSTRUMENTS
PART 1 - GENERAL.
1-1, SCOPE. This section covers the furnishing of analytical instruments and
accessories required for the Plant Control System as indicated on the drawings
and as required.
Equipment and services provided under this section shall be subject to the
General Instrumentation Requirements specified in Section 13500 and Section
13560. This section shall be used and referenced only in conjunction with
Section 13560. Supplementing Section 13560, instrument data, special
requirements, and options are indicated the drawings or an Instrument Device
Schedule, as required.
When multiple analytical instruments of a particular type are indicated on the
Data Sheet, and each requires different selectable features, the required features
are described on the drawings or in the Instrument Device Schedule.
1-1.01. Terminoloqy. When the phrase "as required is stated in this
section it shall mean "as required in the attached Data Sheet".
1-2. DESIGN CRITERIA. Each device shall be a pre-assembled, packaged unit,
Upon delivery to the work site, each device or system shall be ready for
installation with only minor piping and electrical connections required by
CONTRACTOR.
Where possible, each instrument shall be factory calibrated to the calibration
ranges on the drawings or In the Instrument Device Schedule. Transmitters or
similar measurement instruments shall be calibrated using National Institute of
Standards and Technology (NIST) approved bench calibration procedures, when
such procedures exist for the instrument type. For "smart" devices, calibration
data shall be stored digitally in each device, including the instrument tag
designation indicated on the drawings or in the Instrument Device Schedule.
1-3. SUBMITTALS. Submittals shall be made in accordance with the
requirements of Section 13500.
1-4 SHIPMENT, PROTECTION, AND STORAGE. Equipment provided under
this section shall be shipped. protected, and stored in accordance with the
requirements of Section 13500. Identification of packaging shall be as described
in Section 13500.
(Carlsbad Water)
(Recycling Facility)
13564
-6-
PART 2 - PRODUCTS
2-1. GENERAL. The following paragraphs provide minimum device
requirements. The drawings and/or Instrument Device Schedule shall be used to
determine any additional instrument options, requirements, or service conditions.
2-1.01. 'Interconnectinq Cable. For instruments where the primaly element and
transmitter are physically separated, interconnecting cable from the element to
the transmitter shall be provided. The cable shall be the type approved by the
instrument manufacturer for the intended purpose of interfacing the element to
the transmitter. Length of cable shall be a minimum of three meters or as
indicated in the drawings.
2-1.02. Proqrammins Device. For instruments that require a dedicated
programming device for calibration, maintenance, or troubleshooting, one such
programming device shall be provided for each OWNER facility (quantity
required shall be as indicated in the Section 13560 general data sheet). The
programming device shall include appropriate operation manuals and shall be
included in the training requirements.. For systems that allow the programming
device functions to be implemented in software, running on a laptop computer,
the software shall be provided instead of the programming device.
2-1.03. Confiquration SoftwarelSerial Interface. Devices indicated as requiring a
serial interface shall be provided with all accessories required to properly
communicate over the serial link. As a minimum, an appropriate cable shall be
provided to allow the transmitter serial interface to be connected to a personal
computer. One licensed copy of the diagnostidinterface software shall be
provided for each OWNER facility (quantity required shall be as indicated in the
Section 13560 general data sheet). Software shall be capable of running under
Microsoft's Windows Me, Windows 2000, Windows 98, and Windows NT 4.0
operating systems. If the software furnished performs the same functions as the
programming device, specified elsewhere, then the programming device shall not
be furnished.
2-2. ANALYTICAL INSTRUMENTATION
2-2.01. Low Ranqe Turbidity Analvzers. Analyzers shall operate with a
continuous flow of sample through the sample cell to drain. A strong light beam
shall be passed through the sample and the amount of light scattered by the
turbidity particles shall be measured. The analyzer shall utilize an US EPA
approved method of turbidity analysis.
The sample cell shall utilize a lamp operated below rated voltage to extend
operating life and a silicon photocell that detects the reflected light intensity.
Sample flow rate shall be approximately 0.2 gpm [0.01 Us]. The sample cell
shall be constructed of all corrosion-resistant materials and shall have an integral
(Carlsbad Water)
(Recycling Facility) 13564 -7-
bubble trap. Accessories shall be provided as required to allow for a field
calibration check of the analyzer. The secondary calibration standard shall be an
optical glass calibration cube that has a known NTU value. One secondary
calibration device shall be provided for each four analyzers. A one-year supply
of consumables, including a primary standard formazin calibration kit, shall be
provided with each analyzer.
The analyzer shall have a master indicator mounted near the sample cell and
connected to the sample cell with a special cable. The unit shall have an auto-
ranging three or four-digit display that indicates turbidity within a range of 0.001
to 100 nephelometric turbidity units (NTU). The master indicator shall be housed
in a NEMA Type 4X moisture-resistant enclosure and shall be of the ac-powered
type.
The master indicator shall have a linear 4-20 mA dc output signal that
corresponds to a pre-selected turbidity range (typically 0 to 1 NTU).
The turbidity analyzer shall be Great Lakes Instruments model T53-8320 or Hach
Chemical Company 1720D.
2-2.02. Surface Scatter Turbiditv Analvzers. Analyzers shall operate with a
continuous sample flow of approximately 0.3 gpm [0.01 Us] through the analyzer
to drain. The analyzer shall utilize a light beam that is focused on the liquid
surface of the sample at an acute angle. The suspended particles in the sample
will scatter the light, and a photocell mounted above the liquid surface shall
detect the reflected light. The light and photocell sensor shall not come in
contact with the sample liquid. The analyzer shall have an auto-ranging four-digit
display that can indicate from 0.01 to 9999 NTU. The analyzer shall be housed
in a NEMA Type 4X enclosure and shall be suitable for operation in an ambient
temperature range of 0 to 40°C. The analyzer shall be of the ac powered type.
The analyzer shall have an essentially linear 4-20 mA dc output signal that
corresponds to a pre-selected turbidity range.
The turbidity analyzer shall be Hach Chemical Company "Surface Scatter 6.
When required, a bubble trap shall be provided on the sample inlet line to the
analyzer. The bubble trap shall be of corrosion-resistant PVC construction and
shall be specifically designed for use with the above analyzer.
2-2.03. pH Analyzers. The pH sensor and analyzerfiransmitter shall be
products of the same manufacturer. The cable between the sensor and the
transmitter shall be provided by the manufacturer. The sensor shall consist of a
kynar, PVC, polypropylene, or other chemical-resistant electrode housing
containing a glass pH electrode and a fouling-resistant double-junction gel filled
reference electrode. The pH reference electrode shall be self-contained and
(Carlsbad Water)
(Recycling Facility)
13564
-0-
shall not require an external electrolyte reservoir. The sensor shall have
automatic temperature compensation. The pH sensor shall have a flow-powered
cleaner which shall consist of a flow chamber and with four teflon balls.
2-2.03.01. Flow-Throuqh Sensors. Flow-through type sensors when required,
shall have 314 or 1 inch [I9 or 25 mm] NPT process connections and shall be
suitable for a working pressure of 1 to 100 psig [6.9 to 690 kPa gauge] at 140°F
[6O"C], with a sample flow rate of 0.5 gpm [0.03 Us]. Sensor housing hsall be
NEMA 4X. Flow-through sensors shall be Rosemount Model 381+.
Each pH sensor assembly shall be provided with a maintenance kit that shall
include a spare pH electrode, a spare reference electrode, and other spare parts
as recommended by the manufacturer.
2-2.03.02. Insertion1Submersion Sensors. The RO cleaning solution sensor shall
be combination electrode based with a triple junction gel filled reference cell and
integral preamplifier. The sensor preamplifier shall condition the signal at the
sensor and provide a transmission capability of up to a 1000 feet. The sensor
shall be have a full scale range of 0 - 14 pH and capable of accurate analysis on
process streams with conductivity above 75 pS1cm. The sensor shall be housed
in a rugged waterproof assembly and shall be suitable for submersionlinsertion
flow through installations. O-ring seals shall be Viton. The sensor shall be
Rosemount, Model 389.
2-2.03.03. Transmitter. The transmitter shall be enclosed in a cast aluminum or
fiberglass reinforced plastic NEMA Type 4 housing. The transmitter shall be
microprocessor based, with integral diagnostics, and with non-volatile memory.
The transmitter shall be suitable for ambient temperatures of -30 to +60"C and a
relative humidity of 0 to 100 percent. The transmitter shall have an isolated
4-20 mA dc output linearly proportional to the measured range, with an accuracy
of k Or2 percent of scale. The transmitter shall have a graphic dot matrix or
alphanumeric multiline LCD display that is menu driven. Transmitter range shall
be as indicated. The transmitter shall have automatic temperature compensation
over a range of 0 to 50°C. The transmitter shall be of the ac-powered type. The
transmitter shall be supplied with an appropriate length of signal cable for
connecting the transmitter to the sensor.
The pH analyzer1transmitter shall be Rosemount. model 54..
2-2.04. Dissolved Oxvqen Analvzers. Not Used.
2-2.05. Gas Detector Svstems. Not Used
2-2.06. Streaminq Current Analvzers. Not Used
2-2.07. SusDended Solids Analyzers. Not Used
(Carlsbad Water)
(Recycling Facility)
13564
-9-
2-2.08. Particle Counters. Not Used.
2-2.09. Chlorine Residual Analyzers. Analyzers shall be of the amperometric
type, with automatic sample temperature compensator, sample flow control, and
a self-cleaning electrode assembly for operation over a range of 0 to 5 ppm of
chlorine. Analyzers shall measure combined chlorine residual.
Each analyzer shall be furnished with the following accessories:
Integral indicator calibrated 0 to 5 ppm.
Wall mounting brackets.
One year's supply of chemical and consumables.
Drain and appropriate length of overflow hose.
Each analyzer shall transmit an isolated 4-20 mA dc signal proportional to the
measured chlorine residual. Analyzers shall be powered from 120 V ac.
Analyzers shall be housed in a weatherproof NEMA 4 housing, suitable for
operation with an ambient temperature range of 0 to 40 C.
When required, each analyzer shall be provided with a 24 hour, 7 day circular
charts meeting the requirements of Section 13561. A one year's supply of charts
and pens shall be provided for each recorder.
When required, one amperometric titrator shall be furnished for calibration of all
units. When required, one spare electrode shall be furnished.
Chlorine residual analyzers shall be Wallace & Tiernan "Micro12000, or equal
2-2.10. Dissolved Ozone Analvzers. Not Used
2-2.1 1. Low Concentration Ozone Analyzers. Not Used.
2-2.12. High Concentration Ozone Analyzers. Not Used.
2-2.13. Oxvqen Puritv Analyzers. Not Used
2-2.14. Dewpoint Analyzers. Not Used
2-2.15. Hydrocarbon Analyzers. Not Used
2-2.16. Nuclear Sludqe Densitv Meters. Not Used
2-2.17. Conductivity analyzer. Each unit shall consist of sensor,
transmitter/control unit, connecting cables and accessories. Each unit shall
(Carlsbad Water)
(Recycling Facility)
13564
-10-
provide 2 separate analog outputs; and shall incorporate a "hold output" mode to
permit on-line sensor maintenance. Sensor housing shall be NEMA 4.
2-2.17.01. Sensor Tvpe 1 - Hiqh Ranqe. The conductivity sensor shall be an
inductive (toroidal) type sensor with no electrodes exposed to the measured
process with a range up to 2,000,000 pS/cm. The conductivity sensor shall be
an insertionlsubmersion screw-in type. All mounting hardware shall be supplied
with the sensor and shall be constructed of Type 316 stainless steel.
The Type 1 sensor shall be a Rosemount, Model 228; or equal.
2-2.17.02. Sensor TvDe 2 - Low RanQe. The conductivity sensor shall be a
contacting type sensor with a range up to 5,000 pSlcm. The conductivity sensor
shall be an insertion/submersion screw-in type. All mounting hardware shall be
supplied with the sensor and shall be constructed of Type 316 stainless steel.
The electrode shall be Titanium-palladium. Process connector shall be Type 316
stainless steel. Seals shall be EPDM. The Type 2 sensor shall be a Rosemount,
Model 400; or equal.
2-2.17.03. Transmitter/Control Unit. Units shall be microprocessor - based and
accept the conductivity sensor input and an external temperature sensor input.
Each unit shall be housed in a NEMA 4X epoxy coated cast aluminum enclosure.
The analyzer display shall be graphic dot matrix and shall have membrane
keyboard. The transmitter shall display conductivity and process temperature.
The transmttter shall have two 4-20 mA outputs, one for conductivity and one for
temperature.
Accuracy shall be k0.5 percent of reading with a repeatability of f0.25 percent.
The units shall be Rosemount, Model 54C; or equal.
2-2.17.04. Accessories. Provide 500 mL each of stock standardizing solutions
for conductivities of 200 pS/cm; 2,000 pSlcm, and 20,000 pS/cm. Furnish
accessories required for panel mounting the transmitter/control unit. All external
supports and fasteners shall be Type 316 stainless steel.
2-2.18. Sample Pumps. Sample pumps shall be provided where required.
