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HomeMy WebLinkAboutPK Contractors Inc; 2002-07-22; 3675-2 Part 8 of 10B. Certificates: Submit certificates of compliance with applicable referenced standards. C. Technical Manuals: 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 Section 1300. 1.04 PRODUCTION, DELIVERY, STORAGE, AND HANDLING A. Prior to Shipment: 1. Each piece of pipe shall be plainly marked at the manufacturer with schedule number and pressure class. All piping shall be readily identifiable. 2. All piping shall be thoroughly cleaned of sand, scale, rust or other foreign substances. Open ends of piping shall be suitably closed to prevent the entrance of foreign matter after cleaning and during shipment and storage. B. Delivery, Storage and Handling of Materials: 1. All materials shall be delivered to the site, stored, and handled in accordance with the manufacturer's instructions. Contractor shall inspect shipments for damage and content well in advance of the date scheduled for incorporation in the Work. Refer to Section 1614 and Greenbook for additional requirements. PART 2 - PRODUCTS 2.01 PIPE MATERIAL A. PVC pipe shall be made from all new rigid unplasticized polyvinyl chloride and shall be normal impact class 12454-B, Schedule 80 in accordance with ASTM D 1785 Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe. 2.02 PIPE JOINTS A. Solvent Weld: 1. Pipe joints shall be solvent-welded with solvent cement in accordance with ASTM D 2564 - Specification for Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Piping Systems, and with primer in accordance with ASTM F 656 - Specification for Primers for use in Solvent Cement Joints of Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings. (Carlsbad Water) (Recycling Facility) (1 -25-02) 15065 -2- B. C. D. 2.03 A. B. C. 2.04 A. Screwed: Screwed joints that are necessary to match UP to threaded valves or fittings shall be made up with Teflon tape only. Flanged: Flanged joints shall be made with two-piece molded hub PVC raised face flanges, drilled to ANSVASME B 16.5 - Pipe Flanges and Flanged Fittings, Class 150, unless otherwise indicated. Gaskets shall be ANSI 150 Ib. full face, IB-inch thick EPDM. Provide a filler gasket between flanges with a raise face to protect the PVC flange from the bolting moment. Grooved: Where shown on the drawings or specified herein, provide groove type couplings. Housings for groove couplings shall be ductile iron conforming to ASTM A 536 with EPDM gaskets; electroless nickel plated in accordance with MIL-C-26074, Class 1, Grade C. Couplings shall be Victaulic, Style 77; or equal. All bolting shall be Type 316 stainless steel with washers the same material as the bolts. FllTlNGS Solvent Welded Fittings: Solvent-welded fittings shall be Schedule 80 PVC fittings in accordance with ASTM D 2467 - Specification for Socket- Type Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. Threaded Fittings: Threaded fittings shall be Schedule 80 PVC fittings in accordance with ASTM D 2464 - Specification for Threaded Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. Flanged Fittings: Flanged fittings shall be Schedule 80 fabricated Van Stone PVC fittings with 150 Ib. flanges to ANSVASME B 16.5. Bolt up connections to cleaning solution stage valves at each Reverse Osmosis (RO) train shall be 300 Ib. ACCESSORIES Service Saddles: 1. Saddles for piping up through 8-inches diameter shall have solid PVC bodies conforming to ASTM D 1784 (cell classification 12454- B) with EPDM seals and 1-1/2 inch NPT threaded taps. Saddles shall be designed to conform to appropriate performance criteria for 200 psig rated systems, including ASTM D3139 and ASTM D 1599 for dimensions and testing performance. Saddles shall be Clamp It Style II; or equal. 2. Saddles for piping larger than 8-inches diameter shall have Type 304 stainless passivated steel bodies, tie bolts, nuts and washers with EPDM seals and 1-1/2 inch NPT threaded taps. Saddles shall be Romac Industries, Inc. Style 306; or equal. (Carlsbad Water) (Recycling Facility) (1 -25-02) 15065 -3- B. Flexible Couplings: 1. Couplings shall be single or multiple arch bellows type as required to suit specific installation requirements. Bodies shall fabriclmetal reinforced chlorobutyllpolyester with and EPDM liner extending to the flange faces. Backing rings and gusset plates shall be Type 316 stainless steel. Minimum design pressure rating shall be 150 psig at 250 OF. Flanges shall be drilled ANSI Class 150 standard. 2. Couplings shall be provided with Type 316 stainless steel control rod assemblies to prevent excessive deflection or elongation. Rubber washers shall be provided for vibration dampening. 3. Couplings shall be Garlock Style 204 HP; or equal. PART 3 - EXECUTION 3.01 INSTALLATION A. General: 1. All PVC pipes shall be installed in a neat and workmanlike manner, properly aligned, and cut from measurements taken at the site to avoid interferences with structural members, architectural features, openings, and equipment. Exposed pipes shall afford maximum headroom and access to equipment, and where necessary all piping shall be installed with sufficient slopes for venting or drainage of liquids and condensate to low points. 2. All installations shall be acceptable to the Construction Manager. It is recommended that the Contractor obtain the assistance of the pipe manufacturer's field representative to instruct the pipe fitters in the correct installation and support of all PVC piping. B. Supports and Anchors: 1. All piping shall be firmly supported with fabricated or commercial hangers or supports in accordance with Section 15140. Where necessary to avoid stress on equipment or structural members, the pipes shall be anchored or harnessed. Expansion joints and guides shall compensate for pipe expansion due to temperature differences. C. Valves and Unions: 1. Unless otherwise indicated, all connections to fixtures, groups of fixtures, and equipment shall be provided with a shutoff valve and union, unless the valve has flanged ends. Unions shall be provided (Carlsbad Water) (Recycling Facility) (1 -25-02) 15065 -4 - at threaded valves, equipment, and other devices requiring occasional removal or disconnection. D. Pipe Taps: 1. Pipe taps to the PVC pipe barrel are not allowed. All taps shall be made using standard fittings or a service saddle. The exception shall be that 1/4-inch taps for instruments may be used in pipes over 4-inches diameter when the tap is made at a fitting, such that the tapped wall includes both pipe and fitting. 3.02 PIPE PREPARATION A. Prior to installation, each pipe length shall be carefully inspected, flushed clean of any debris or dust, and be straightened, if not true. Ends of threaded pipes shall be reamed and filed smooth. All pipe fittings shall be equally cleaned before assembly. 3.03 PIPE JOINTS A. Threaded Joints: 1. Pipe threads shall conform to ANSVASME B 120.1 - Pipe Threads, General Purpose (inch), and shall be full and cleanly cut with sharp dies. Not more than three threads shall remain exposed after installation. All joints shall be made with Teflon tape. B. Solvent-Welded Joints: 1. Solvent-welded joints shall be made with fresh primer and solvent cement on clean, dry pipe ends. The primer and cement cans shall be kept closed at all times and the joints shall be made up at the recommended ambient temperatures, to the pipe Manufacturer's written recommendations. All pipe ends shall be inserted to the full depth of the socket. C. Flange Joints: 1. Flanged joints shall be made with gaskets and Type 316 stainless steel bolts and nuts and washers. Care shall be taken not to over- torque the bolts. + + END OF SECTION + + (Carlsbad Water) (Recycling Facility) (1-25-02) 15065 -5- SECTION 15066 DOUBLE WALL CHEMICAL PIPE SYSTEM PART 1 -GENERAL 1.01 A. 1.02 A. B. C. D. E. 1.03 A. DESCRIPTION Description of Work: 1. This section covers the double wall chemical containment pipe system to be installed on the chemical feed piping that is not located within secondary containment areas. The system shall include but is not limited to the double wall containment pipe, plexiglass enclosures, and the leak detection system as specified herein. 2. The Contractor shall furnish all labor, materials, equipment and incidentals necessary and install the double wall chemical pipe system as shown on the drawings and as specified herein. RELATED WORK Chemical feed systems are included in Division 11. General piping requirements are included in Section 15051. Pipe hangers and supports are included in Section 15140. Control requirements are included in Division 13. Electrical requirements are included in Division 16. SUBMITTALS Shop drawings submittals shall be made in accordance with the requirements of Section 1300 and Greenbook, except as modified herein. 1. Provide detailed pipe fabrication drawings for the double wall containment 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 (Carlsbad Water) (Recycling Facility) 15066 -1 - 1.04 A. B. C. D. 1.05 A. B. manufacturer's catalog number. Identify all in-line equipment and valves by project equipment number. 