Sample pumps shall consist of a constant speed close-coupled electric motor
driving a stainless steel pumping unit. Appurtenences and accessories shall be
provided as required for proper operation and as recommended by the
associated analyzer manufacturer. Appurtenances shall include, but not be
limited to, pressure reducinglregulating valves, pressure relief or recirculation
valves, and electrical controls, Control shall be local-manual On-Off. Power
supply to the pump will be 120 volts, 60 Hz. single phase. The pump housing
and impeller shall be CPVC or stainless steel. The shaft shall be stainless steel.
Pump capacity and pressure rating shall be as required by the associated
analyzers.
PART 3 - EXECUTION
(Carlsbad Water)
(Recycling Facility)
13564
-1 1-
3-1, FIELD SERVICES. Manufacturer's field services shall be provided for
installation, field calibration, startup, and training as specified in Section 13560.
Instruments shall not be shipped to the Work Site until two weeks prior to the
scheduled installation. CONTRACTOR shall be responsible for coordinating the
installation schedule with the Installation Contractor. Each shipment shall
contain a listing of protective measures required to maintain sensor operation,
including a listing of any common construction or cleaning chemicals that may
affect instrument operation.
End of Section
(Carlsbad Water)
(Recycling Facility) 13564
-12-
Section 13565
MISCELLANEOUS INSTRUMENTS
Weld mounted
(Carlsbad Wafer)
(Recycling Facility) 13565
-1-
I ILimit Switches rewired. lr Yes Bee other 1
IG No
I IModulating Valve Positioners Ir Yes
!sections
I required.
required.
Current -to- Pressure Transducers
r Yes Valve Position Transmitters
r Yes
spec No required.
See other
G No
G No
Sections
(Carlsbad Water)
(Recycling Facility) 13565
-2-
Section 13565
MISCELLANEOUS INSTRUMENTS
PART 1 - GENERAL
1-1. SCOPE. This section covers the furnishing of all miscellaneous instruments
and accessories required for the Plant Control System as indicated on the
drawings and as required.
Equipment and services provided under this section shall be subject to the
General Instrumentation Requirements specified in Section 13500 and Section
13560. This section shall be used and referenced only in conjunction with
Section 13560. Supplementing Section 13560, instrument data, special
requirements, and options are indicated on the Instrument Device Schedule, as
required.
When multiple miscellaneous instrumenfs of a particular type are indicated on the
Data Sheet, and each requires different selectable features, the required features
are described in Instrument Device Schedule.
1-1.01. Terrninoloqy. When the phrase "as required" is stated in this
section it shall mean "as required in the attached Data Sheet".
1-2. DESIGN CRITERIA. Each device shall be a pre-assembled, packaged unit.
Upon delivery to the work site, each device or system shall be ready for
installation with only minor piping and electrical connections required by
CONTRACTOR.
Where possible, each instrument shall be factory calibrated to the calibration
ranges indicated in the Instrument Device Schedule. Transmitters or similar
measurement instruments shall be calibrated using National Institute of
Standards and Technology (NIST) approved bench calibration procedures, when
such procedures exist for the instrument type. For "smart" devices, calibration
data shall be stored digitally in each device, including the instrument tag
designation indicated on the Instrument Device Schedule.
1-3 SUBMITTALS. Submittals shall be made in accordance with the
requirements of Section 13500.
1-4 SHIPMENT, PROTECTION, AND STORAGE. Equipment provided under
this section shall be shipped, protected, and stored in accordance with the
(Carlsbad Water)
(Recycling Facility) 13565
-3-
requirements of Section 13500. Identification of packaging shall be as described
in Section 13500.
PART 2 - PRODUCTS
2-1. GENERAL. The following paragraphs provide minimum device
requirements. The Instrument Device Schedule shall be used to determine any
additional instrument options, requirements, or service conditions.
2-1.01. lnterconnectinq Cable. For systems where the primary element and
transmitter are physically separated, interconnecting cable from the element to
the transmitter shall be provided. The cable shall be the type approved by the
instrument manufacturer for the intended purpose of interfacing the element to
the transmitter. Length of cable shall be a minimum of three meters or as
indicated in the Instrument Device Schedule.
2-1.02. Proaramrninq Device. For systems which require a dedicated
programming device for calibration, maintenance, or troubleshooting, one such
programming device shall be provided. The programming device shall include
appropriate operation manuals and shall be included in the training requirements.
For systems that allow the programming device functions to be implemented in
software, running on a laptop computer, the software shall be provided instead of
the programming device.
2-1.03. Confiquration SoftwarelSerial Interface. Devices indicated as requiring a
serial interface shall be provided with all accessories required to properly
communicate over the serial link. As a minimum, an appropriate cable shall be
provided to allow the transmitter serial interface to be connected to a personal
computer. One licensed copy of the diagnosticlinterface software shall be
provided. Software shall be capable of running under Microsoft's Windows Me,
Windows 2000, Windows 98, and Windows NT 4.0 operating systems, If the
software furnished performs the same functions as the programming device,
specified elsewhere, then the programming device shall not be furnished.
2-2. MISCELLANEOUS INSTRUMENTS.
2-2.01. Resistance Temperature Detectors. Not Used
2-2.03. Temperature Switches. Temperature switches shall be ambient
compensated, filled type, with integral sensor and thermowell. Switches shall be
field adjustable type, with trip point repeatability better than 1 percent of actual
temperature. Switches shall be housed in EEMAC Type 4 enclosures. Switch
wetted parts shall be compatible with the process fluid. Where the process fluid
(Carlsbad Water)
(Recycling Facility)
13565
-4-
is not defined, the switch shall be provided with an AIS1 Type 316 stainless steel
sensing element and an AIS1 Type 316 stainless steel thermowell.
All temperature switches shall ranged in degrees Fahrenheit [Celsius]. Unless
otherwise indicated, switches shall have a fixed deadband and shall be auto-
reset type. As a minimum, switches shall be SPDT, rated 10 amp at 120 V ac.
Each switch shall be provided with a thermowell. Unless otherwise indicated in
the drawings or Instrument Device Schedule, thermowells shall be weld mount
style. Thermowell materials shall be compatible with the process fluid. Where
the process fluid is not defined, thermowells shall be AIS1 Type 316 stainless
steel.
Switches shall be installed at the locations indicated on the drawings, with
installation conforming to the installation standards. All switches shall be
installed in the vertical, upright position. Thread sealer, suitable for use with the
associated process, shall be used in the assembly of threaded connections. All
connections shall be free from leaks.
Each switch shall be provided with all required mounting hardware to securely
mount the unit according to the mounting requirements indicated in the Drawings
or Instrument Device Schedule.
Unless otherwise indicated, mounting and installation hardware shall be AIS1
Type 316L stainless steel.
Temperature switches shall be Ashcroft, or equal,
2-2.04. Temperature qauqes. Temperature gauges for general service shall be 4
inches in diameter with bottom or back connection for field or panel mounting, as
noted or shown.
2-2.04.01. Sensor: The sensor mechanism shall consist of a direct drive, n-type
bourdon coil. The unit shall offer overtemperature protection of 150% of
maximum rated temperature without shift. The bourdon tube sensor shall be
constructed of inconel x-750 with a type 316 stainless steel connecting capillary.
Provide a case mounted bimetal compensator for head and line as a unit.
Fittings shall be type 316 stainless steel. Bulb shall be sliding union type for use
with the specified thermowell. Accuracy shall be 1 percent of full scale.
2-2.04.02. m: The gauge face shall be white with black graduations in
engineering units of psig. The gauge case shall be constructed of aluminum
alloy. Gauges shown or specified as panel mounted shall be furnished with a
front flange to permit flush mounting the dial face. Fittings shall be 112-inch
mnpt, constructed of type 316 stainless steel. The gauge shall be factory
connected to the capillary.
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2-2.04.03. Accessories: Provide a type 316 stainless steel thermowell with a
5/8-inch to 1-inch mnpt fitting for coupling the sensor to the process line.
Provide a type 316 stainless steel flexible, liquid filled capillary with bulb.
Capillary length shall be as required to suit device locations-2 feet minimum; 33
feet maximum. Provide an alarm relay, spdt dry type rated 5a at 120 vac. Alarm
setpoint shall be adjustable over the full range of the gauge. Initial setpoint shall
be as noted.
2-2.04.04. Manufacturers. 3d instruments inc., Model 136x, or equal, with
specified accessories.
2-2.05. Field-Mounted Process Indicators. Field-mounted process indicators that
are not integral with the transmitter shall be of the two-wire type that accepts a
4-20 mA dc input and does not require a direct power source connection.
Indicators shall have corrosion-resistant, weatherproof housings and shall be
suitable for operating over an ambient temperature range of -10 to +55"C.
Indicators shall read in engineering units. A nameplate that describes the
indicator service function and the scale units shall be provided on the indicator.
When required, indicators shall be of the digital display type with an accuracy of
0.1 percent. The display shall be 3-112 digit LCD type, with a digit height of not
less than 0.5 inch [12.7 mm] and with a selectable decimal point. Indicators shall
be Action Instruments "Series V560". Ametek "Series 7000, or Precision-Digital
"Model PD686. "
2-2.06. Milliamp Calibrator. Not
2-2.07. Pressure Calibrator. Not Used.
2-2.08. Multi-function Instrument Calibrator. Not
2-2.09. Manometer. Not Used.
2-2.10. Proximitv (Door) Switches. Not Used
2-2.11. Vibration Switches. Not Used.
2-2.12. Instrument Shutoff Valves. Instrument shutoff valves shall be provided
for instruments as indicated on the drawings and as detailed in the specifications.
The indicated shutoff valves shall be provided by CONTRACTOR for all
instruments furnished under Sections 13560 thru 13565. Shutoff valves shall be
compatible with the measured process and shall be selected in accordance with
the manufacturer's recommendations for the specified process. Unused ports of
multi-port gauge valves shall be plugged. An instrument shutoff valve schedule
shall be submitted indicating the quantity, material, size, and associated
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instrument. Permanent tagging of the instrument valves is not required.
However, temporary hand-written tags or other means of identification shall be
provided to ensure that the appropriate valve is installed for a given instrument.
Instrument shutoff valves shall be D/A Manufacturing, Anderson-Greenwood, or
equal.
2-2.13. Limit Switches. Not Used.
2-2.14. Modulatinq Valve Positioners. Not Used.
2-2.15. Current-to-Pressure Transducers. Not Used,
2-2.16. Valve Position Transmitters. Not Used
PART 3 - EXECUTION
3-1. FIELD SERVICES. Manufacturer's field services shall be provided for
installation, field calibration, startup, and training as specified in Section 13560.
Instruments shall not be shipped to the Work Site until two weeks prior to the
scheduled installation. The CONTRACTOR shall be responsible for coordinating
the installation schedule with the Installation Contractor. Each shipment shall
contain a listing of protective measures required to maintain sensor operation,
including a listing of any common construction or cleaning chemicals that may
affect instrument operation.
End of Section
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Section 13570
PANELS, CONSOLES, AND APPURTENANCES
Data Sheet
r NO
Top removable access plate@)
required.
F yes
r Yes Required
Filter Consoles (PR 2-3)
Drawings r Yes Instrument Arrangement Shown on
r NO
r No
No I! Construction r steel
r Fiberglass
I IMounting Floor I
r Raised curb
/Height IC 54 inches [1.35 m]
r Other
IWhen "Othef is selected, indicate 1 I
lalternative console height
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RO CLEANING SYSTEM PANEL
Wall Mounted Cabinets required. c Yes
r NO
lhnstrument /RO FEED INSTRUMENT PANEL CP- "" ~
Subpanels (PR 2-5) 11601
RO TRAIN INSTRUMENT PANEL CP-
1602-1, -2
RO CLEANING PANEL
Instrument Subpanels Required F Yes
r No
Controt System Consoles and
Enclosures (PR 2-6)
Control System Console(s)
required. r Yes
Printer enclosures c Yes
6 No
r No
Number of printer enclosures
required
Printer stands r Yes
c No
Number of printer stands required
Provide additional wiring and
receptacles far: r CCN r security system r Intercom
r Radio
Provide mounting kits for: r CCTV r Security system
r Intercom r Radio
[CPU shelves Ir Fixed
r Slideout
\Exterior panels Oak eneer
r Metal
(Work surface nosing (r Solid oak
I Sot urethane
Console front r Oak eneer
r Plastic laminate
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1
40.
40.
I pask lighting I
r Retractable I
Control System Main Control Room Computer Desks
Furniture (PR 2-7)
Control system furniture required i= Yes
r NO
Task lighting required r Yes
r No
CPU mounting required i= Yes
r No
I /Printer stand required IC Yes I
r No
Cabinet required r Yes
r NO
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Section 13570
PANELS, CONSOLES, AND APPURTENANCES
PART 1 - GENERAL
1-1. SCOPE. This section covers furnishing free standing vertical panels for
instruments and controls and for PLCs, wall mounted cabinets, control system
consoles and enclosures for computer hardware and building monitoring
equipment, and printer stands as indicated on the drawings and as required.
1-1.01. Control Svstem. Section 13500 shall apply to all equipment furnished
under this section.
1-1.02. 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 and assembled in full conformity with the drawings, specifications,
engineering data, instructlons, and recommendations of the equipment
manufacturer. unless exceptions are noted by ENGINEER.
1-2.01. General Equipment Requirements. When required, the General
Equipment Requirements shall apply to all equipment provided under this
section.
1-2.02. Drawinas. General dimensions and arrangements are indicated on the
drawings. CONTRACTOR shall be responsible for coordinating the console and
enclosure sizes and arrangements to accommodate the equipment provided.
1-3. SUBMIlTALS. Submittals shall be as required in Section 13500
1-4. DELIVERY. STORAGE, AND SHIPPING. Delivery, storage and shipping
shall be as required in Section 13500.
1-5. SPARE PARTS. Spare parts shall be provided as required.
PART 2 - PRODUCTS.
2-1. PANEL DESIGN AND FABRICATION FEATURES. All panels furnished
shall conform to the requlrements of NEMA ICs-6-1993. Unless indicated
otherwise on the drawings, the following paragraphs describe general fabrication
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requirements for the PLC cabinets, instrument panels, consoles, enclosures, and
subpanels.
2-1.01. m. Pneumatic tubing shall be 114 inch [6 mm] OD, Type 316
stainless steel with compression fittings. Tubing and fittings shall be as specified
in the miscellaneous piping section.
2-1.01.01. FittinQs. Compression type bulkhead fittings shall be provided near
the bottom or the top of the panel for all field connections. Compression nuts
and sleeves shall be provided for the field connections. Indicators, recorders,
controllers, and other pneumatic devices shall be provided with plugged test
connections and shutoff valves for isolation.
2-1.01.02. m. All devices shall have separate air supply shutoff valves.
Valves and compression fittings shall be as manufactured by Nupro, Parker
Hannifin, Swagelock, Tylok, or Whitey.
2-1.02. Instrument Wirinq. All internal instrument and component device wiring
shall be as normally furnished by the manufacturer. Annunciator and indicating
light circuits shall be minimum 16 AWG. Electronic analog circuits shall be
16 AWG twisted and shielded pairs rated not less than 600 volts. Analog circuits
shall be separated from ac power circuits.
2-1.03. Power Entrance. The power entrance to each panel shall be provided
with a surge protection device. Surge protectors shall be nominal 120 volts ac
with a nominal clamping voltage of 200 volts. Surge protectors shall be of a
nonfaulting and noninterrupting design, with a response time of not more than
5 nanoseconds. Surge protectors shall be Innovative Technology "SP-l2OV,
Power Integrity Corporation "ZTAS", or Transtector "ACP 100 BW.
2-1.04. Power Wiring. Power distribution wiring on the line side of panel fuses
shall be minimum 12 AWG. Secondary power distribution wiring and wiring for
control circuits shall be minimum 14 AWG. Wiring for ac power distribution, dc
power distribution, and control circuits shall have different colors and shall agree
with the color-coding legend on CONTRACTOR'S panel wiring diagrams. With
the exception of electronic circuits, all interconnecting wiring and wiring to
terminals for external connection shall be stranded copper, insulated for not less
than 600 volts, with a moisture resistant and flame retardant covering rated for
not less than 90°C.
2-1.05. Terminal Blocks. Terminal blocks for external connections shall be
suitable for 12 AWG wire and shall be rated 30 amperes at not less than
600 volts. Terminal blocks shall be fabricated complete with marking strip,
covers, and pressure connectors. Terminals shall be labeled to agree with
identification shown on the supplier's submittal drawings. A terminal shall be
provided for each conductor of external circuits, plus one ground for each
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shielded cable. Not less than 8 inches of clearance shall be provided between
the terminal strips and the base of vertical panels for conduit and wiring space.
Not less than 25 percent spare terminals shall be provided. Each control loop or
system shall be individually fused, and all fuses or circuit breakers shall be
clearly labeled and located for easy maintenance.
2-1.06. Device Taq Numberina System. All devices shall be provided with
permanent identification tags. The tag numbers shall agree with the instrument
device schedules and with the supplier's equipment drawings. All field-mounted
transmitters and devices shall have stamped stainless steel identification tags.
Panel, subpanel, and rack-mounted devices shall have laminated phenolic
identification tags securely fastened to the device. Hand-lettered labels or tape
labels will not be permitted.
2-1.07. Nameplates. Nameplates shall be provided on the face of the panel or
on the individual device as required. Panel nameplates shall have approximate
dimensions and legends, as indicated on the drawings, and shall be made of
laminated phenolic material having engraved letters approximately 3/16 inch
[5 mm] high extending through the black face into the white layer. Nameplates
shall be secured firmly to the panel. Panel face nameplates do not replace the
requirement for device identification tags as specified under the Device Tag
Numbering System paragraph.
2-1.08. Painting. Interior and exterior surfaces of all panels shall be thoroughly
cleaned and painted with rust inhibitive (universal) primer. The panel interior
shall be painted white with the manufacturer's standard coating. All pits and
blemishes in the exterior surface shall be filled. Exterior surfaces shall be
painted with one or more finish coats of the manufacturer's standard coating.
Finish coats shall have a dry film thickness of at least 4 mils [IO0 mm]. Color
samples shall be submitted to ENGINEER for color selection. One quart [I liter]
of paint shall be furnished with the panels for future touchup painting.
2-1.09. Factory Test. Panels shall be factory tested electrically and
pneumatically by the panel fabricator before shipment.
2-2. FREESTANDING VERTICAL PANELS. The following paragraphs describe
specific requirements for the freestanding vertical panels:
2-2.01. Construction. Panel construction shall be an indoor, dusttight,
completely enclosed cubicle formed from steel structural members and steel
plates. The base shall be formed of steel channels, with flanges extending
upwards. The base shall be provided with 112 inch [12.5 mm] diameter holes at
12 inch 1300 mm] centers so that the base can be bolted to the concrete
equipment base. Welds, seams, and edges on all exposed surfaces shall be
ground smooth. Suitable lifting facilities shall be provided for handling and '
shipment.
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2-2.02. Structure. Panel structure shall be suitably braced and of sufficient
strength to support all equipment mounted on or within, to withstand handling
and shipment, to remain in proper alignment. and to be rigid and freestanding.
Top, sides, and back shall be fabricated from USS 10 gage (3.42 mm thick] or
heavier carbon steel sheets, with stationary back suitable for back to wall
installation, or designed for rear access with hinged back doors as required.
Doors shall not be greater than 28 inches wide and spaced not greater than
30 inches center to center as required.
2-2.03. Panel Front. When required, the front shall be a hinged door, or doors,
with mounted instruments and control devices, fabricated from USS 10 gage
[3.42 mm thick] carbon steel sheet and suitably braced and supported to
maintain alignment. Panels with hinged fronts shall be of sufficient width to
permit door opening without interference with rear projection of flush mounted
instruments.
2-2.04. m. Doors shall be essentially full height, having turned back edges
and additional bracing to ensure rigidity and prevent sagging. Doors shall be
mounted with strong, continuous, piano type hinges. Positive latches, acting
from a common door handle, shall hold doors securely compressed at top, side,
and bottom against rubber gaskets.
2-2.05. Mounted Instruments. When required, the front shall be stationary, with
mounted instruments and control devices, fabricated from 3/16 inch [5 mm]
carbon steel plate. Panel fronts shall be suitably reinforced between mounting
cutouts and drilling to support instruments and devices without deformation and
shall be free from waves and other imperfections. When required, panel fronts
shall be recessed at the base. Adjoining panel sections shall be accurately shop
fitted to assure satisfactory assembly in the field.
2-2.05.01. Instrument Arranqement. Not used.
2-2.06. Conduit Entrance. When required, the bottom shall be open, and
components shall be arranged for external wiring conduit and piping to enter from
below. When required, the top shall be provided with nominal 1 square foot
IO.09 m3] removable access plates, which may be drilled to accommodate
external wiring and conduit to be installed from above.
2-2.07. Size and Arranaement. Panel dimensions shall be as indicated on the
drawings. The panel front shall have louvered ventilation as required to keep
panel interior components at or below their design operating temperature.
2-2.08. Interior Liqhtinq. Illumination of panel interiors shall be provided by
ceiling mounted lamp fixtures spaced at approximately 2'-6 [760 mm] and near
the door. Fixtures shall be 100 watt, incandescent or fluorescent tube type, with
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a common "OnOff" switch near each end door. Duplex-grounded receptacles
shall be provided for service and maintenance tools at spacing not greater than
5 feet [I 52 m] throughout the length of a panel. The lighting and receptacle
circuit shall be fused separately from the instrumentation systems.
2-3. FILTER CONSOLES. Not used.
24. WALL-MOUNTED CABINETS. Cabinets, which contain the system
components indicated on the drawings, shall be NEMA Type 4, enclosures as
required, suitable for wall mounting. The enclosures shall be fabricated from
USS 14 gage I1.9 mm thick], or heavier, stainless steel. Cabinets shall be
equipped with full size gasketed doors with hinges and a chromium-plated or
stainless steel three-point latch. A screened vent shall be provided in the bottom
of enclosures that contain pneumatic devices.
All wall-mounted cabinets shall meet the requirements of the panel fabrication
paragraph of this section.
The RO Cleaning System Panel enclosure shall be mounted onto the RO
Cleaning System Subpanel.
Outdoor cabinets shall be provided with sunshades as indicated on the drawings
and as required.
2-5. INSTRUMENT SUBPANELS. Frame-mounted instrument subpanels and
enclosures shall be provided where indicated on the drawings and as required.
Instruments and control devices shall be mounted on the subpanel as indicated
on the P&ID drawings. Devices shall be mounted between 3 to 5 feet above the
operating floor.
2-5.01. Pipe Framework. Fabricate from 2-inch Schedule 40 Type 316L stainless
steel pipe, butt weld caps and flanges in a welded configuration that is anchored
to the support pad. The assembly shall be welded and electropolished. All
fasteners shall be Type 316 stainless steel. All component and piping device
supports shall be fabricated from Type 316 stainless steel plate. The use of
unistrut-type support members is not allowed.
2-5.02. Flat Panel. The flat panel mounting surface of the instrument subpanel
shall be constructed of 6061-T6 aluminum flat sheet, minimum Il8-inch thick.
Provide cutouts for devices, including rotameters, pressure gauges, valve
operators and other like devices. Polyester powder coat white after fabrication.
2-6. CONTROL SYSTEM CONSOLES AND ENCLOSURES. Not used.
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desk, a control system desk, printer enclosure(s). a printer stand(s) shall be
provided as indicated on the drawings
2-7.01. Control System Desk. The control system desk shall be a freestanding
desk-based system consisting of linked work surfaces on pedestals in the
general arrangement indicated on the drawings. CONTRACTOR shall
coordinate the types and quantities of console components required, and shall
furnish and install all additional components, including supports and connecting
brackets.
2-7.02. Work Surfaces. Work surfaces shall of be high-pressure plastic laminate
over a high-density wood composite and shall be 1-1/4 inches [32 mm] thick,
30 to 36 inches [762 mm] wide, and of the length required. Special corner work
surfaces shall be provided where required. Back panels at least 19 inches
1483 mm] high shall be provided for all work surfaces. Work surface dimensions
shall be coordinated with the pedestals to ensure proper stability and access to
wireways. Where indicated on the drawings, work surfaces shall be provided
with hinged corner access channels for wire and cables.
2-7.03. Pedestals. Pedestals shall be provided as indicated on the drawings or
as required to support the work surface arrangement. Pedestals shall be of
painted steel, with integral, double-walled desk drawers.
2-7.04. Internal Wirinq. The console shall be provided with a concealed wireway
system, mounted near the back edge of the work surface and accessible from
the console back without the use of special tools. An integral power raceway
system shall be provided to distribute power to the control system components.
Power will be received from receptacles located in the walls behind the computer
furniture. The power system shall consist of sufficient receptacles and wiring to
accommodate the control system components and task lighting.
2-7.05. Task Liqhting. Task lighting for work surfaces shall be installed along
the back panels. Lighting shall consist of continuous track lighting or articulating
lamps mounted on brackets.
2-7.06. CPU Mounting. When required mounting kits shali be provided for
installing CPUs under the work surfaces. The numbers and locations of the
CPUs are indicated on the drawings.
2-7.07. Color Samples. CONTRACTOR shall submit color samples for all work
surfaces, back panels, and pedestals to the Engineer for color selection.
2-7.08. Manufacturers. The console shall be Allsteel "Syntrax 11" or equal
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2-7.09. Printer Stands. The printer stand shall be of open shelf design, with
lockable doors, sized to support the report, alarm, or color printer furnished, and
with shelved storage space under the mounting surface. The control console
manufacturer shall provide the prmter stand.
2-7.10. Cabinet. The cabinet shall be constructed of materials to match the
control system console exterior panels. Printer mounting surface shall be of
approximately the same height as the work surface of the control console.
PART 3 - EXECUTION
3-1, GENERAL INSTALLATION REQUIREMENTS. Installation requirements
are specified in Section 13500. In addition, equipment furnished under this
section shall conform to the following manufacturing requirements.
3-1.01. m. All tubing shall be run in horizontal and vertical planes and shall
be rigidly supported to withstand handling and shipment. Flexible polyethylene
tubing shall be used to connect devices mounted on hinged doors.
3-1.02. m. All wiring shall be grouped or cabled and firmly supported inside
the panel. Wiring shall be bundled in groups and bound by nylon cable ties or
shall be routed in Panduit or similar nonmetallic slotted ducts. Ducts shall be
readily accessible within the panel with removable covers and shall have a space
of at least 40 percent of the depth of the duct available for future use after
installation is complete and all field wiring installed. Sufficient space shall be
provided between cable groups or ducts and terminal blocks for easy installation
or removal of cables.