3. Provide scaled drawings showing the locations of all probes and installation details for each location. 4. Provide detailed drawings of the plexiglass enclosures showing sizing for each location, weight, materials, support details, and installation instructions. 5. Submit complete panel fabrication drawings for the leak detection control panels. Provide complete catalog information for all components that make up the panel. Provide a wiring diagram for each leak detection system showing the probes, the control panel, and electrical requirements. REFERENCE STANDARDS American Society for Testing and Materials (ASTM) 1. ASTM D 1784 - Standard Specification for Rigid Poly(Viny1 Chloride)(PVC) Compounds and Chlorinated Poly(Viny1 Chloride)(CPVC) Compounds National Electric Code (NEC) National Electrical Manufacturers Association (NEMA) Other references that apply to the installation and fabrication of the Stainless steel pipe and fittings specified herein and referenced shall apply. QUALITY ASSURANCE Double Wall Chemical Pipe System shall be furnished by a manufacturer who is fully qualified, experienced and reputable in the fabrication, and installation of the secondary containment and leak detection system specified herein. The system shall be designed constructed and installed in accordance with the best practices and methods and shall comply with these specifications as applicable. Equipment Factory Testing: Factory test control panels, including alarm circuitry and indicating lamps. Submit certification report(s). PART 2 - PRODUCTS 2.01 PIPE AND FlTlNGS (Carlsbad Water) (Recycling Facility) 15066 -2- A. Double Wall Containment Piping: All chemical pump suction and transfer piping outside of containment areas and all injection piping shall be of double wall construction. Piping materials shall be per the individual chemical feed system subsections. B. Equipment Manufacturers: 1. Clear PVC Containment Piping System: a. Flo-Safe b. Or equal. 2.02 PLEXIGLASS ENCLOSURES A. General: 1. Where the use of double wall piping is not possible (e.g., around the pumps and discharge accessories and at the injection point), plexiglass enclosures shall be provided around the equipment for personnel protection. 2. Enclosures shall be designed for easy removal and with easy access to the pump head and pump controls. 3. Enclosure components shall be furnished with integral handles, pulls, and other accessories needed to remove portions of the assembly and access shielded equipment. 4. Enclosures weighing in excess of 20 Ibs. shall have hinged access doors with closure latches. B. Hinges, mounting brackets, supports, latches and accessories shall be constructed of Type 316 stainless steel. C. Each plexiglass enclosure located outside of secondary containment areas shall have a fittings for the attachment of a leak detection probe. Plexiglass enclosures outside of secondary containment areas shall have a sloped bottom to drain leaking chemical to a low point to be detected by the probe. Accumulated liquid shall be drained to the respective chemical containment area or other location as approved by the Owner's Representative. 2.03 LEAK DETECTION SYSTEMS - (NOT USED) (Carlsbad Water) (Recycling Facility) 15066 -3- PART 3 - EXECUTION 3.01 A. B. 3.02 A. B. SHIPMENT, HANDLING, AND STORAGE Insofar as is practical, the equipment specified herein, shall be factory assembled and ready for installation around the fabricated piping systems. The parts and assemblies that are shipped unassembled shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. INSTALLATION General 1. The Contractor shall be responsible for the proper installation of all double wall chemical 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. Double Wall Containment Piping 1. Preparation for Installation a. Keep pipe clean and free of foreign material during storage and installation. b. Move pipe spools by hand or with slings. Do not store or drop pipe directly on concrete or ground. 2. Containment Pipe Installation a. Alignment: 1) Containment pipe shall be installed around the chemical feed piping system and shall match the alignment. 2) Adjust containment pipe around fittings to prevent misalignment and stresses in pipe and connections. b. Connections: (Carlsbad Water) (Recycling Facility) 15066 -4- C, D. 3.03 A. B. 1) Containment pipe shall be sealed at the ends to capture any leakage. 2) Field locate fittings as required for component installation and removal. Plexiglass Enclosures 1. Installation a. The Contractor shall exercise care in installing the plexiglass enclosures around injection points, and equipment within piping. b. The plexiglass enclosures shall be installed and supported such that there are no stresses in the piping, equipment or injection points. c. Field modification of the plexiglass enclosures is not acceptable. Leak Detection Panel and Probe Installation 1. Installation of the Leak Detection Panels and probes shall be in accordance with the manufacturers recommendations and specifications. FIELD TESTING Pipe Pressure Test 1. The carrier pipe system shall be tested for leaks prior to performing the pressure test on the containment piping. The carrier piping shall be tested in conformance with the 2. The containment piping shall be tested to a maximum of 5 psi with air. A pressure regulator should be used to ensure that over pressurizing and brittle fracture of the containment piping does not occur. 3. The joints shall be soaped and visually inspected for leaks. Leaks shall be corrected and the piping retested. Leak Detection System Performance and Operation Test 1. The Contractor shall submit the functional test procedure and shall get approval prior to conducting the system performance and operation test. (Carlsbad Water) (Recycling Facility) 15066 -5- 2. Performance testing shall be conducted as part of the pre- operational testing. 3. A complete functional checkout of the system shall be performed to verify system integrity. The manufacturer shall inspect the system and proved a Certificate of Proper Installation certifying that the system is installed correctly and meets the requirements specified herein. + + END OF SECTION + + (Carlsbad Water) (Recycling Facility) 15066 -6- Section 15067 MISCELLANEOUS PLASTIC PIPE, TUBING, AND ACCESSORIES Data Sheet IPara- IDescription IData lunits General General Equipment Requirements required. F Yes Service Condnions Services for Material Classification r Yes FRP-1. r NO P No hhen "Yes" is selected, indicate the services. PVC-1 Services for Material Classification r Irrigation system supply mains I 1" r Irrigation system lateral piping Other I hen "OtheP is selected, indicate (Carlsbad Water) (Recycling Facility) ( 1-25-02) 15067 -1- vc-2 Aqua ammonia solution piping, Ir Carbon dioxide solution piping r chlorine pressure relief bent piping Chemical ent piping (except downstream from ewpomtor) Chlorine gas piping from MCUUm r regulator to injector r Chlorine solution piping F Ferric chloride solution piping r Ferric sulfate solution piping r Ferrous chloride solution piping r Ferrous sulfate solution piping r solution piping Hydrofluosilicic acid (Ruoride) Lime slurry piping in pump disharge Neat polymer and polymer Solution r piping r Polyphosphate solution piping piping Potassium permanganate solution F Sampling lines r Sleebes for copper tubing r Soda ash solution piping r Sodium bisulfite solution piping r Sulfur dioxide solution piping r Sump pump discharge in buried r 2nc orthophosphate solution piping Other then "Other" is selected, indicate Reverse osmosis process piping le alternative. Microfilter process piping Chemical vent piping as shown (Carlsbad Water) (Recycling Facility) (1-25.02) 15067 -2- Services for Material Classification joints in irrigation system PVC-3. r Other when "Other" is selected, indicate I Other hhen "Other" is selected. indicate I the alternative. Services for Material Classification PVCB. r Yes When "Yes" is selected, indicate R No the services. Services for Material Classification PVC-7. r yes When "Yes" is selected. indicate No the services. Services for Material Classification Emergency gas treatment system CPVC-1 recirculation and drain piping I- piping Neat polymer and polymer solution oerRow, and drain piping Odor control scrubber recirculation, buried or submerged Sodium hydroxide solution piping, Sodium hypochlorite solution piping r Other the alternative. When "Other" is selected, indicate Services for Material Classification PE-1 r Natural gas in buried locations r LP gas in buried locations r Other the alternative. When "Other" is selected, indicate (Carlsbad Water) (Recycling Facility) (1 -25-02) 15067 -3- LP gas in buried locations PE-5. F No (When "Yes" is selected, indicate I the services. Services for Material Classification PE-6. r Yes When "Yes" is selected, indicate R No Laboratory deionized water piping in non-buried locations piping located in air plenums (Carlsbad Water) (Recycling Facility) (1-25-02) 15067 4- piping located in air plenums Sulfuric acid solution piping, buried piping 112 inch 113 mm] and smaller r Plexo "PE 3406 /For Material Classification PE-5, IC Solid wall pe of tubing. r Slotted wall (Carlsbad Water) (Recycling Facility) (1 -25-02) 15067 -5- Section 15067 MISCELLANEOUS PLASTIC PIPE, TUBING, AND ACCESSORIES PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing of miscellaneous plastic pipe, tubing, and accessories for the services as required. Pipe and tubing shall be furnished complete with all fittings, flanges, unions, jointing materials and other necessary appurtenances. 