3-1.03. More Than One Panel. Where signal or loop wiring must be routed to
more than one panel or device, the required circuit routing shall be as indicated
on the one-line diagrams. The panel fabricator shall provide such additional
circuits as may be indicated on the electrical schematic drawings.
End of Section
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Section 13580
UNINTERRUPTIBLE POWER SUPPLY
Data Sheet
Other NEMA Type
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-1 -
24. @ Yes Static transfer switch required
r NO
r NO
2-5. Maintenance bypass switch @ Yes required
p Integral
i7 External
23 r Yes Output receptacle panel
@ No
i7 Connect to distribution panel
2-7.02. C Yes LED indicators for bypass ready,
bypass mode and on line mode. No
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Section 13580
UNINTERRUPTIBLE POWER SUPPLY
PART 1 - GENERAL
1-1, SCOPE. This section covers the furnishing of a complete on-line
uninterruptible power supply (UPS) for The Computer Control System as
indicated on the drawings and as required.
The system shall convert incoming single phase, 60 Hz, power into dc power,
maintain and charge backup batteries and reconvert outgoing power into a
sinusoidal single phase, 60 Hz, ac power source. The system shall consist of a
rectifier, battery charger, batteries, inverter, integral static bypass switch, and
maintenance bypass switch as required.
Additional accessories and appurtenances shall be provided as specified herein
and as required to provide a complete and properly operating system.
1-1.01. Control Svstem. Section 13500 shall apply to all equipment furnished
under this section.
1-1.02. Control Svstem Loads. The UPS shall supply Control System and other
loads located in or external to the control room as shown on the drawings or as
listed herein.
Control Room Loads:
File ServerlHistorian Computer
MF System Operator Workstation Computer
SCADA Server No. 1 Workstation Computer
SCADA Server No. 2 Workstation Computer
Ethernet Switch, Routers and other communications hardware
1-1.03. Terminoloqy. 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 under this section shall be fabricated and
assembled in full conformity with the drawings, specifications, engineering data,
instructions, and recommendations of the equipment manufacturer, unless
exceptions are noted by ENGINEER.
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1-2.02. General EauiDment Requirements. When required, the General
Equipment Requirements shall apply to all equipment provided under this
section.
1-2.03. Drawinqs. Supplementing this section, the drawings indicate locations
and arrangement of enclosures and provide one-line diagrams regarding the
connection and interaction with other equipment.
1-2.04. Nameplates. Each UPS shall be identified with a suitable engraved
nameplate mounted on the top front and when required, a nameplate shall also
be provided for each of the external manual bypass switches. The nameplates
shall be made of laminated black and white plastic. The lettering shall be bold,
not less than 1/4 inch [6 mm] square, engraved by cutting through the black
outside layer so that the letters appear white.
1-3. SUBMITTALS. In addition to the requirements of Section 13500, all
material and equipment documentation shall be submitted for review in
accordance with the submittals section. Each sheet of descriptive literature
submitted shall be clearly marked to identify the material or equipment as follows:
a. Equipment and materials descriptive literature and drawings shall
show the specification paragraph for which equipment applies.
b. Sheets or drawings showing items not applicable to this system,
or not requiring review, shall contain clear indication as to which
section or sections require review.
c. Functional line diagrams showing all major system components
and external connection diagrams for all electrical equipment shall
be submitted for review. A manufacturer's standard connection
diagram or schematic showing more than one scheme of
connection will not be accepted, unless it is clearly marked to
show the intended connections.
d. A report certifying that the UPS will provide the required backup
time at the specified UPS loading and UPS ambient temperature
The report shall include anticipated continuous electrical load
calculations, backup time calculations and shall indicate the
battery end-voltage used in the analysis.
1-4. DELIVERY, STORAGE, AND SHIPPING. Delivery, storage and shipping
shall be as required in Section 13500.
1-5. SPARE PARTS. Spare parts shall be provided as required
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PART 2 - PRODUCTS
2-1. GENERAL. All equipment, enclosures, and accessories shall be designed,
assembled and connected in accordance with the requirements of these
specifications and the drawings.
2-1.01. System Desiqn Requirements. The UPS system shall conform to the
following standards and features and other features as required.
Capacity 3Kw
Capacity, peak (minimum) 150 percent of continuous power
rating for 10 seconds.
Frequency stability, battery mode - + 0.5 percent.
Harmonic distortion (max) 5 percent.
Efficiency, overall on-line 75 percent minimum,
Operating temperature-humidity 0 to 40°C; 0 to 95 percent relative
humidity, non-condensing.
Recharge time (max) 4 hours,
Input Voltage at 60Hz +10 - 15 percent 120
Output Voltage at 60Hz AC 120
2-1.02. Acceptable Manufacturers. All systems supplied under this contract
shall be of the same manufacturer. The uninterruptible power supply systems
shall be MGE EXL series, Powerware 9170 series, Best Power, or equal.
2-1.03. Terminal Blocks. Wiring for external circuits, including all alarm contacts,
shall be brought to grouped terminal blocks located for convenient connection.
Provisions shall include suitable marked terminal blocks for connection of No.
12 AWG control wiring and for inpuffoutput power conductors as sized on the
drawings. Terminal designations shall agree with manufacturer’s wiring diagram.
2-2. BAlTERY CHARGERlRECTlFlER AND BATTERIES. The battery charger
and the rectifier shall have the following characteristics:
a. The rectifier shall convert the incoming ac power to dc power to
energize the static inverter.
b. The battery charger shall supply a float current to the batteries to
maintain them at a fully charged state while incoming power is
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being provided. The charging voltage shall be temperature-
compensated over the entlre operating temperature range to avoid
overcharging or undercharging the batteries. The battery charger
shall automatically apply an elevated voltage (equalization charge)
to the batteries if and as required by the battery manufacturer.
c. The batteries shall provide backup power for the UPS when
incoming commercial power is not available. The batteries shall be
valve-regulated or gelled-electrolyte lead-acid type. The batteries
shall be integral to the UPS. Batteries shall have capacity to supply
the dc power to the UPS while operating at full load for a period of
not less than as required at 25°C. The batteries shall have an
expected life of 5 years and shall carry a one-year warranty.
2-3. STATIC INVERTER. The solid-state inverter shall employ silicon-controlled
rectifiers (SCRs) and other devices for converting direct current power to
essentially sinusoidal alternating current power. The static inverter shall conform
to the following characteristics and requirements.
a
b.
C.
Automatic Synchronization: During normal operation, the inverter
shall provide power to critical loads. The utility electric system will
act as an alternate supply. Inverter equipment shall include stable
solid-state devices designed to automatically maintain inverter
output in phase with the utility electric system.
Overload, Short Circuit, and Load Loss: The inverter shall have
input and output fuses and other equipment necessary to protect
from overload. short circuit, and 100 percent loss of load. Current
limiting features shall also be provided.
Loss of Supply Voltages: The inverter shall include protective
devices to prevent damage resulting from excursion, loss, or
restoration of its synchronization voltage and its dc input voltage
and any inrush current occurrences associated with such
conditions.
2-4. STATIC TRANSFER SWITCH. When required, the static transfer switch
shall use SCRs and other static devices required to automatically transfer loads
from the off-line (bypass) to the on-line operating condition and back again. In
off-line mode, the static transfer switch shall connect clean filtered power to the
load. The primary ac line shall be monitored and the load shall be transferred to
the inverter if the voltage drops below 85 percent. During on-line mode
operation, any inverter problem shall cause an instantaneous transfer to the
bypass mode.
(Carlsbad Water)
(Recycling Facility)
13580
-6-
2-5. MAINTENANCE BYPASS SWITCH. When required, a maintenance
bypass switch shall be provided so maintenance can be performed on the UPS
without disrupting control system operation. The bypass switch shall be
independent of the UPS electronics.
2-6. OUTPUT RECEPTACLE PANEL. Not Used
2-7. CONTROL, INDICATION AND ALARM. Controls, indicators and alarms
shall be provided as a part of the UPS. Control buttons and LED indicators shall
be provided on the UPS panel and shall be permanently labeled.
2-7.01. Controls. A dc battery circuit breaker, a mode selector switch, and
system "ON" and "OFF" buttons shall be provided.
2-7.02. Indication. A digital display for selection and indication of input, output,
and battery voltages shall be provided.
LED indicators for inverter ready, frequency, battery voltage, overload, over
temperature, and impending shutdown conditions shall be provided.
When required, LED indicators for bypass ready, bypass mode, and on-line
mode shall be provided.
2-7.03. Remote Alarms. The UPS shall have the following provisions for remote
alarms, for possible future use.
2-7.03.01. General Alarm. An audible alarm shall be provided on the unit. A
common, isolated, dry, alarm contact rated 3 amperes at 120 volts ac shall be
provided with the UPS for indication of general alarm. The contact shall close
under any UPS fault condition.
2-7.03.02. Power Failure. An isolated, dry, alarm contact rated 3 amperes at
120 volts ac shall be provided with the UPS for remote indication of power failure.
The contact shall open upon loss of commercial power to the UPS,
PART 3 - EXECUTION
3-1. INSTALLATION REQUIREMENTS. Installation requirements are specified
in Section 13500C.
3-2. OWNER TRAINING. CONTRACTOR shall provide a qualified
representative at the jobsite to train OWNER'S personnel in operating,
maintaining, and repairing the equipment. The training shall consist of one full
4 hour session and the schedule shall be arranged and coordinated with
OWNER.
(Carlsbad Water)
(Recyclmg Facility) 13580 -7 -
(Carlsbad Water)
(Recycling Facility)
End of Section
13580
-8-
Division 15
Mechanical
SECTION 15051
PIPING, GENERAL REQUIREMENTS
PART 1 -GENERAL
1.01
A.
B.
1.02
1.03
A.
DESCRIPTION
Description of Work
1. The Contractor shall fabricate, install, test, clean and place into
Service piping systems where shown and where specified.
Reference Specifications
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
See Division 1 specifications for general requirements.
Painting is specified in Section 09940.
Steel piping is specified in Section 15062.
Stainless steel piping is specified in Section 15062-1.
PVC piping is specified in Section 15065.
Double wall chemical piping systems are specified in Section
15066.
Miscellaneous plastic piping systems are specified in Section
15067.
Alloy 20 piping is specified in Section 15067-1.
Valves and appurtenances are specified in Section 15100.
Pipe hangers and supports are specified in Section 15140
QUALITY CONTROL I QUALITY ASSURANCE (QNQC) - NOT USED
SUBMITTALS
Shop Drawings: Submittals shall be made in accordance with these
Specifications. Not all submittals are required for every piping system.
See the individual piping specification sections for identification of
required submittals.
(Carlsbad Water)
(Recycling Facility)
15051
-1 -
1. Prepare a piping schedule organized by the line service
designations shown on the Drawings (e.g., ROP). Include the
following items as a minimum:
a.
b.
C.
d.
e.
Pipe and fitting material specifications, including compliance
with specified standards, diameter, pressure rating andlor
schedule.
List of proposed joint type(s)lmethod(s).
Summary information on all bolts, gaskets, solvent cements,
primers, and thread sealants.
Summary identification of special fittings and accessories
cross-referenced to manufacturer's catalog information.
Summary identification of exterior and interior lining systems
cross-referenced to manufacturer's catalog information.
2. Provide detailed pipe layout drawings.
a. Provide double-line scaled drawings showing all fittings,
valves, in-line devices, chemical injectors, and supports.
b. Identify each support and cross-reference to applicable
mechanical details or manufacturer's catalog number.
c. Identify all in-line equipment and valves by project equipment
number.
3. Identify by unique number and detail all proposed external
equipment and pipe supports located outside pipe trenches.
4. Provide detailed shop and assembly drawings, catalog information
and other details for the metal framing support system and
appurtenances used in pipe trenches.
5. Provide catalog sheets for all piping accessories, including
expansion joints, gaskets, fasteners, couplings, service saddles,
solvents, lubricants, internal and external coating systems.
B. Test Reports
1. Provide for field inspection of shop fabricated pipe assemblies
where noted in the detailed pipe specification sections.
(Carlsbad Water)
(Recycling Facility)
15051
-2 -
2. Submit signed copies of all pipe test records (minimum three).
Include one copy in the startup file for the respective piping sub-
system. Test records shall include the following:
a. Test date.
b. Identification of pipeline tested by material and service.
c. Test fluid
d. Test pressure.
e. Test duration.
f. Signatures of the Owner’s Representative and Contractor.
C. Installation Instructions
1, Complete operation and maintenance instruction, lubrication
schedules and troubleshooting guides shall be submitted for review
in accordance with the procedures and requirements set forth in
these Specifications.
D. Certificates, Warranties and Guarantees
1. Submit certificates of compliance with applicable referenced
standards.
2. Submit qualification records for personnel performing work where
required.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. General
1. Pipe material and size designations are indicated on the Pipe
Schedule included herein.
2. Specific requirements for piping, fittings, and appurtenances are
specified in the individual piping system sections.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Identification
(Carlsbad Water)
(Recycling Facility)
15051
-3-
1. Provide identification devices for all piping using color bands,
lettering, flow direction arrows, and related permanent identification
devices and accessories in compliance with ANSVASME A13.1 -
Scheme for the Identification of Piping Systems.
2. Provide one label for every 10 lineal feet of exposed run andlor
within 2 feet of all changes in direction.
3. For PVC and FRP piping 2-inches in diameter and over, color
bands and lettering shall be painted directly on the pipe, with a
series of flow arrows to indicate the direction of process flow.
4. For un-pigmented thermoplastic and stainless steel piping systems,
and all piping less than 2-inches in diameter, provide snap-around
or strap-on labels.
a. Labels shall attach to the pipe without the use of stainless
steel or plastic straps.
b. Labels shall be plastic or vinyl, embossed with the process
stream identification and a series of flow direction arrows.
c. Label color shall be selected so as to match existing plant
identification devices.
d. Labels shall be WSS Snap-Around as manufactured by T&B
Westline; Setmark Series as manufactured by Seton Name
Plate Corporation; or equal.
B. Painting
1. Paint all exposed piping systems. This includes those portions of
piping inside the membrane process areas including those runs
located within piping trenches, where specified in the individual
piping sections.
2. See Section 09940, Protective Coatings.
2.03 EQUIPMENT AND COMPONENTS
A. General
1. Piping accessories are specified by system, or in these
Specifications.
B. Test Equipment
(Carlsbad Water)
(Recycling Facility) 15051
-4-
1, The Contractor shall provide all required components necessary to
conduct hydrostatic pressure tests of all pipelines, including pump,
suction strainer, suction and discharge valves, safety relief valve
and pressure gauges.
2. The relief valve shall have a set pressure 20 to 25 percent above
the intended test pressure and shall be calibrated before use.
3. Pressure gauges shall have a maximum span not less than 50
percent over the intended test pressure and shall be calibrated
before use.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Delivery
1, Special care shall be given to the shipping, unloading, storage and
installation of fabricated pipe assemblies.
2. Flanges, threads, and open connections shall be closely covered
with rigid plastic caps or other material firmly secured to each
component. Covers shall not be removed prior to installation.
Following installation, open connections shall be re-covered.
B. Preparation for Installation
1. Keep pipe clean and free of foreign material during storage and
installation.
2. Move pipe spools by hand or with slings. Do not store or drop pipe
directly on concrete or ground.
3. Cut plastic piping (PVC, PP, and PVDF) in accordance with the
manufacturer's printed instructions. Field cutting of other pipe
systems is not permitted.
4. Gasketed Joints:
a. Take care that the gaskets and flange faces are free of all
foreign matter.
b. Seat gaskets carefully and tighten bolts sequentially with a
torque limiting wrench to assure uniform gasket compression.
c. If a gasketed joint fails a pressure test, the gasket shall be
discarded and replaced with a new gasket.
(Carlsbad Water)
(Recycling Facility)
15051
-5-
5. Threaded Joints:
a. Clean male and female threads of metallic piping with cutting
oil and solvent.
b. Lubricate male pipe threads as required in the applicable pipe
specification.
c. Tighten threaded plastic joints only with a strap wrench to
prevent over-tightening.
C. Pipe Installation
1. Alignment
a.
b.
C.
d.
e.
Pipe shall be installed level, plumb and parallel or
perpendicular to the major axes of the equipment, unless
otherwise shown.
Vertical pipe headers on the RO train shall be aligned such
that top caps are at a uniform elevation and the complete
assembly looks correct to the naked eye.
Rotate fittings to prevent misalignment and stresses in pipe
and connections to equipment.
Bolts in flanges shall be located symmetrically about the
vertical axis of the adjacent pipe.
Where possible, locate pipe of similar diameters parallel and
adjacent to one another.
2. supports
a. Install pipe supports designed to transmit seismic loads to the
support member or structure.
b. Install pipe supports designed to permit thermal expansion
and disconnection from connected equipment.
c. Where possible, support multiple parallel pipes on common
supports.
3. Connections
a. Connect pipe to equipment with connections designed to allow
minor movement.
(Carlsbad Water)
(Recycling Facility)
15051
-6-
b. Field locate union fittings as required for component
installation and removal.
c. Field taps to PVC piping will be allowed for 1/4-inch taps to
pipes 4-inches in diameter and larger. The taps must be in
the sleeve portion of the fitting where the thickness includes
both pipe and fitting. Field taps to other piping systems are
forbidden.
3.02 COMMISSIONING
A. Pressure Testing
1.
2.
3.
4.
5.
6.
7.
8.
The test fluid for all testing of process piping shall be water unless
otherwise approved by the Owner's Representative.
The applied test pressure shall be 1-1/2 times the design operating
pressure unless otherwise specified in the detailed piping section.
Temporary external vents and drains shall be provided where
permanent facilities do not exist.
Take precautions to suitably protect all equipment or devices that
should not be subjected to the test pressure.
Coordinate the time of testing with the Owner's Representative and
provide sufficient notification.
Fill the lines to be tested slowly and bring the pressure up to the
test condition gradually.
Maintain the test pressure for a minimum time of four hours.
Examine all exposed joints and fittings for visible leakage.
Lines exhibiting leakage shall be repaired and retested.
B. Final Cleaning
1. Following installation and pressure testing, sequentially isolate all
piping and flush it with water at a scouring velocity of at least 2.5
feet per second.
2. Sequentially disconnect piping from equipment and isolate sections
with blind plates or paddles.
C. Disinfection: Disinfect all potable and service water piping in accordance
with local requirements.
(Carlsbad Water)
(Recycling Facility)
15051
-7-
D. Drying
1. Drain and dry all lines following testing and disinfection.
2. Drain sulfuric acid lines completely using compressed nitrogen
Drain other lines with compressed air, or allow to air dry.
++ END OF SECTION ++
(Carlsbad Water)
(Recycling Facility)
15051
-0-
Section 15061
DUCTILE IRON PIPE
Data Sheet
Yes, see next row of data sheet
eet" is selected, indicate option
Restrained push-on joints
Mechanical joints
Restrained mechanical joints
Threaded connections
Mechanical couplings
Groowd couplings
Locking wedge type
lnits
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061
-1 -
-2 - (i Yes When "Mechanical joints" are
selected, indicate if any tie rods are
Joints" are selected, indicate the
required. No
r Field cut spigot type required.
-2 - Factory prepared spigot When "Restrained Mechanical
hen "Grooved couplings" are R Rigid
elected, indicate type of joints. r Flexible (shouldered)
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061
-2-
ha Yes Wall castings required.
22 r No
3-16 R Yes, eccentric Reducers required.
F Yes, concentric r N~
3-17 Connections to existing piping t- Yes required. No
3-18 C Yes Concrete encasement required.
No
3-20 C Yes Reaction anchorage and blocking
required. No
3-21 Pressure and leakage testing Yes required. r NO
bchedule
bee Schedule 15061-Sol. Ir Yes
3-23 No
(Carlsbad Water)
(Recycling Facility)
(1-25-02)
15061
-3-
Section 15061
DUCTILE IRON PIPE
PART 1 -GENERAL
1-1. SCOPE. This section covers the furnishing and installing of ductile iron
pipe. Ductile iron pipe shall be furnished complete with all fittings, jointing
materials, pipe hangers and supports, anchors, blocking, encasement, and other
appurtenances. Piping shall be furnished by CONTRACTOR or OWNER, as
indicated in the Project Requirements section.
Piping furnished hereunder shall be complete with all joint gaskets, bolts, and
nuts required for installation of any valves and equipment furnished by others for
installation under this contract.
Pipe hangers and supports, pressure and leakage testing, cleaning, disinfection,
and cathodic protection are covered in other sections. Cast iron soil pipe is
covered in the miscellaneous piping section. Pipe trenching, bedding, and
backfill are covered in the trenching and backtilling section.
Other materials as required will be permitted as an alternative to ductile iron pipe.
1-1.02. Pipe Manufacturer's Experience and Field Services. All ductile iron pipe,
fittings, and specials shall be fabricated, lined, and coated by the pipe
manufacturer. Minimum required experience qualifications shall include
manufacture of a pipeline at least 1 mile in length, of equal or larger diameter
than the pipe to be provided, with joints, lining, and coating suitable for the same
or greater pressure rating, which has performed satisfactorily for the past
5 years.
An experienced, competent, and authorized field service representative shall be
provided by the pipe manufacturer to perform all pipe manufacturer's field
services specified herein. The field service representative's minimum required
experience qualifications shall include 5 years of practical knowledge and
experience installing ductile iron pipe with joints, lining, and coating of the pipe to
be provided. The pipe manufacturer's field service representative shall be
acceptable to OWNER. A resume of the proposed pipe manufacturer's field
service representative shall be submitted for review. The resume shall include
the field service representative's experience record which meets the specified
minimum required experience qualifications.
(Carlsbad Water)
(Recycling Facility)
(1-25-02)
15061
4-
All ductile iron pipe shall be installed in accordance with the pipe manufacturer’s
recommendations.
1-1.03. Emeraencv Repair Manual. CONTRACTOR shall submit an emergency
repair manual prepared and furnished by the pipe manufacturer. The emergency
repair manual shall include procedures for handling emergency calls and repairs;
a list of stock replacement pipe sections, closures, and other parts needed for
emergency repairs; names and emergency telephone numbers of pipe
manufacturer’s engineering staff and factory-trained field service representatives
who can be contacted day or night during an emergency; response and delivery
times; and installation instructions for the materials and methods used in making
repairs. The pipe manufacturer shall provide emergency assistance that may be
required at no additional cost to OWNER.
1-2. SUBMITTALS. Drawings, details, specifications, and installation schedules
covering all ductile iron pipe and accessories shall be submitted in accordance
with the procedure set forth in the submittals section. The drawings and data
shall include, but shall not be limited to, the following:
Certification by manufacturer for each item furnished in accordance with the
ANSVAWA Standards.
Certification of gaskets.
Certification of proof-of-design tests for joints.
Certification of proof-of-design tests for welded-on outlets.
Laying schedule complete with an explanation of all abbreviations used in
the schedule.
Two samples of the polyethylene encasement, each sample clearly
indicating all identification required by the Governing Standard.
Submittal data shall clearly indicate the country of origin of pipe, fittings,
restraining devices, and accessories. Certified copies of physical and chemical
test results as outlined in AWWA C151 shall be submitted for the materials to be
provided.
CONTRACTOR shall obtain and submit a written statement from the gasket
material manufacturer certifying that the gasket materials are compatible with the
joints specified herein and are recommended for the specified field test pressures
and service conditions.
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061
-5-
1-3. DELIVERY, STORAGE, AND SHIPPING. Shipping shall be in accordance
with the shipping section. Handling and storage shall be in accordance with the
handling and storage section,
Pipe, fittings, and accessories shall be handled in a manner that will ensure
installation in sound, undamaged condition. Equipment, tools, and methods used
in handling and installing pipe and fittings shall not damage the pipe and fittings.
Hooks inserted in ends of pipe shall have broad, well-padded contact surfaces.
Unpadded hooks, wire brushes or other abrasive tools shall not be permitted to
come into contact with polyethylene lining when it is specified.
CONTRACTOR furnished pipe and fittings in which the lining has been damaged
shall be replaced by and at the expense of CONTRACTOR. With the
concurrence of ENGINEER, small and readily accessible damaged areas may be
repaired.
If the lining of OWNER furnished pipe or fittings is damaged by CONTRACTOR
during unloading or handling, the damaged pipe or fittings shall be replaced by
and at the expense of CONTRACTOR. Where the damaged areas are small and
readily accessible, CONTRACTOR may be permitted to repair the lining.
CONTRACTOR shall repair any damage to pipe coatings before the pipe is
installed.
PART 2 - PRODUCTS
2-1. PIPE CLASS. The ductile iron pipe shall be Class 150. The specified class
includes corrosion allowance and casting allowance.
Pipe wall thickness for grooved and threaded pipe shall be increased if
necessary to comply with the following minimum thickness:
Pipe Size Minimum Class
inches Mm Threaded Ends Grooved Ends
(1) (2)
4-1 6 100-400 53 53
18 450 53 54
20 500 53 55
24 600 53 56
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061
-6-
30-54 750-1400 53 "
60 & 64 1500-1600 350 "
(1) Complies with ANSVAWWA C115/A21.15 for minimum pipe
wall thickness for threaded flanges.
(2) Grooved couplings are cataloged through 24 inch; larger sizes
require cast-on or threaded-on shoulders.
2-2. MATERIALS
Pipe Ductile iron, ANSVAWWA C1511A21.51,
Table 1 or Table 3.
Fittings
Gaskets -All Joint Types Gaskets shall be synthetic rubber.
Natural rubber will not be acceptable. For
potable water service, gaskets shall be
certified as suitable for chlorinated and
chlorarninated potable water; a certificate
of gasket suitability shall be submitted.
ANSVAWA C11O/A21.1 (except shorter
laying lengths will be acceptable for U.S.
Pipe), or ANSVAWWA C153/A21.53,
minimum working pressure rating as
follows, unless indicated otherwise on the
drawings.