1-1.01. Terminology. When the phrase "as required" is stated in this section it shall mean "as required in the Data Sheet". 1-2. GENERAL. 1-2.01. General Equipment Requirements. When required, the General Equipment Requirements shall apply to all materials provided under this section 1-3. SUBMITTALS. 1-3.01. Drawinqs and Data. Complete specifications, data, and catalog cuts or drawings shall be submitted in accordance with the submittals section. Items requiring submittals shall include, but not be limited to, the following: Chemical resistant waste pipe and fittings, Expansion joints. Flange gaskets. FRP double wall pipe and fittings, Gas pipe and fittings Pipe sleeves. Polyethylene pipe and fittings. Polypropylene pipe and fittings. PVC pipe and fittings. CPVC pipe and fittings (Carlsbad Water) (Recycling Facility) ( 1-25-02) 15067 -6- PVDF pipe and fittings Name of manufacturer Type and model. Construction materials, thickness, and finishes. Pressure and temperature rating. 14. DELIVERY, STORAGE, AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. All materials shall be stored in a sheltered location above the ground, separated by type, and shall be supported to prevent sagging or bending. Pipe, tubing, and fittings shall be stored between 40°F and 90°F. PART 2 - PRODUCTS 2-1. MATERIALS. 2-1.01. PiDe Materials. Miscellaneous plastic pipe materials shall be as indicated. Material Classification FRP-1 FRP Pipe Pipe Fittings and Flanges ASTM D2996, filament-wound, glass fiber reinforced, vinyl ester resin pipe with 20 mil reinforced resin-rich liner; Fibercast "F-Chem 1222" or Smith Fiberglass Products "Poly Thread". Glass fiber reinforced, compatible with the specified pipe, with ratings and chemical resistance equal to or greater than the specified pipe. Material Classification PVC-1 Schedule 40 PVC Pipe With Solvent Welded Joints (Carlsbad Water) (Recycling Facility) ( 1-25-02) 15067 -7- Pipe Fittings ASTM D1785, Cell Classification 12454, bearing NSF seal. ASTM D2466, Cell Classification 12454, bearing NSF seal. Material Classification PVC-2 Schedule 80 PVC Pipe With Solvent Welded Joints For single-walled applications, refer to specification section 15065 "PVC Pipe". For double-walled or secondarily contained applications, refer to specification section 15066 "Double Wall Chemical Pipe System." Material Classification Schedule 80 PVC Pipe With Threaded Joints Pipe Fittings Material Classification PVC DWV Pipe (Single Wall) With Solvent Welded Joints Pipe Fittings Material Classification PVC-3 ASTM 01785, Cell Classification 12454, bearing NSF seal. ASTM D2464, Cell Classification 12454, bearing NSF seal. PVC-4 ASTM D1785, cell classification 12454, bearing NSF seal. ASTM D2665 and ASTM D3311, cell classification 12454, bearing NSF seal. PVC-5 (Carlsbad Water) (Recycling Facility) (1-25-02) 15067 -8- PVC DWV Pipe (Double Wall Containment) Wih Solvent Welded Joints Pipe Fittings Material Classification PVC Underdrain Pipe and Fittings Pipe Fittings Sloan "GSR Contain-it"; with manufacturer's standard spacers, fittings, and suitable chemical service solvent or equal. ASTM D2665 and ASTM D332 1, cell classification 12454, bearing NSF seal. PVC-6 ASTM F758, solid or perforated wall, as required, Cell Classification 12454 or 12364, Type PS 46, with solvent welded or elastomeric gasket joints, as required. ASTM D3034, Cell Classification 12454, wall thickness SDR 35, with solvent welded or elastomeric gasket joints, as required. Material Classification PVC-7 Double-Contained Chemical Feed Pipe System Containment Pipe Interstitial Supporting Devices Prefabricated system consisting of primary pipe supported within a Schedule 80 PVC secondary containment housing. Primary pipe material and fittings shall be as specified for single-contained piping for the respective chemical. ASTM D1785, Cell Classification 12454, bearing NSF seal. Polypropylene spider clips or C-type, within the secondary containment pipe. 15067 -9- Karlsbad Water) Material Classification CPVC-1 Schedule 80 CPVC Pipe With Solvent Welded Joints Pipe Fittings Material Classification PE Pipe (4 inch [IO0 mm] and smaller) With Socket Fusion Fittings Pipe ASTM F441, Schedule 80, Cell Classification 23447, bearing NSF seal. ASTM F439, Cell Classification 23447, bearing NSF seal. Flanges or unions shall be provided where needed to facilitate disassembly of equipment or valves. Flanges or unions shall be joined to the pipe by a solvent weld. Solvent for sodium hypochlorite pipelines shall be IPS Weld-on 724. When acceptable to ENGINEER, threaded joints may be used instead of solvent welded joints in exposed interior locations for the purpose of facilitating assembly. The use of threaded joints in this system shall be held to a minimum. PE-1 ASTM D3350, Cell Classification PE345434C. ASTM D2513, IPS, SDRII; Chevron Chemical Co. "Plexco Yellow-stripe PE3408 Gas Pipe". (Carlsbad Water) (Recycling Facility) (1-25-02) 15067 -1 0- Fittings Material Classification PE Pipe (6 inch [I50 mm] and larger) With Butt Fusion Fittings Pipe Fittings ASTM D1248, Type 111, Class c, Grade P34. ASTM D2683, socket type, with wall thickness same as for pipe. P E-2 ASTM D3350, Cell Classification PE345434C. ASTM D2513, IPS, SDR11; Chevron Chemical Co. "Plexco Yellow-stripe PE3408 Gas Pipe". ASTM D1248, Type 111, Class C, Grade P34. ASTM D3261, butt heat fusion type, with wall thickness same as for pipe. Material Classification PE-3 PE Tubing With Compression Fittings Tubing Fittings 1/8 through 5/8 inch OD, 1/16 inch wall thickness, 130°F max operating temperature. As recommended by the chlorine feed system manufacturer. Material Classification PE4 PE Pipe (Carlsbad Water) (Recycling Facility) (1 -25-02) 15067 -1 1- Pipe Fittings ASTM D3350, Cell Classification PE334434C. ASTM F714, DR as required, Phillips "Driscopipe 1000, "Driscopipe 8600", or Plexco "PE 3408, as required. Molded or manufactured from pipe; cell classification of material and pressure rating same as for pipe. Material Classification PE-5 Corrugated PE Drainage Tubing AASHTO M252 and ASTM F405, with and Fittings solid or slotted wall, as required. Material Classification PE-6 Polyethylene Tubing and Fittings 1/8 through 3/4 inch OD, III6-inch wall thickness, 130°F maximum operating temperature with compression fittings. Material Classification PP-1 150 psi Polypropylene Pipe Polypropylene pipe and fittings used for chemical service shall be 150 psig rated, unpigmented pipe; Superproline as manufactured by ASAHVAmerica or equal. Joints shall be butt fusion type, except where connecting to unions, valves, and equipment with threaded connections that may require future disassembly. (Carlsbad Water) (Recycling Facility) (1-25-02) 15067 -12- Fittings Material Classification PP DWV Pipe With Heat Fused Joints Pipe Fittings Joints Flanges shall be ring type, flat faced, with epoxy powder coated ductile iron backing, 150-lb standard. Gaskets shall be 118-inch thick, fabricated from ethylene propylene rubber (EPR) or EPDM. When the mating flange has a raised face, use a flat ring gasket and provide a filler gasket between the OD of the raised face and the flange OD to protect the plastic flange from the bolting moment. Bolting shall be Type 316 stainless steel with washers the same material as the bolts. Thread lubricant shall be Teflon tape. All fused connections shall be joined by thermal butt fusion using a Poweld Butt Fusion Machine as manufactured by ASAHVAmerica, or equal as approved by the pipe manufacturer. PP-2 Schedule 40, ASTM 04101. Orion "Brownline" for standard type or "Blueline" for flame retardant type, Enfield, or R&G Sloan. Schedule 40, drainage pattern. Fittings and pipe shall be provided by the same manufacturer. Manufacturers' standard heat fused socket joint. Solvent weld joints not permitted. Material Classification PP-3 PP DWV Pipe With Mechanical Joints (Carlsbad Water) (Recycling Facility) (1 -25-02) 15067 -1 3- Pipe Fittings Schedule 40, ASTM D4101. Orion "Brownline" for standard type or "Blueline" for flame retardant type, Enfield, or R&G Sloan. Schedule 40, drainage pattern. Fittings and pipe shall be provided by the same manufacturer. Joints Manufacturers' standard Material Classification PP-4 Schedule EO PP Pipe with Socket Fusion Fittings Pipe Fittings Schedule 80, natural polypropylene, unpigmented. Schedule EO, same material as the pipe. Socket fusion type. Material Classification PVDF-1 PVDF DWV Pipe With Heat Fused Joints Pipe Fittings Joints Schedule 40, UL 9440, non- combustible. Orion or equal. Schedule 40, drainage pattern. Fittings and pipe shall be provided by the same manufacturer. Manufacturers' standard heat fused socket joint. Solvent weld joints not permitted. Material Classification PVDF-2 PVDF DWV Pipe With Mechanical Joints Pipe (Carlsbad Water) (Recycling Facility) (1-25-02) Schedule 40, UL 94-V0, non- combustible. Orion or equal. 15067 -14- Fittings Joints Material Classification 230 psig PVDF With Socket Type Heat Fusion Welded Joints Pipe (Carlsbad Water) (Recycling Facility) (1-25-02) Schedule 40, drainage pattern. Fittings and pipe shall be provided by the same manufacturer. Manufacturers' standard. PVDF-3 Polyvinylidene Flouride (PVDF) pipe shall be used for sulfuric acid service where shown. The PVDF shall be unpigmented type rated at 230 psig. Materials shall meet or exceed the requirements for a Type I resin listed in Table 2 of ASTM D-3222 when tested according to the requirements stated in section 7 of the aforementioned ASTM specification. In addition, they shall meet or exceed requirements set forth by the Code of Federal Regulations, Title 21, Chapter One for polyvinylidene fluoride resins. PVDF piping shall be as manufactured by ASAHllAmerica or equal. Nipples shall be same as pipe. 15067 -1 5- Fittings Material Classification Schedule 80 PVDF With Threaded Joints Pipe Fittings Fittings shall be same as pipe, injection molded. Joints shall be standard butt fusion, except where connecting to unions, valves, and equipment with threaded connection that may require future disassembly. Flanges shall be ring type, flat faced flanges with epoxy powder coated ductile iron backing, 150-pound standard. Gaskets shall be Viton, full face, meeting ASTM D 2000 HK 710, with a hardness of 65 - 75 durometer and minimum tensile strength of 1000 psi. Gaskets shall be Garlock Style 9518 - Viton; or equal. Bolting shall shall be Type 316 stainless steel. Provide washers the same material as the bolts. When mating flange has raised face, use flat ring gasket and provide filler gasket between OD of raised face and flange OD to protect PVDF flange from bolting moment. Bolt torque and tightening procedures shall be in accordance with the recommendations of the pipe manufacturer. All fused connections shall be joined by thermal butt fusion using a Proweld Butt Fusion Machine as manufactured by ASAHVAmerica or equal, as approved by the pipe manufacturer. Thread lubricant shall be Teflon tape. PVDF4 ASTM D3222 for Type 1 homopolymers manufactured to wall thicknesses specified in ASTM Dl785 for Schedule 80 Pipe. ASTM D2464 (Carlsbad Water) (Recycling Facility) (1-25-02) 15067 -16- Material Classification RPT-1 Reinforced Plastic Tubing Wire reinforced PVC hose; Cobon Plastics Corp. "Cobovin Type s" or NewAge Industries Inc. "Vardex". 2-1.02. Accessow Materials. Accessory materials for the miscellaneous plastic pipe systems shall be as indicated. Material Classification FRP-1 Flanges Diameter and drilling shall conform to ANWASME B16.5, Class 150. Flange Bolts and Nuts ASTM A307, Grade B, galvanized, length such that, after installation, the bolts will project 118 to 318 inch beyond outer face of the nut. Flat Washers Flange Gaskets Expansion Joints Material Classification Flanges Flange Bolts and Nuts ANSI B18.22.1, plain, galvanized. Full face, 1/8 inch thick, chemical- resistant elastomeric material suitable for the specified service. Edlon "Thermo-molded TFE or Resistoflex "Style R6905" molded expansion joint. Any PVC-1 through PVCJ, any PVDF- 1 through PVDF-4 Diameter and drilling shall conform to ANWASME B16.5, Class 150. Schedule 80 for DWV systems. ASTM A307, Grade B, length such that, after installation, the bolts will project 1/8 to 3/8 inch beyond outer face of the nut. 316 Stainless steel for DWV and chemical feed system, microfiltration. and reverse osmosis piping; galvanized (Carlsbad Water) (Recycling Facility) (1 -25-02) 15067 -17- steel for all other systems. ANSI 818.22.1, plain Stainless steel for DWV and chemical feed systems, galvanized steel for all other systems. Viton, full face meeting ASTM D2000 HK 710, with a hardness of 65 - 75 durometer and minimum tensile strength of 1000 psi. Gaskets shall be Garlock Style 9518 - Viton or equal. Flat Washers Flange Gaskets Expansion Joints Material Classification Flanges Flange Bolts and Nuts Flat Washers Flange Gaskets Expansion Joints Edlon "Thermo-molded TFE or Resistoflex "Style R6905" molded expansion joint. CPVC-1 Diameter and drilling shall conform to ANSVASME 816.5, Class 150. ASTM A307, Grade 8, length such that, after installation, the bolts will project 118 to 3/8 inch beyond outer face of the nut. Stainless steel for chemical feed systems, galvanized steel for all other systems. ANSI 818.22.1, plain. Stainless steel for chemical feed systems, galvanized steel for all other systems. Full face, 118 inch thick, chemical- resistant elastomeric material suitable for the specified service. Edlon "Thermo-molded TFE" or Resistoflex "Style R6905" molded expansion joint. (Carlsbad Water) (Recycling Facility) (1-25-02) 15067 -18- Material Classification Flanges Flange Bolts and Nuts Fittings and Flange Adapters Any PE-1 through PE-6 Schedule 80 PVC; diameter and drilling shall conform to ANWASME B16.5, Class 150. ANSI B18.2.1, ASTM AI 93, AIS1 Type 304, heavy hex head, length such that after installation the bolts will project 1/8 to 318 inch beyond outer face of the nut. ASTM Al94, AIS1 Type, ANSVASME B18.2.2, heavy hex pattern. Molded or manufactured from the pipe; cell classification of material and pressure rating same as for pipe. PART 3 - EXECUTION 3-1. INSTALLATION. Materials furnished under this section will be installed in accordance with Division 15. End of Section (Carlsbad Water) (Recycling Facility) (1 45-02) 15067 -1 9- SECTION 15067-1 ALLOY 20 PIPE AND FllTlNGS PART 1 -GENERAL 1.01 DESCRIPTION A. Description of Work: 1. This section covers Alloy 20 pipe and fittings to be installed in the sulfuric acid system. 2. The CONTRACTOR shall furnish all labor, materials, equipment and incidentals necessary and install all Alloy 20 pipe, fittings and appurtenances as shown on the drawings and as specified herein. 1.02 SUBMITTALS A. 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 Alloy 20 piping. 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. 1.03 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) 1. ASTM A 193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service. 2. ASTM A 380 - Standard Specification for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems. 3. ASTM B 366 - Standard. Specification for Factory-Made Wrought Nickel and Nickel Alloy Fittings. 4. ASTM B 462 - Specification for Forged or Rolled UNS N08020, UNS N08024, UNS N08026, UNS N08367, and UNS R20033 Alloy (CARLSBAD WATER) 15067-1 (RECYCLING FACILITY) -1 - (100% SUBMITTAL) Pipe Flanges, Forged Fitting and Valves, and Parts for Corrosive High Temperature Service. 5. ASTM B 463 - Specification for UNS N08020, UNS N08026, and UNS NO8024 Alloy Plate, Sheet and Strip. 6. ASTM B 464 - Standard Specification for Welded UNS N08020, N08024, and NO8026 Alloy Pipe. 7. ASTM D 2000 - Standard Classification System for Rubber Products in Automotive Applications. B. American National Standards Institute (ANSI): 1. ANSI B16.5 - 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 B16.28 - Wrought Steel Butt Welding Short Radius Elbows and Returns 5. ANSI 836.19 - Stainless Steel Pipe C. American Society of Mechanical Engineers (ASME) 1. ASME Boiler and Pressure Vessel Code 2. ASME Code for Pressure Piping D. American Welding Society (AWS) 1. AWS A5.9 - Specification for Bare Stainless Steel Welding Electrodes and Rods E. Other references that apply to the installation and fabrication of the alloy 20 pipe and fittings specified herein and referenced shall apply. 1.04 QUALITY ASSURANCE A. Welder Qualifications 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 (CARLSBAD WATER) (RECYCLING FACILITY) (100% SUBMITTAL) 15067-1 -2- of the ASME Boiler and Pressure Vessel Code. Welders and welding operators shall be qualified for making groove welds in Alloy 20 stainless steel pipe in position 69 for each welding process to be used. 2. Prior to the start of the work, CONTRACTOR shall submit a list of the welders he/she 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 expense if the welder successfully passes the test. If the welder fails the retest, all cost shall be at the CONTRACTOR'S 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. a. The CONTRACTOR shall schedule an inspection of the piping when 10% of the welds are complete. b. The CONTRACTOR shall schedule a second inspection after correction of any deficiencies noted in the 10% inspection and the completion of the welding. 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. 3. 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 inspection. PART 2 - PRODUCTS (CARLSBAD WATER) (RECYCLING FACILITY) (100% SUBMITTAL) 15067-1 -3- 1.01 PIPE AND FllTlNGS A. Pipe: Stainless steel alloy, ASTM 8464 (UNS Designation N08020), Schedule 40s. B. Fittings: Butt Welding Type, where future disassembly is not required 1. Stainless steel alloy, ASTM 8462 (UNS Designation N08020) in accordance with ASTM 8366, Type WP20CBW, with schedule to match connected piping. C. Branch Connections: Tees or reducing tees in conformance with requirements for “Fittings” above. 