Fittinq Size Min. Workinq Pressure
in Material l&= Ratina, psi -
4 to 24 Dl Mechanical and Push- 350
on joints
4 to 24 Dl Flanged joints 250
30 to 48 Dl All joints 250
54 to 64 Dl All joints 150
All fittings shall be ductile iron and suitable for a test pressure of 1.5 times
rated working pressure without leakage or damage,
Push-on Joints ANSI/AWWACIII/A21.11.
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061
-7-
Restrained Push-on Joints,
gaskets with stainless steel
gripping segments, as required
(4 inch through 12 inch)
Restrained Push-on Joints,
locking wedge type, as
required. (4 inch through 20
inch)
Restrained Push-on Joints,
positive locking segments
and/or rings, as required. (4
inch through 64 inch)
Flanged Joints
Flanges
Class 250
All Others
Flanges
Bolts
Nuts
Gaskets
Insulated Flanges
Flanges
Insulation Kits
US.Pipe "Field Lok Gasket", or American
"Fast Grip".
EBAA Iron "Megalug" Series 1700,
without exception.
American "Flex-Ring,'' or "Lok-Ring";
Clow "Super-Lock; US. Pipe "TR Flex";
or Griffin "Snap-Lok."
ANSVAWA C115/A21.15.
Ductile iron, flat faced, with ANSllASME
816.1, Class 250 diameter and drilling.
Ductile iron, ANSIIAWWA C115/A21 .15.
All flanges shall be suitable for test
pressure of 1.5 times rated pressure
without leakage or damage.
ASTM A307, chamfered or rounded ends
projecting 114 to 1/2 inch beyond outer
face of nut.
ASTM A307, hexagonal, ANWASME
B18.2.2, heavy semifinished pattern.
ASTM D1330, Grade I rubber, full face
type, 1/8 inch thick.
As specified herein, except bolt holes
shall be enlarged as needed to accept
bolt insulating sleeves.
As manufactured by Central Plastics or
PSI Industries.
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061 -a-
Insulating Gaskets Type E, pyrox 1E glass reinforced epoxy,
1/8 inch thick, with Buna-N sealing
element.
Bolt Insulating Sleeves Mylar, 1/32 inch thick.
Insulating Washers Phenolic laminate, 118 inch thick, one for
each flange bolt.
Backing Washers Steel, 118 inch thick, two for each flange
bolt.
Mechanical Joints ANSI/AWAC1111A21.11.
Restrained Mechanical Joints American "MJ coupled Joints", or Griffin
(Factory prepared spigot), as "Mech-Lok".
required. (4 inch through
48 inch) [I00 mm through
1200 mm]
Restrained Mechanical Joints, Not used.
(field cut spigot), as required.
(4 inch through 20 inch)
1100 mm through 500 mm]
Wall Castings Mechanical joint with water stop and
tapped holes; single casting or fabricated
ductile iron. All holes shall be sized in
accordance with the details on the
drawings and shall be provided with
removable plugs.
Mechanical Joints with Tie See details on the drawings.
Rods
Tie Rods ASTM A307.
Steel Pipe ASTM A53, standard weight.
Washers ANSI B18.22.1, plain steel.
(Carlsbad Water)
(Recycling Facility)
(1 -25-02)
15061
-9-
Threaded Connections
Mechanical Couplings
Couplings
Gaskets
Grooved Couplings
Pipe Ends (rigid joints), as
required.
Pipe Ends (flexible joints),
as required.
Couplings (non-shouldered
pipe)
pipe)
Couplings (shouldered
Flanged Coupling Adapters
Tapping Saddles
Shop Coating and Lining
Cement Mortar Lining
ANWASME B1.20.1, NPT; provide boss
or tapping saddle wherever wall thickness
minus the foundry tolerance at the tapped
connection is less than that required for
4-thread engagement as set forth in
Table A.1, Appendix A, of ANSVAWA
C151/A21.51.
Dresser ”Style 38,” Smith-Blair “441 or
41 1 Flexible Coupling,” or Romac ”Style
501”; without pipe stop.
Oil-resistant synthetic rubber.
AWWA C606.
Grooved, with dimensions conforming to
AWWA C606, Table 3.
Shouldered, with dimensions conforming
to AWWA C606, Table 4.
Grinnell “Figure 7001 ,” Gustin-Bacon “No.
500 Gruvajoint,” or Victaulic “Style 31 .”
Victaulic “Style 41” or “Style 44”.
Smith-Blair “Type 912” or Rornac ”Style
FCA501”, with anchor studs for 12 inches
[300 mm] and smaller as required;
Smith-Blair “Type 913” or Romac “Style
FC400”, 14 inches and larger.
Ductile iron, with stainless steel straps
and rubber sealing gasket, 250 psi
pressure rating.
ANSVAWWA C104/A21.4.
(Carlsbad Water)
(Recycling Facility)
( 1-25-02)
15061
-1 0-
Polyethylene Lining
Ceramic Epoxy Lining
Calcium Aluminate Lining
Glass Lining
Universal Primer
Asphaltic Coating
Coal Tar Epoxy
Liquid Epoxy
Medium Consistency Coal Tar
Polyethylene Encasement
ASTM D1248, Class C, heat bonded,
40 mil nominal thickness, except min
thickness shall be at least 30 mils.
Thickness may taper to not less than
10 mils beginning 4 inches from the end
of pipe or fitting.
lnduron “Protect0 401 Ceramic Epoxy”
La Farge “SewperCoat”
Two-coat system applied over blast-
cleaned surface; ground and finish coats
separately fired; finished lining thickness
at least 8 mils, Mohs’ Hardness 5 to
6 density as determined by ASTM D792;
Ceramic Coating ”Non-Stick Glass Lining”
or Victo ”SG-14 Glass Lined Pipe.”
Manufacturer’s standard.
Manufacturer’s standard.
Manufacturer’s standard.
ANSVAWWA C210.
Carboline “Bitumastic Super Service
Black or Tnemec “46-465 H.B.
Tnemecol.“
Seamless, ANSIIAWWA C105/A21.5;
LLD-8 mil or HDCL-4 mil.
2-3. SHOP COATING AND LINING. The interior of all pipe and fittings for water
or water treatment service shall be cement mortar lined. The interior of all pipe
for gravity sewers shall be lined with the material as required. The interior of all
pipe for other services, unless noted otherwise, shall be cement mortar lined.
The interior of all air piping shall be unlined and uncoated.
Glass-lined pipe or other lining, as required, shall be provided for the following
wastewater facilities services:
Waste thickened pipeline from Thickener to EWPCF
GMF backwash pipeline from GMF to Thickener
(Carlsbad Water)
(Recycling Facility)
(1-25-02)
15061
-11-
Where buried or embedded in concrete, glass-lined pipe shall be ductile iron with
mechanical or push-on joints; glass-lined pipe installed in interior locations may
be flanged ductile iron with flanged cast or ductile iron fittings.
The exterior surfaces of all pipe and fittings which will be exposed in interior
locations shall be shop primed. Flange faces shall be coated with a suitable rust-
preventive compound. Exterior surfaces of all other pipe and fittings shall be
coated with asphaltic coating.
PART 3 - EXECUTION
3-1. INSPECTION. Pipe and fittings shall be carefully examined for cracks and
other defects immediately before installation; spigot ends shall be examined with
particular care. All defective pipe and fittings shall be removed from the site of
the work.
3-2. PREPARATION. The interior of all pipe and fittings shall be thoroughly
cleaned of all foreign matter prior to installation. Before jointing, all joint contact
surfaces shall be wire brushed if necessary, wiped clean, and kept clean until
jointing is completed.
Precautions shall be taken to prevent foreign material from entering the pipe
during installation. Debris, tools, clothing, or other objects shall not be placed in
or allowed to enter the pipe.
3-3. CUTTING PIPE. Cutting shall be done in a neat manner, without damage
to the pipe or the lining. Cuts shall be smooth, straight, and at right angles to the
pipe axis. After cutting, the ends of the pipe shall be dressed with a file or power
grinder to remove all roughness and sharp edges. The cut ends of push-on joint
pipe shall be suitably beveled.
All field cutting of existing gray cast iron pipe shall be done with mechanical pipe
cutters, except where the use of mechanical cutters would be difficult or
impracticable.
Ends of ductile iron pipe shall be cut with a portable guillotine saw, abrasive
wheel, saw, milling cutter, or oxyacetylene torch. The use of hydraulic squeeze
type cutters will not be permitted. Field-cut holes for saddles shall be cut with
mechanical cutters; oxyacetylene cutting will not be permitted.
3-4. ALIGNMENT. Piping shall be laid to the lines and grades indicated on the
drawings. Pipelines or runs intended to be straight shall be laid straight.
Deflections from a straight line or grade shall not exceed the values stipulated in
Table 4 or Table 5 of AWA C600, unless specially designed bells and spigots
are provided.
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Either shorter pipe sections or fittings shall be installed where needed to conform
to the alignment or grade indicated on the drawings. Batter boards, laser beam
equipment, or surveying instruments shall be used to maintain alignment and
grade.
If batter boards are used to determine and check pipe subgrades, they shall be
erected at intervals of not more than 25 feet. At least three batter boards shall
always be maintained in proper position when trench grading is in progress.
If laser beam equipment is used, periodic elevation measurements shall be made
with surveying instruments to verify accuracy of grades. If such measurements
indicate thermal deflection of the laser beam due to differences between the
ground temperature and the air temperature within the pipe, precautions shall be
taken to prevent or minimize further thermal deflections.
3-5. LAYING PIPE. Buried pipe shall be protected from lateral displacement by
placing the specified pipe embedment material. Under no circumstances shall
pipe be laid in water, and no pipe shall be laid under unsuitable weather or trench
conditions.
Whenever pipe laying is stopped, the open end of the pipe shall be sealed with a
watertight plug, which will prevent trench water from entering the pipe.
Pipe shall be laid with the bell ends facing the direction of laying, except when
reverse laying is specifically authorized by ENGINEER.
3-6. FIELD JOINTS. Joints in buried locations shall be mechanical or push-on
type unless otherwise indicated on the drawings. Bells on wall castings and wall
sleeves shall be mechanical joint type, with tapped holes for tie rods or stud
bolts. All other joints shall be flanged unless otherwise indicated on the
drawings.
Certification of joint design shall be provided in accordance with ANSVAWA
C111/A21.11, Section 4.5, Performance Requirements, as modified herein. The
joint test pressure shall be not less than 2 times the working pressure or
1-112 times the test pressure of the pipeline, whichever is higher. The same
certification and testing shall also be provided for restrained joints. For
restrained joints, the piping shall not be blocked to prevent separation and the
joint shall not leak or show evidence of failure. It is not necessary that such tests
be made on pipe manufactured specifically for this project. Certified reports
covering tests made on other pipe of the same size and design as specified
herein and manufactured from materials of equivalent type and quality may be
accepted as adequate proof of design.
Where acceptable to ENGINEER, as required, grooved couplings may be used
instead of flanges, provided that rigid grooving is used to preclude longitudinal
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pipe movement and angular deflection at joints. Fittings, valves, and equipment
installed using grooved couplings shall be adequately supported and blocked or
restrained to prevent rotation.
3-7. MECHANICAL JOINTS. Mechanical joints shall be carefully assembled in
accordance with the manufacturer’s recommendations. If effective sealing is not
obtained, the joint shall be disassembled, thoroughly cleaned, and reassembled.
Bolts shall be uniformly tightened to the torque values listed in Appendix A of
ANSVAWWA Clll/A21.11. Overtightening of bolts to compensate for poor
installation practice will not be permitted.
The holes in mechanical joints with tie rods shall be carefully aligned to permit
installation of the tie rods. In flange and mechanical joint pieces, holes in the
mechanical joint bells and the flanges shall straddle the top (or side for vertical
piping) centerline. The top (or side) centerline shall be marked on each flange
and mechanical joint piece at the foundry.
3-8. PUSH-ON JOINTS. The pipe manufacturer’s instructions and
recommendations for proper jointing procedures shall be followed. All joint
surfaces shall be lubricated with heavy vegetable soap solution immediately
before the joint is completed. Lubricant shall be suitable for use in potable water,
shall be stored in closed containers, and shall be kept clean. Each spigot end
shall be suitably beveled to facilitate assembly.
Pipe ends for restrained joint pipe shall be prepared in accordance with the pipe
manufacturer’s recommendations.
3-9. FLANGED JOINTS. Pipe shall extend completely through screwed-on
flanges. The pipe end and flange face shall be finish machined in a single
operation. Flange faces shall be flat and perpendicular to the pipe centerline.
When bolting flanged joints, care shall be taken to avoid restraint on the opposite
end of the pipe or fitting which would prevent uniform gasket compression or
would cause unnecessary stress in the flanges. One flange shall be free to move
in any direction while the flange bolts are being tightened. Bolts shall be
tightened gradually and at a uniform rate, to ensure uniform compression of the
gasket.