1.02 JOINTS A. For shop fabricated assemblies: Butt welded without exception. 1. All welding shall carried out in the shop and shall be 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. (CARLSBAD WATER) (RECYCLING FACILITY) (100% SUBMITTAL) 15067-1 -4 - 2) d. Welding: 1) 3) Root opening at the joint shall be as stated in the procedure specification. 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. Finished welds shall conform to requirements under Chapter V of ASME 831.3 (severe cyclic), as applicable. B. For connections requiring field assembly: 1. Threaded: For connections to instrument taps only. 2. Union Fittings: Where noted or shown. 3. Flanged: For connections to flanged devices, or where otherwise noted or shown. a. Type: Factory-made wrought fittings, lap-joint stub end in conformance with ASTM 8366, Type WPZOCB; schedule to match pipe. b. Dimensions: To match connected piping, faced and drilled ANSI Class 150. (CARLSBAD WATER) (RECYCLING FACILITY) (1 00% SUBMITTAL) 15067-1 -5- C. Gaskets: Viton, full face meeting ASTM D2000 HK 710, with a hardness of 65 - 75 durometer and minimum tensile strength of 1000 psi. Gaskets shall be Garlock Style 9518 - Viton or equal. d. Bolting: Flanged Joints: Type 316 stainless steel. ASTM Al93, Grade B8M hex head bolts and washers; Grade B8M hex head nuts. 1.03 ACCESSORIES A. Thread Lubricant: Teflon tape. B. Welding Rod and Bare Electrodes: AWS 5.9, ER 320LR. 1.04 FINISHING A. Pickle all stainless steel pipe, fittings, and finished assemblies following fabrication to remove all mill scale, weld inclusions and color in accordance with ASTM A380. B. Electropolish the outer surface of all components until a homogeneous, polished appearance is attained. PART 3 - EXECUTION 1.01 SHIPMENT, HANDLING, AND STORAGE A. 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. B. Special care shall be given to the shipping, unloading, storage and installation of fabricated pipe assemblies. C. Flanges, threads, and open connections shall be closely covered with rigid plastic caps or other material firmly secured to each component. 1.02 INSTALLATION A. General 1. The CONTRACTOR shall be responsible for the proper installation of all Alloy 20 Pipe system components. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the (CARLSBAD WATER) (RECYCLING FACILITY) (100% SUBMITTAL) 15067-1 -6- Specifications, manufacturer's printed instructions, and approved shop drawings. 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. Field cutting of Alloy 20 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. (CARLSBAD WATER) (RECYCLING FACILITY) (100% SUBMITTAL) 15067-1 -7- 2. Connections: a. Connect pipe to equipment with connections designed to allow minor movement. b. Field locate union fMings as required for component installation and removal. c. Field taps in the Alloy 20 piping system 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 E. Pressure Test: Pressure test all Alloy 20 piping at 100 psig in with blind plates or paddles. accordance with requirements of Section 15051. F. Drying: Drain and dty the Alloy 20 lines and interconnected components which will be in direct contact with the sulfuric acid using compressed nitrogen. (CARLSBAD WATER) (RECYCLING FACILITY) (100% SUBMITTAL) End Of Section 15067-1 -0- Section 15098 PLUG VALVES Data Sheet Para- graph Unit! Data Description General General Equipment Requirements required. (i- Yes CNO Certified copies of physical and chemical r Yes test results. Valves. r vp-1 R VP-2 No (Carlsbad Water) (Recycling Facility) (1 -29-02) 15098 -1- Section 15098 PLUG VALVES PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing of manually operated or remote activated two position (open-close) plug valves. Piping, pipe supports, insulation, and accessories that are not an integral part of the valves or are not specified herein are covered in other sections. Valve actuators are covered in Section 15100-2.02. 1-1.01. Terminoloqy. When the phrase “as required” is stated in this section it shall mean “as required in the drawings”. 1-2. GENERAL. 1-2.01. General Equipment Requirements. The General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.02. Number Plates. Each valve covered by this section which has been assigned a number on the drawings shall be provided with a number plate mounted on or adjacent to the valve in a manner acceptable to ENGINEER. Number plates shall be aluminum with engraved letters at least 314 inch [I9 mm] high. Letters shall be painted black after fabrication. 1-3. SUBMITTALS. Complete drawings, details, and specifications covering the valves and their appurtenances shall be submitted in accordance with the submittals section. Included in the submittal shall be drawings by the valve manufacturer to indicate the position of the valve actuator and valve shaft. Submittal drawings shall clearly indicate the country of origin of all cast gray iron and ductile iron valve components. 1-4. DELIVERY, STORAGE, AND HANDLING. Shipping shall be in accordance with Section 15100-1.04 ”Product Delivery, Storage and Handling”. PART 2 - PRODUCTS 2-1. CONSTRUCTION. Carlsbad Water) ~ (Recycling Facilib) (1-29-02) 15098 -2- 2-1.01, Valves VP-1. Not used, 2-1.02. Valves VP-2. Rating 175 WOG Code Body Cast iron Trim Plug Seal Hycar Plug Bronze or nickel plated cast iron Stem Seal Buna End Connection Flanged, ASME B16.1, Class 125 Temp. Limitations -20 to 180°F 1-29 to 82"CI Valve Operator Lever Manufacturers Key Port "Fig 425-RS51" ,2-I .03. Lenath Tolerance. Unless otherwise specified, the actual length of valves shall be within plus or minus 1/16 inch 11.6 mm] of the specified or theoretical length. 2-1.04. ShoD Coatinas. All ferrous metal surfaces of valves and accessories, both interior and exterior, shall be shop coated for corrosion protection. The valve manufacturer's standard coating will be acceptable, provided it is functionally equivalent to the specified coating. Coatina Materials Asphalt Varnish Fed Spec lT-C-494. Medium Consistency Coal Tar Carboline "Bitumastic Super Service Black or Tnemec "46-465 H.B. Tnemecol". Epoxy Enamel Ameron "Amercoat 385 Epoxy", Carboline "Carboguard 890", or Tnemec "Series 69 Hi-Build Epoxoline (Carlsbad Water) (Recycling Facility) (1-29-02) 15098 -3- Rust-Preventive Compound 11". As recommended by the manufacturer. Surfaces To Be Coated Unfinished Surfaces Interior Surfaces EPOW Exterior Surfaces of Valves Asphalt varnish or coal tar. To Be Buried, Submerged, or Installed in Manholes or Valve Vaults Exterior Surfaces of All Other Universal primer. Valves Polished or Machined Surfaces Rust-preventive compound Actuators and Accessories Universal primer. 2-2. VALVE ACTUATORS. Requirements for valve actuators shall be as specified in Section 15100-2.02. 2-3. ACCESSORIES. 2-3.01. Extension Stems. Extension stems and stem guides shall be furnished when indicated in the respective valve schedules, indicated on the drawings, or otherwise required for proper valve operation. Extension stems shall be of solid steel and shall be not smaller in diameter than the stem of the actuator shaft. Extension stems shall be connected to the actuator with a single Lovejoy "Type D" universal joint with grease-filled protective boot. All stem connections shall be pinned. At least two stem guides shall be furnished with each extension stem, except for buried valves. Stem guides shall be of cast iron, bronzebushed, and adjustable in two directions. Stem guide spacing shall not exceed 100 times the stem diameter or 10 feet [3 m], whichever is smaller. The top stem guide shall be designed to carry the weight of the extension stem. The extension stem shall be provided with a collar pinned to the stem and bearing against the stem thrust guide. (Carlsbad Water) (Recycling Facility) (I -29-02) 15098 -4- Extension stems for buried valve actuators shall extend to within 6 inches [I50 mm] of the ground surface, shall be centered in the valve box using spacers, and shall be equipped with a wrench nut. Extension stems for buried valve actuators shall be provided with position indicators as specified in the valve schedules. 2-3.02. Position Indicators. Not used. 2-3.03. Floor Boxes. Not used 2-3.04. ODeratinq Stands. Not used. 2-3.05. Valve Boxes. Each valve buried to a depth of 4 feet [I .2 m] or less shall be provided with a slide type valve box. Valve boxes shall be cast iron, extension sleeve type, suitable for the depth of cover indicated on the drawings. Only one extension will be allowed with each slide type valve box. Valve boxes shall be at least 5 inches [I25 mm] in inside diameter, shall be at least 3116 inch [4.7 mm] thick, and shall be provided with suitable cast iron bases and covers. Each valve buried deeper than 4 feet [I .2 m] shall be provided with a valve box consisting of a cast iron cover and a 6 inch [I50 mm] cast iron pipe section. The cover shall be Clay & Bailey "No. 2193". The pipe shaft shall extend from the valve to 5 inches [I25 mm] inside the valve box cover. All parts of valve boxes, bases, and covers shall be shop coated by dipping in asphalt varnish. Valve boxes which are to be provided with position indicators shall have top sections and covers designed for proper installation of the position indicator and accessories. PART 3 - EXECUTION 3-1. INSTALLATION. Materials furnished under this section will be installed in accordance with Section 15100 Part 3 - Execution. End of Section (Carlsbad Water) (Recycling Facility) ( 1-29-02) 15098 -5- SECTION 15100 VALVES AND APPURTENANCES PART 1 - GENERAL 1.01 DESCRIPTION A. Description of Work: 1, Furnish all labor, materials, equipment and incidentals required and install complete and ready for operation and test all valves as shown on the Drawings and as specified herein. 2. The equipment shall include, but not be limited to, the following: a. b. C. d. e. f. 9. h. I. I. k. I. m n. Valve Actuators - General Valve Actuators - Manual Valve Actuators - Electric Globe Style Control Valves Butterfly Valves Ball Valves Check Valves Vacuum Relief Valves Pressure Relief Valves Pressure RegulatinglControl Valves Sample Valves Diaphragm Valves Multiport Valves Needle Valves B. Coordination 1. All valves are shown on the Drawings by unique tag number and listed in the Valve Schedule appended to the end of this Section. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -1- 2. The valve schedule assigns each tagged valve and actuator a code identifier. Each valve and actuator identified by a given code identifier is bound to the requirements corresponding to that identifier under Part 2 herein. 3. The CONTRACTOR shall identify each valve by its assigned tag number on all shop drawings and equipment submittals. 1.02 QUALITY CONTROUQUALITY ASSURANCE (QAIQC) A. Manufacturer’s Qualifications 1. Manufacturer(s) of the valves and appurtenances furnished under this Section shall have experience in providing similar products and shall show evidence with his submittal of at least five (5) installations where the components of the same type in similar application to that specified herein have been in satisfactory operation for at least five (5) years. 2. All valves and components of a similar type or class shall be the product of a single manufacturer for consolidation of spare parts and manufacturer’s services. B. Reference Standards 1. Comply with applicable provisions and recommendations of the following: a. Standards of American Water Works Association, AWWA. b. Standards of American Society for Testing and Materials, ASTM. c. Standards of American National Standards Institute, ANSI. d. Standards of the American Society of Mechanical Owner‘s Representatives, ASME. e. Standards of the U.S. Department of Defense, MIL f. Standards of the American Welding Society, AWS. g. Standards of the Manufacturers Standardization Society of the Valve and Fittings Industry, MSS. h. National Sanitation Foundation, NSF. 1.03 SUBMITTALS (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -2 - A. Shop Drawings 1. Submit materials required to establish compliance with these Specifications in accordance with Section 01300. Submittals shall include the following: a. b. C. d. e. f. 9. h. I. Equipment tag number or name used in the Specifications The manufacturer or supplier. The address at which equipment will be fabricated or assembled. Certified drawings showing all important details of construction and dimensions. Descriptive literature, bulletins and/or catalogs of the equipment. The total weight of each item. A complete bill of materials. Additional submittal data, where noted with individual pieces of equipment. Individual electrical control schematics and wiring diagrams for each valve operator with all external interfaces, identified. Standard catalogue cut sheets that show typical wiring diagrams only are not acceptable. Valve actuators shall be coordinated with electrical requirements shown on the Drawings and valves as specified herein. B. Factory Test Reports 1. Factory inspection, testing and correction of deficiencies shall be done in accordance with the referenced Standards and as noted herein. 2. Provide certified hydrostatic test data, per manufacturers standard procedure or MSS-SP-82 -Valve Pressure Testing Methods, for all valves. 3. In addition to all tests required by the referenced Standards, the following shall also be factory tested: a. Pressure regulating valves shall be factory tested at the specified pressures and flows. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -3- C D E. 1.04 A. B. b. All types of air and vacuum valves. Installation Instructions 1, Provide all necessary manufacturer’s installation instructions with all valves and appurtenances. Operation and Maintenance Manuals 1. Operating and maintenance instructions shall be furnished to the Owner’s Representative as provided in Section 01300. 2. The instructions shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions and other information required to instruct operating and maintenance personnel unfamiliar with such equipment. Certificates Warranties and Guaranties 1. For each valve specified to be manufactured, tested andlor installed in accordance with AWWA, ASTM, ANSI and other standards, submit an affidavit of compliance with the appropriate standards, including certified results of required tests and certification of proper installation. PRODUCT DELIVERY, STORAGE AND HANDLING Reference is made to Section 01400 for additional information. Packing and Shipping 1. 2. 3. 4. 5. Care shall be taken in loading, transporting and unloading to prevent injury to the valves, appurtenances, or coatings. Equipment shall not be dropped. All valves and appurtenances shall be examined before installation and no piece shall be installed which is found to be defective. Any damage to the coatings shall be repaired as acceptable to the Owner’s Representative. Prior to shipping, the ends of all valves shall be acceptably covered to prevent entry of foreign material. Covers shall remain in place until after installation of connecting piping is completed. a. All valves 3-inches and larger shall be shipped and stored on site until time of use with wood or plywood covers on each valve end. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -4 - b. Valves smaller than 3-inches shall be shipped and stored as above except that heavy cardboard covers may be used on the openings. c. Rising stems and exposed stem valves shall be coated with a protective oil film, which shall be maintained until the valve is installed and put into use. d. Any corrosion in evidence at the time of acceptance by the Owner's Representative shall be removed, or the valve shall be removed and replaced. 6. 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. 7. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. C. Storage and Protection 1. Special care shall be taken to prevent plastic and similar brittle items from being directly exposed to the sun, or exposed to extremes in temperature, to prevent deformation. 2. See the individual valve specifications and manufacturer's information for further requirements. PART 2 - PRODUCTS 2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE A. General Valve Requirements 1. The use of a manufacturer's name andlor model or catalog number is for the purpose of establishing the standard of quality and general configuration desired. 2. Valves and appurtenances shall have the name of the maker, nominal size, flow directional arrows, working pressure for which they are designed and standard referenced, cast in raised letters or indelibly marked upon some appropriate part of the body. 3. Unless otherwise noted, items shall have a minimum working pressure of 150 psig or be of the same working pressure as the (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -5- pipe they connect to,. whichever is higher and suitable for the pressures noted where they are installed. 4. Joints, size and material - unless otherwise noted or required by the Owner's Representative: a. Except where noted, all joints referred to herein shall be of the same type, nominal diameter, material and with a minimum rating equal to the pipe or fittings they are connected to. b. Valves and appurtenances shall be of the same nominal diameter as the pipe or fittings they are connected to. 5. Provide all special adapters as required to ensure compatibility between valves, appurtenances and adjacent pipefittings. 6. Valves and actuators located outdoors but not within a building; within maximum 2-17 above liquid; in vaults or piping trenches; or where otherwise noted shall be designed for submerged service where water may completely submerge the valve and operator. All other units shall be as a minimum weather tight. 