Special care shall be taken when connecting piping to any pumping equipment to
ensure that piping stresses are not transmitted to the pump flanges. All
connecting piping shall be permanently supported so that accurate matching of
bolt holes and uniform contact over the entire surface of flanges are obtained
before any bolts are installed in the flanges. In addition, pump connection piping
shall be free to move parallel to its longitudinal centerline while the bolts are
being tightened. Each pump shall be leveled, aligned, and wedged into position,
which will fit the connecting piping, but shall not be grouted until the initial fitting
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and alignment of the pipe, so that the pump may be shifted on its foundation if
necessary to properly install the connecting piping. Each pump shall, however,
be grouted before final bolting of the connecting piping. After final alignment and
bolting, the pump connections shall be tested for applied piping stresses by
loosening the flange bolts which, if the piping is properly installed, should result in
no movement of the piping relative to the pump or opening of the pump
connection joints. If any movement is observed, the piping shall be loosened and
re-aligned as needed and then the flanges bolted back together. The flange
bolts shall then be loosened and the process repeated until no movement is
observed.
3-10. FLANGED COUPLING ADAPTERS. Flanged coupling adapters shall be
installed in strict accordance with the coupling manufacturer’s recommendations.
After the pipe is in place and bolted tight, the proper locations of holes for the
anchor studs shall be determined and the pipe shall be field-drilled. Holes for
anchor studs shall be drilled completely through the pipe wall. Hole diameter
shall be not more than 118 inch larger than the diameter of the stud projection.
The inner surfaces of couplings shall be prepared for coating in accordance with
instructions of the coating manufacturer and shall then be coated with liquid
epoxy in accordance with ANWAWA C210. The remaining surfaces, except
flange mating surfaces, shall be cleaned and shop primed with universal primer.
3-1 1. MECHANICAL COUPLINGS. Mechanical couplings shall be carefully
installed in accordance with the manufacturer’s recommendations. A space of at
least 114 inch, but not more than 1 inch, shall be left between the pipe ends.
Pipe and coupling surfaces in contact with gaskets shall be clean and free from
dirt and other foreign matter during assembly. All assembly bolts shall be
uniformly tightened so that the coupling is free from leaks, and all parts of the
coupling are square and symmetrical with the pipe. Following installation of the
coupling, damaged areas of shop coatings on the pipe and coupling shall be
repaired to the satisfaction of ENGINEER.
The interior surfaces of the middle rings shall be prepared for coating in
accordance with instructions of the coating manufacturer and shall then be
coated with liquid epoxy in accordance with ANSVAWA C210. The remaining
components shall be cleaned and shop primed with universal primer.
3-12. GROOVED END JOINTS. Grooved couplings with rigid type grooving
shall be installed in accordance with the coupling manufacturer’s
recommendations. Completed joints shall be rigid and shall not allow angular
deflection or longitudinal movement. Except for closure pieces, field grooving of
pipe will not be permitted.
Special care shall be taken when connecting to pumping equipment to avoid
transmitting pipe stresses to the pump flanges. Piping shall be permanently
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supported to obtain accurate matching of piping and abutting pump flanges
before bolts are installed in the flanges.
3-13. POLYETHYLENE ENCASEMENT. All buried ductile iron pipe, including
all straight pipe, bends, tees, adapters, closure pieces, and other fittings or
specials, and all valves shall be provided with a minimum of one wrap of
polyethylene encasement. Locations where ductile iron pipe shall be double
wrapped with polyethylene encasement are indicated on the drawings andlor as
specified in the provisions for corrosion protection section.
Polyethylene tube protection shall be installed in accordance with AWA C105,
Method A. Preparation of the pipe shall include, but is not limited to, removing
lumps of clay, mud, cinders, etc., prior to installation.
Where ductile iron pipe is also embedded or encased in concrete, the
polyethylene tube shall be installed over the pipe for 5 feet either side of each
end of the concrete encasement.
The terms “polyethylene tube protection” and “polyethylene encasement” are
interchangeable and shall have the same meaning in these Contract Documents.
3-14. OUTLETS. Where a 12 inch or smaller branch outlet is indicated and the
diameter of the line pipe is at least twice the diameter of the branch, a tee, a
factory welded-on boss, or a tapping saddle will be acceptable.
Where a 4 inch or larger branch outlet is indicated on the drawings and the
diameter of the branch pipe for a given diameter of parent pipe is less than equal
to the maximum diameter listed herein, a factory welded-on outlet fabricated from
centrifugally cast ductile iron pipe will be acceptable.
Parent Pipe Diameter Versus Maximum Branch Pipe
Diameter for Welded-On Outlets
Parent Max Branch Parent Max Branch
Pipe Dia Pipe Dia Pipe Dia Pipe Dia
inches inches inches inches
8 4
10 6
12 8
14 8
16 10
30 20
36 24
42 30
48 30
54 30
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18 12 60 30
20 14 64 30
24 16
All welded-on outlets shall be rated for a working pressure of 250 psi and shall
have a minimum factor of safety of 2.0. The pipe manufacturer shall provide test
data and certification of proof of design. It is not necessary that these tests be
performed on pipe manufactured specifically for this project. Certified reports
covering tests made on other pipe of the same size and design as specified
herein and manufactured from materials of equivalent type and quality may be
accepted as adequate proof of design. Welded-on outlets may be provided as a
radial (tee) outlet, a tangential outlet, or a lateral outlet fabricated at a specific
angle to the parent pipe (in 15 degrees increments between 45 degrees and
90 degrees from the axis of the parent pipe), as indicated on the drawings. The
fillet weld dimensions for welded-on outlets shall be as specified herein. Parent
pipe and branch pipe shall meet hydrostatic test requirements in accordance with AWWA C151, Sec. 51-9, prior to fabrication.
Welded-on Outlet Fillet Weld Dimensions for Specified
Outlet Confiqurations
Radial and Lateral Outlets
Parent
Pipe Dia
Inches
24 and
smaller
30-48
54-64
42-54
60-64
Branch
Pipe Dia
inches
24 and
smaller
24 and
smaller
24 and
smaller
30
30
Weld Fillet - Size
inches
1x1
1-114 X 1-114
2-114 X 2-112
2-112 x 2-112
2-314 X 2-314
Parent
Pipe Dia
Inches
8-30
36-54
60-64
42-54
60-64
Tangential Outlets
Branch
Pipe Dia
inches
24 and
smaller
24 and
smaller
24 and
smaller
30
30
Weld Fillet
inches - Size
1-114 X 1-114
1-112 x 1-112
2-112 x 2-112
2-112 x 2-112
2-314 X 2-314
All joints on welded-on branch outlets shall be made in accordance with the latest
revision ofANSIlAWWAC111lA21.11 andlorANSIlAWWAC115lA21.15, as
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applicable. All outlets shall be fabricated from centrifugally cast ductile iron pipe
designed in accordance with ANSVAWA C150/A21.50 and manufactured and
tested in accordance with ANSVAWA C151/A21.51. Ni-Rod FC 55melectrodes
manufactured by International Nickel Corporation (or an electrode with equivalent
properties) shall be used in the manufacture of the fillet welds. Carbon steel
electrodes will not be acceptable. Special Thickness Class 53 pipe shall be used
for all branch pipe and parent pipe in 4 to 54 inch sizes. Pressure Class 350 pipe
shall be used for 60 inch and 64 inch parent pipe. After welding, each fabricated
outlet shall be subjected to a 15 psi air test. A soap and water solution shall be
applied during the testing procedure to inspect the weld for leakage. Any welds
that show air seepage shall be refabricated and retested.
Welded-on outlets shall be fabricated by the pipe manufacturer at its production
facilities. Manufacturers of welded-on outlets shall have at least 5 years of
satisfactory experience in the manufacture and performance of these products.
The manufacturer shall have a documented welding quality assurance system
and shall maintain resident quality assurance records based on ANSVAWS
Dl 1.2, the Guide for Welding Iron Castings. The manufacturer shall also
maintain appropriate welding procedure specifications (WPS), procedure
qualification (PQR), and welder performance qualification test (WPQR) records.
The type of pipe end for the branch outlet shall be as specified or indicated on
the drawings. The maximum size and laying length of the welded-on branch
outlet shall be as recommended by the pipe manufacturer and shall be
acceptable to ENGINEER for the field conditions and the connecting pipe or
valve. Pipe embedment material and trench backfill shall be placed and
compacted under and around each side of the outlet to hold the pipe in proper
position and alignment during the subsequent pipe jointing, embedment, and
backfilling.
At locations acceptable to ENGINEER, drilling and tapping of the pipe wall for
2 inch [50 mm] and smaller pipe connections will also be acceptable, provided
that the wall thickness, minus the casting allowance, at the point of connection
equals or exceeds the wall thickness required for 4-thread engagement in
accordance with Table A.l, Appendix A of ANSI/AWA C151/A21.51.
3-15. WALL CASTINGS. Wall castings shall be provided where ductile iron
pipes pass through concrete walls, unless otherwise indicated on the drawings
Where a flange and mechanical joint piece is to connect to a mechanical joint
wall casting, the bolt holes in the bell of the wall casting shall straddle the top (or
the side for vertical piping) centerline of the casting and shall align with the bolt
holes in the flange and mechanical joint piece. The top centerline shall be
marked on the wall casting at the foundry.
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3-16. REDUCERS. Reducers shall be eccentric or concentric as indicated on
the drawings. Reducers of eccentric pattern shall be installed with the straight
side on top, so that no air traps are formed.
3-17. CONNECTIONS WITH EXISTING PIPING. Not used
3-18. INSULATED FLANGED JOINTS. Insulated flanged joints shall be
installed where indicated on the drawings. In addition to one full-faced insulated
gasket, each flange insulating assembly shall consist of one full-length sleeve,
one insulating washer, and two backing washers for each flange bolt. The
insulating gasket ID shall be 1/8 inch less than the ID of the flange in which it is
installed. The insulated flanged joint accessories shall be installed in accordance
with the instructions and recommendations of the manufacturer.
3-19. CONCRETE ENCASEMENT. Not used.
3-20. REACTION ANCHORAGE AND BLOCKING. Not used.
3-21. LEAKAGE AND PRESSURE TESTS. Pipe and fittings shall be subjected
to a leakage test and a pressure test, as required.
3-21.01. Pressure and Leakaae Test. Pressure and leakage testing shall be in
accordance with the pipeline pressure and leakage testing section.
CONTRACTOR shall provide all necessary pumping equipment; piping
connections between the piping and the nearest available source of test water;
pressure gauges; and other equipment, materials, and facilities necessary for the
tests.
All pipe, fittings, valves, pipe joints, and other materials which are found to be
defective shall be removed and replaced with new and acceptable materials, and
the affected portion of the piping shall be retested by and at the expense of
CONTRACTOR.
3-21.02. Visual Leakaae Inspection. When a leakage test is not conducted, all
joints shall be watertight and free from visible leaks. Each leak which is
discovered within the correction period stipulated in the General Conditions shall
be repaired by and at the expense of CONTRACTOR.
3-22. CLEANING. The interior of all pipe and fittings shall be kept clean of any
foreign matter until the work has been accepted.
3-23. SCHEDULE. Not used.
End of Section
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1506 1
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SECTION 15062-1
STAINLESS STEEL PIPE AND FllTlNGS
PART 1 -GENERAL
1.01
A
B
1.02
A
1.03
A
SCOPE OF WORK
This section covers stainless steel pipe and fittings to be installed on the
RO system and the threshold inhibitor feed system.
The CONTRACTOR shall furnish all labor, materials, equipment and
incidentals necessary and install all stainless steel pipe, fittings and
appurtenances as shown on the drawings and as specified herein.
SUBMITTALS
Shop drawings submittals shall be made in accordance with the
requirements of Section 01300, except as modified herein.
1. Provide detailed pipe fabrication drawings for the stainless steel
pipe and fittings. Identify all components in a list of materials.
Detail each unique spool, identifying all dimensions, welds, and
methods of construction.
2. 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
manufacturer's catalog number. Identify all in-line equipment and
valves by project equipment number.
REFERENCE STANDARDS
American Society for Testing and Materials (ASTM)
1. ASTM A 182 - Standard Specification for Forged or Rolled Alloy-
Steel Pipe Flanges, Forged Fittings, And Valves and Parts for High-
Temperature Service.
2. ASTM A 193 - Standard Specification for Alloy-Steel and Stainless
Steel Bolting Materials for High-Temperature Service.
3. ASTM A 312 - Standard Specification for Seamless and Welded
Austenitic Stainless Steel Pipes.
4. ASTM A 380 - Standard Specification for Cleaning, Descaling, and
Passivation of Stainless Steel Parts, Equipment, and Systems
5. ASTM A 536 - Standard Specification for Ductile Iron Castings
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6. ASTM A 967 - Standard Specification for Chemical Passivation
Treatments for Stainless Steel Parts
7. ASTM B 403 - Standard Specification for Wrought Austenitic
Stainless Steel Piping Fittings.
8. ASTM B 733 - Standard Specification for Autocatylitic (Electroless)
Nickel-Phosphorus Coatings on Metal
9. ASTM D 2000 - Standard Classification System for Rubber
Products in Automotive Applications.
B. American National Standards Institute:
1. ANSI 816.5 - Pipe Flanges and Flanged Fittings
2. ANSI B16.9 -Wrought Steel Butt Welding Fittings
3. ANSI B16.11 - Forged Steel Fittings, Socket-Welding and
Threaded
4. ANSI 816.28 - Wrought Steel Butt Welding Short Radius Elbows
and Returns
5. ANSI 836.19 - Stainless Steel Pipe
C. Military Specification
1. MIL-C-26074 - Coatings, Electroless Nickel Requirements For
D. American Society of Mechanical Owner’s Representatives (ASME)
1. ASME Boiler and Pressure Vessel Code
2. ASME Code for Pressure Piping
E. American Welding Society (AWS)
1. AWS A5.9 - Specification for Bare Stainless Steel Welding
Electrodes and Rods
F. Where reference is made to one of the above standards, the revision in
effect at the time of bid opening shall apply.