7. Each valve operator shall be provided with a 1-112-inch minimum diameter stainless steel tag. Each tag shall bear the valve number shown on the Drawings. The tags shall be attached to the operator with key rings so that ring and tag cannot be removed. The numbers and letters shall be of block type, with 1/4-inch high numbers and letters stamped thereon. B. General Valve Actuator Requirements 1. The valve manufacturer shall supply and integrally, rigidly mount all actuators, including any type of manual or electric actuators, on valves at the factory. The valves and their individual actuators shall be shipped as a unit. Electric actuators shall be tested and adjusted on the valve for which it is supplied by the valve supplier, the operator manufacturer, or an authorized distributor and service facility for the actuator. 2. All actuators shall be capable of moving the valve from the full open to full close position and in reverse and holding the valve at any position part way between full open or closed. 3. Each operating device shall have cast on it the word "OPEN" and an arrow indicating the direction of operation. 4. All position indication and direction of opening arrows shall be embossed, stamped, engraved, etched or raised decals. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -6- 2.02 A. 5. Unless otherwise noted, all valves larger than 3-in nominal diameter shall be provided with position indicators at the point of operation. EQUIPMENT DESIGN AND FABRICATION Manual Valve Actuators 1. Unless otherwise noted, valves shall be manually actuated; non- buried valves shall have an operating wheel, unless otherwise shown or specified. The lever type operators may be supplied on quarter-turn type valves, 2-inches and smaller, if recommended by the valve manufacturer. Buried valves and those with operating nuts shall have a non-rising stem with an AWWA 2-in square nut. 2. Except as otherwise shown on the Drawings or specified herein, all valves 3-in diameter or larger, with the valve center line located 6.54 or more above the operating floor, shall be provided with chain wheel operators complete with chain guides and 316SS chain, which loop within 4-ft of the operating floor. 3. Gear Actuators a. Unless otherwise noted, gear actuators shall be provided for the following: 1) All valves of larger than 4-in nominal diameter; 2) All buried valves with operating shaft mounted horizontally (butterfly, plug, etc.); 3) Where specified and/or indicated on the Drawings; 4) Where manual operator effort is greater than 40 ft-lbs rim pull. b. Gear actuators shall be of the worm or helical gear type with output shaft perpendicular to valve shaft, having a removable hand wheel mounted on the output shaft. Unless noted, they shall conform to AWWA C504, except with butterfly valves, they need not be certified. c. Actuators shall be capable of being removed from the valve without dismantling the valve or removing the valve from the line. d. Gearing shall be machine-cut steel designed for smooth operation. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -7- e. f. 9. h. I. j. Bearings shall be enclosed and permanently lubricated, with bronze bearing bushings provided to take all thrusts and seals and to contain lubricants. Housings shall be sealed to exclude moisture and dirt, allow the reduction mechanisms to operate in lubricant and be of the same material as the valve body unless otherwise noted. Manual operator input effort to the handwheel shall be a maximum of 40 ft-lbs for operating the valve from full open to full close, under any conditions. Gear actuators shall indicate valve position and have adjustable stops. Maximum handwheel size shall be 24-indiameter. Minimum handwheel size shall be 8-in diameter. Operators located beneath trench grating shall be 2-inch square nut gear operators. B. Electric Valve Actuators 1. General a. Components shall include motor, integral reversing starter, gear box, local or remote control facilities (as specified), control enclosure, limit switches, torque switches, terminals for remote interface signals, and manual override hand wheel with de-clutching lever, except where otherwise noted or specified. b. Actuators shall comply with the requirements of AWA C540. c. The actuator shall be sized to guarantee valve closure at the maximum anticipated operating condition. The safety margin of motor power available for seating and unseating the valve shall be sufficient to ensure torque switch trip at maximum valve torque with the supply voltage 10% below normal, or 1.5 times the maximum valve operating torque required, whichever is greater. d. Actuator shall be capable of operation at ambient temperatures between 22°F - 158°F. e. Motor rating and power supply shall be as specified. Protective features shall include the following unless otherwise specified: (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -a- External, above grade power disconnect switch. Motor shall be de-energized in the event of a stall when attempting to unseat a jammed valve. Motor temperature shall be sensed by a thermostat to protect against overheating. Single phasing protection. Adjustable maximum torque setting between 40 and 100% of rated torque. Type El and E2 actuators shall have syncrophase protection No heaters, breathers or vents. Enclosures to be suitably protected. f. Gearing: Actuator gearing shall be totally enclosed in an oil-filled gear case suitable for operation at any angle. Actuators shall be permanently lubricated at the factory. Type El and E2 actuators shall incorporate a lost motion hammerblow feature. For rising spindle valves the output shaft shall be hollow to accept a rising stem and incorporate thrust bearings of the ball or roller type at the base of the actuator. All main drive gearing and components shall be of metallic construction. Arrangement shall permit the inspection and/or disassembly of the gear case without releasing the stem thrust or taking the valve out of service. For Type El and E2 actuators in 1/4 turn applications, use suitable gearbox with multi-turn motordrive. g. Manual Operation: For non-fail safe valves, a hand wheel drive independent of the motor drive shall be provided for emergency operation, engaged when the motor is de-clutched by a lever or similar means. It should be possible to select hand operation while the actuator is running or start the actuator motor while the handlauto selection lever is locked in the hand position without damage to the drive shaft. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -9- h. Controls: All actuator controls shall be modular with plug in sections. Enclosure rating shall be NEMA 6 submersible to IP68, 10 feet of water for 48 hours. Local operator interface units shall be integral or remote mounted, as noted or shown. Provide a digital or mechanical indicator that provides continuous visual indication of valve position. Where noted or shown, provide the following: a) LOCAL-OFF-REMOTE selector switch or pushbuttons. b) OPEN-STOP-CLOSE pushbuttons, for local control of the valve in the LOCAL operating mode. c) LED indicating lights for valve fully OPEN and fully CLOSED positions. Remote Interface: a) Where noted or shown, provide 2 wire control signals for the following: (1) Valve in REMOTE operating mode. (2) Valve in LOCAL operating mode. (3) Valve OPEN (limit switch selectable over the full operating range of the valve). (4) Valve CLOSED (limit switch selectable over the full operating range of the valve). b) Where noted or shown, accept remote control signals to control the actuator in REMOTE operating mode: (1) OPEN. (2) STOP (stop the actuator in mid-travel) (3) CLOSE. Integral Starter and Transformer: (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -10- a) The reversing starter and control transformer shall be integral with the valve actuator, suitably housed to prevent breathing and condensation build up. b) The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal. 2. Quarter-Turn Electric Motor Actuators for OPENlCLOSE Service (Type El): a. General: Where indicated, electric motor actuators shall be the AC reversing type complete with local or remote mounted control station (as indicated) with OPENlCLOSE and LOCAUREMOTE selector switches or pushbuttons and OPENlCLOSE indicating lights. b. Setting of torque, turns and configuration of the indicating contacts shall be performed without opening or removing the any compartment covers, by using a infra-red setting tool. 1) The contractor shall provide one infra-red setting tool with this project. c. Control Stations: When a remote control station is specified or shown, the actuator shall be furnished without integral controls, or with the integral control station permanently disabled so that there is no control interference between the remote control station and actuator mounted integral controls. Integral control stations shall be rated NEMA 6 in accordance with the actuator enclosure requirements. Remote control stations that are panel mounted shall be rated NEMA 4X, minimum. d. Motor: 1) Power Supply: 480 volt, 3 phase, 60 Hz. 2) Construction: NEMA Class H insulation, totally enclosed, high starting torque, non-ventilated. 3) Duty: 15 minutes, or twice the valve stroking time, whichever is greater at 104°F and an average load of at least 33 percent maximum valve torque. 