1.04 QUALITY ASSURANCE / QUALITY CONTROL (QNQC)
A. Welder Qualifications
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1. All welders and welding operators shall be qualified at the
CONTRACTOR'S sole expense by an ASME-approved testing
laboratory before performing any welding under this section.
Qualification tests shall be in accordance with Section IX, Article 111
of the ASME Boiler and Pressure Vessel Code. Welders and
welding operators shall be qualified for making groove welds in
Type 316L stainless steel pipe in position 6g for each welding
process to be used.
2. Prior to the start of the work, CONTRACTOR shall submit a list of
the welders he proposes using and the type of welding for which
each has been qualified.
3. Qualification tests may be waived if evidence of prior qualification is
deemed suitable by the Owner's Representative. The
CONTRACTOR shall retest any welders at any time Owner's
Representative considers the quality of the welder's work
substandard. When Owner's Representative requests the retest of
a previously qualified welder, the labor costs for the retest will be at
the Owner's Representative's expense if the welder successfully
passes the test. If the welder fails the retest, all cost shall be at the
CONTRACTORS expense.
4. Each weld shall be marked with a symbol which identifies the
person who made the weld.
B. Shop Inspection
1. Inspection by the Owner's Representative of all assemblies
fabricated to this Specification is required prior to shipment to the
project site, unless specifically waived in writing by the Owner's
Representative. Shop inspections shall not be scheduled prior to
approval of all shop drawings and shall be scheduled no later than
7 days prior to the inspections.
a. Fabricated stainless steel pipe assemblies shall be inspected
at the CONTRACTOR or fabricator's facility by a
representative of the Owner's Representative.
b. An initial inspection shall be conducted once initial fabrication
work has begun, prior to completion of 10 percent of the
welds. The CONTRACTOR shall make available a borescope
for use by the Owner's Representative's representative in
visually checking the completed welds. Deviations from the
Drawings andlor requirements specified herein shall be
grounds for rejection and rework.
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c. A final inspection shall be conducted on all the finished
assemblies, following fabrication but prior to electropolishing.
The CONTRACTOR shall make available a borescope for use
by the Owner's Representative's representative in visually
checking the completed welds. Deviations from the Drawings
and/or requirements specified herein shall be grounds for
rejection and rework. The manufacturer must receive written
acceptance of the finished assemblies prior to shipment to the
site.
2. A clearance for shipment does not relieve the CONTRACTOR of
his responsibility as to performance guarantees, quality of materials
and workmanship, or compliance with specific requirements of the
Contract Documents.
PART 2 -PRODUCTS
2.01
A.
B.
C.
D.
PIPE AND FITTINGS
Pipe: Stainless steel ASTM A312, welded process, Grade TP316L,
unless otherwise specified hereinafter. Schedule as noted or shown.
Seamless material may be substituted for welded material but not the
reverse.
Fittings: Butt Welding Type where noted or shown
1. Stainless steel, ASTM A403, Grade WP316L, Class W with
schedule to match connected piping unless noted otherwise.
2. Dimensions in accordance with MSS SP-43 and ANSI B16.9.
Grooved End: Where noted or shown.
1. Machine grooves into pipe end (Schedule 40, minimum) in
accordance with grooved fitting manufacturer's recommended
dimensions, tolerances, and finishes.
2. Roll cutting of grooves into piping will not be permitted. The interior
pipe wall shall be smooth and free of crevices, gouges, or other
anomalies.
Branch Connections:
1. Tees' or reducing tees in conformance with requirements for
"Fittings" above. Tees shall have no welds in the throat area and
the crotch shall be reinforced with long radius design to eliminate
sharp comers.
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2. Forged commercial welding branch fittings with butt welded outlet,
stainless steel, ASTM A182, Grade F316L, with schedule to match
connected piping unless noted otherwise. No repair welding shall
be performed on forged fittings without prior approval of the
Owner’s Representative. If permitted, the restrictions imposed by
the referenced standard under Section 14 shall apply.
3. Extruded reducing branches in conformance with requirements for
“Fittings” above.
4. Weld-0-let, FNPT outlet, 112-inch maximum, Type 316L stainless
steel; where noted or shown, to match connected pipe size and
schedule.
2.02 JOINTS
A. For shop fabricated assemblies: Butt welded
1. All welding shall be performed in the shop in accordance with the
latest editions of Section IX of the ASME Boiler and Pressure
Vessel Code and ASME Code for Pressure Piping, ASME B31.3
(severe cyclic), as applicable.
2. All welds shall have 100 percent penetration. The internal weld
bead shall be small, smooth and continuous with no crevices, pits
or other voids. The external weld bead shall be well rounded,
smooth and continuous with no anomalies.
3. All welded connections shall be parallel and perpendicular to the
extent that the piping appears to be correct to the naked eye.
4. Procedure:
a. Pipe edges shall be prepared by machine cutting or shaping
using an aluminum oxide blade. Beveled ends shall conform
to the requirements of ANSI B16.9.
b. Clean weld joints and weld joint areas both before and after
welding in accordance with ASTM A380 using stainless steel
wire brushes or stainless steel wool.
c. Alignment:
1) Align ends to be joined within commercial tolerances on
diameter, wall thickness, and out-of-roundness.
2) When joining pipes of different wall schedule, taper bore
the interior of the larger schedule pipe to match the
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interior diameter of the connecting pipe with a maximum
1:3 slope.
3) Root opening at the joint shall be as stated in the
procedure specification.
d. Welding:
The direct current, straight polarity, gas tungsten-arc
(GTAW) process shall be used for all welding. Welding
may be by manual GTAW or automatic (orbital) GTAW
processes.
The inside of the pipe shall be purged with Argon gas
during welding and while the weld is cooling to prevent
oxidation of the weld.
Tack Welds:
All tack welds shall be made by a qualified welder.
All tack welds shall be made with welding rod the
same as that used for the succeeding root pass.
Tack welds shall be small enough to be readily
fused into the bead of the root pass.
Thoroughly clean tack welds with a stainless steel
wire brush prior to the root pass to prevent
pinholing or excessive porosity.
Tack welds which have cracked shall be
completely removed prior to making the root pass.
Surface defects which will affect the soundness of the
weld shall be removed, visually inspected, and re-
welded.
Where permitted, branch connections shall be fitted and
groove-welded in accordance with the details described
and shown in Chapter V of ASME 831.3.
Finished welds shall conform to requirements under
Chapter V of ASME 831.3 (severe cyclic), as applicable.
B. 'For connections requiring field assembly:
1. Welded: Field welding of stainless steel piping connections will not
be allowed.
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2. Threaded: For connections to weld-0-let outlet for instrument or
sample taps only.
3. Union Fittings: Where noted or shown.
4. Flanged: For connections to flanged devices, or where otherwise
noted or shown.
a. Type: Forged stainless steel, ASTM A182, Grade F316, lap
joint flange with stainless steel stub end, ASTM A240, Type
316L, welded grade conforming to MSS-SP43; schedule to
match pipe.
b. Dimensions: To match connected piping, faced and drilled
ANSI Class 150, Ill6-inch raised face, unless otherwise
shown or required for connection to equipment.
5. Groove Fittings: Where noted or shown.
a. Size: As noted or shown.
b. Materials:
c. Housing: Ductile iron conforming to AST"A536; electroless
nickel plated in accordance with MIL-C-26074, Class 1, Grade
C. (0.0015-inch minimum thickness).
d. Manufacturer: Victaulic, Style 77; or equal.
C. Gaskets
1. Flanged Joints:
a. Test Pressure > 200 psig: Manufactured with spiral wound
316L stainless steel with chlorocarb (non-asbestos) filler and
316 stainless steel inner ring and outer centering ring. The
spiral wound component shall be wound from metal preformed
in a chevron configuration. Gaskets shall be Spiraseal Style
WR as manufactured by Lamons or equal.
b. Test Pressure 200 psig: Full faced, 1/8-inch thick, EPDM.
2. Grooved Joints: EPDM.
D. Bolting
1. Flanged Joints: Type 316 stainless steel. ASTM A193, Grade B8M
hex head bolts and washers; Grade B8M hex head nuts.
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2. Grooved Joints: Type 316 stainless steel. Grade B-8M. Class 2;
coupling manufacturer's standard size and shapes.
2.03 ACCESSORIES
A. Thread Lubricant: Teflon tape.
B. Welding Rod and Bare Electrodes: AWS 5.9, ER 316L.
2.04 FINISHING
A. Pickle all stainless steel pipe, fittings, and finished assemblies inside and
out following fabrication to remove all mill scale, weld inclusions and
color; and passivate inside and out in accordance with ASTM A967.
B. Electropolish the outer surface of all components until a homogeneous,
polished appearance is attained.
PART 3 - EXECUTION
3.01
A.
B.
C.
3.02
A.
B.
SHIPMENT, HANDLING, AND STORAGE
Insofar as is practical, the equipment specified herein, shall be factory
assembled. 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.
Special care shall be given to the shipping, unloading, storage and
installation of fabricated pipe assemblies.
Flanges, threads, and open connections shall be closely covered with
rigid plastic caps or other material firmly secured to each component.
INSTALLATION
General
1. The CONTRACTOR shall be responsible for the proper installation
of all stainless steel pipe 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.
Preparation for Installation
1. Keep pipe clean and free of foreign material during storage and
installation.
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2. Move pipe spools by hand or with slings. Do not store or drop pipe
directly on concrete or ground.
3. Field cutting of stainless steel pipe is not permitted.
4. Gasketed Joints:
a. Take care that the gaskets and flange faces are free of all
foreign matter.
b. Seat gaskets carefully and tighten bolts sequentially with a
torque limiting wrench to assure uniform gasket compression.
c. If a gasketed joint fails a pressure test, the gasket shall be
discarded and replaced with a new gasket.
5. Threaded Joints:
a. Clean male and female threads of metallic piping with cutting
oil and solvent.
b. Lubricate male pipe threads as required in the applicable pipe
specification.
C. Pipe Installation
1. Alignment:
a. Pipe shall be installed level, plumb and parallel or
perpendicular to the major axes of the equipment, unless
otherwise shown.
b. Rotate fittings to prevent misalignment and stresses in pipe
and connections to equipment.
c. Bolts in flanges shall be located symmetrically about the
vertical axis of the adjacent pipe.
d. Where possible, locate pipe of similar diameters parallel and
adjacent to one another.
2. Connections:
a. Connect pipe to equipment with connections designed to allow
minor movement.
b. Field locate union fittings as required for component
installation and removal,
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C. Field taps in the stainless steel piping systems are not
acceptable.
D. Final Cleaning
1. Following installation sequentially isolate all piping and flush it with
water at a scouring velocity of at least 2.5 feet per second.
2. Sequentially disconnect piping from equipment and isolate sections
with blind plates or paddles.
E. Pressure Test
1. Pressure test the stainless steel piping to be used for the threshold
inhibitor piping at 100 psig in accordance with requirements of
Section 15051. Pressure test the threshold inhibitor carrier piping
after the installation of the double wall containment piping.
2. Pressure test the vertical stainless steel RO permeate headers at
100 psig in accordance with the requirements of Section 15051.
3. Pressure test remaining stainless steel piping on the RO trains at
300 psig in accordance with the requirements of Section 15051.
4. The full hydrostatic testing of some of the RO System piping(e.g.,
vertical feedkoncentrate manifolds) will have to be conducted
during performance testing of the train, when orifice plugs are
installed in the pressure vessel permeate ports.
F. Drying: Drain and dry all lines following the pressure test.
End Of Section
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SECTION 15065
PVC PIPE
PART 1 -GENERAL
1.01
A.
1.02
A.
B.
C.
1.03
A.
DESCRIPTION
Scope:
1. The Contractor shall provide all piping as shown on the Drawings,
specified and required.
2. The drawings show a general process schematic and location of
the piping. It is the intention of the Drawings and Specifications to
provide complete and workable piping systems.
QUALITY ASSURANCE
Manufacturer Qualifications: Manufacturer(s) of the piping furnished
under this Section shall have experience in providing similar type of
piping and shall show evidence with his submittal of at least five (5)
installations where the piping of the same material and same application
of the type specified herein have been in satisfactory operation for at
least five (5) years. All piping of the same type shall each be the product
of one manufacturer.
Reference Standards: Comply with applicable provisions and
recommendations of the following:
1. Standards of American Water Works Association, AWWA.
2. Standards of American Society for Testing and Materials, ASTM,
3. Standards of American National Standards Institute, ANSI.
4. Standards of National Electrical Manufacturer's Association, NEMA.
5. National Sanitation Foundation, NSF.
Manufacturer: Plastic piping shall be obtained from a manufacturer who
has a continuous quality control program. All PVC plastic molding
materials used to manufacture pipe and fittings under this Section shall
be tested for conformance to the requirements of ASTM D 1784 and
ASTM D 1785. Submit results of the tests.
SUBMllTALS
Shop Drawings: Submit detailed drawings and data for piping.
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