15100 - 11 - (Carlsbad Water) (Recycling Facility) (2-1-02) 3. 4) Rating: NEMA 6 submersible to IP68, 10 feet of water for 48 hours. 5) Actuator motor to be protected by a thermostat in the motor winding. e. Starter: 1) The starter shall be a suitably sized amperage rated reversing starter with its coils rated for operation on 480- volt, 3-phase, 60-Hz current. 2) A control power transformer shall be included to provide a 120-volt source, unless otherwise indicated. 3) The starter shall be equipped with 3 overload relays of the automatic reset type. Its control circuit shall be wired as indicated. f. Manufacturers: 1) Rotork; IQ 2) Or Approved Equal. Multi-Turn Electric Motor Actuators for Modulating Service (Type E2): a. General: Where indicated, modulating electric motor actuators shall be the AC modulating type complete with a remote control station with OPENISTOPICLOSE, LOCAUOFFIREMOTE control functions and OPENICLOSED indication functions. b. Motor: 3) 4) (Carlsbad Water) (Recycling Facility) (2-1-02) Power Supply: 480 volt, 3 phase, 60 Hz. Construction: NEMA Class H insulation, totally enclosed, high starting torque, non-ventilated. Duty: 30 minute. Rating: NEMA 6 submersible to IP68, 10 feet of water for 48 hours. Actuator motor to be protected by a thermostat in the motor winding. 15100 -12- c. Starter: 1) The actuator shall control a solid-state reversing starter designed for minimum susceptibility to power line surges and spikes. 2) The solid-state starter and control module shall be rated for a maximum of 1200 starts per hour. 3) Power supply shall be 480-volt, 3-phase, 60-Hz. d. Construction: 1) The actuator shall contain an integral position control system capable of receiving an external input setpoint signal for valve position control. 2) The actuator shall be matched to the valve and have such integral feedback controls to insure that a control resolution of 1 percent of valve opening or better can be achieved. 3) In addition, the controller shall contain as standard features a loss of command signal protection selectable to lock in last or lock in preset valve position and a valve position output signal for remote indication. e. Manufacturers: 1) Rotork; IQ 2) Or Approved Equal 4. Quarter-Turn Fail Safe Spring Return Electric Actuators (Type E4): a. Where indicated, valves shall be fitted with a fail safe spring return electric motor actuator. b. The valves shall fail safe in the OPEN position on loss of power or control signal, unless otherwise indicated or specified. c. Design Requirements: 1) The valves shall have a maximum opening differential pressure of 50 psig. 2) Actuators shall be sized to produce at least 1.5 times the operating torque required. (Carlsbad Water) 15100 (Recycling Facility) -13- (2-1-02) 3) The actuators shall be self-contained units consisting of electric motor, integral reversing contractor starter, high torque internal spring return, brake, gearbox, limit switches, travel stops, and other devices as specified. d. Operating Requirements: With power ON, the OPEN control signal shall cause the electric motor to drive the valve gear train that in turn shall wind an integral spring return device. An internal limit switch shall deenergize the motor and energize the brake to holds the spring device in position. With power ON, the CLOSE control signal shall close the valve using the electric motor. On loss of power or control signal, the brake shall be de- energized and the spring shall drive the valve OPEN. Operating time shall be a maximum of 10 seconds from fully OPEN to fully CLOSED, or the reverse. e. Motors shall operate on 120-volt, I-phase, 60Hz power. f. Controls: 1) The actuator shall include a LOCAUOFFlREMOTE weatherproof selector switch, OPENlCLOSE weatherproof pushbuttons, and replaceable LED indicating lights that will indicate if the valve is either in the fully OPEN or fully CLOSED position. 2) The controls for each valve shall be remote mounted on a local panel as indicated on the Drawings. 3) Provide Form C dry contacts for LOCAL, REMOTE, fully OPEN, and fully CLOSED status indication. g. Actuators shall be as manufactured by RCS Texsteam, Inc., or equal. C. Pneumatic Valve Operators 1. Designation: PI a. Description: General service quarter turn butterfly and ball valves b. Operating Conditions: Install where noted or shown (Carlsbad Water) 15100 (Recycling Facility) - 14 - (2-1-02) c. Design Requirements: 2.03 A. Cylinder actuators shall have working mechanism fully enclosed, and shall be sized for operation using 80 psig pneumatic supply. Cylinder actuators shall have pilot valves where indicated on the drawings. Units shall have adjustable end position stops All valve actuators shall include limit switches unless otherwise shown or specified. Pneumatic actuators shall be capable of producing a minimum of 1.5 times the required operating torque. Provide valve disc position indicator on operator. d. Materials: 1) Actuator Body: Aluminum 2) Piston: Nylon or Aluminum 3) Seals: Nitrile or EPDM. 4) Pinion Shaft: Carbon Steel e. Manufacturers: 1) Keystone, Model 79U 2) Bray, Series 90/91 3) Ultraflow, Ultratorq. EQUIPMENTAND COMPONENTS Globe Style Control Valves 1. Designation: FCVI. a. Description: High performance, linear cage guided globe valve with one-stage anti-cavitation trim. b. Operating Conditions: 1) Service: RO concentrate control valve(s). (Carlsbad Water) {Recycling Facilh) (2-1-02) 15100 - 15- 2) Flow: 42 - 100 gpm. 3) Maximum Inlet Pressure: 300 psig. 4) Minimum Outlet Pressure: Atmosphere. c. Design Requirements: 1) Valve Size: 1 112-inch. 2) Minimum Valve Coefficient (Cv): 2.5 3) Maximum Valve Coefficient (Cv): 19.0 4) Sound Pressure Level: 65 dB(A), Maximum measured 3 feet downstream of valve and 3 feet from the pipe surface, at any point in the valve operating range. d. End Connections: Flanged, raised face, ANSI Class 300 standard. e. Actuator: Power, Type 2E as specified herein. f. Materials: Body: Type 316 stainless steel. Bonnet: Type 316 stainless steel. Cage Retainers: Type 316 stainless steel. Cage: 17-4 PH. Seat Ring: 17-4 PH. Plug: Heat Treated type 420 stainless steel, Packing: PTFE. Bolting: Type 316 stainless steel. g. Manufacturers: 1) Fisher, Design ET with one stage Cavitroll 111 trim; 2) Masoneilan, Model 41512; 3) Or equal. B. Butteffly Valves (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -16- 1. Designation: BFVl. a. Description: Low pressure, general service process isolation valve in sizes up to 24-inches. Valve shall be suitable for corrosive service conditions. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Body: Single piece design. 2) Seats: Fully replaceable, covering all wetted portions of the valve body. Seats shall extend to the flange interface to provide sealing without the use of a gasket. Seats shall provide an internal seal with the disckhaft. 3) Shaft shall be single piece design. 4) Maximum Operating Pressure: 175 psig. 5) Rated Operating Temperature: 73" F. d. End Connections: Lugged, ANSI Class 150 standard drilling e. Actuator: Manual or power, as shown on the Drawings and Valve Schedule. f. Manual Actuators: 1) For 2-inch Valves: Lever actuator, 10-position with positive latching. 2) For Valves over 2-inches: Rotary manual actuator. g. Materials: 1) Body: Cast iron; ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings, Class B. 2) Disc and Shaft: Stainless steel, Type 316; ASTM A351 - Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex) for Pressure-Containing Parts, Grade CF8M. 3) Seats: EPDM, food grade 4) Stem Seal: EPDM or PTFE (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 17- 5) Fasteners: Type 316 stainless steel. h. Manufacturers: 1) Dezurik, BRS; 2) Bray, Series 31; 3) Or equal. 2. Designation: BFVI-PI. a. b. C. d. e. f. Description: Low pressure, general service process isolation valve in sizes up to 24-inches with pneumatic valve actuator. Valve shall be suitable for corrosive service conditions. Operating Conditions: Install where noted or shown, Design Requirements: Body: Single piece design. Seats: Fully replaceable, covering all wetted portions of the valve body. Seats shall extend to the flange interface to provide sealing without the use of a gasket. Seats shall provide an internal seal with the disckhaft. Shaft shall be single piece design. Maximum Operating Pressure: 175 psig. Rated Operating Temperature: 73" F. End Connections: Lugged, ANSI Class 150 standard drilling. Actuator: Pneumatic valve actuator PI Manual Actuators: 1) For 2-inch Valves: Lever actuator, IO-position with positive latching. 2) For Valves over 2-inches: Rotary manual actuator. Materials: 1) Body: Cast iron; ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings, Class B. 15100 - 18 - (Carlsbad Water) (Recycling Facility) (2-1-02) 2) Disc and Shaft: Stainless steel, Type 316; ASTM A351 - Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex) for Pressure-Containing Parts, Grade CF8M. 3) Seats: EPDM, food grade. 4) Stem Seal: EPDM or PTFE, 5) Fasteners: Type 316 stainless steel. h. Manufacturers: 1) Dezurik, BRS; 2) Bray, Series 31; 3) Or equal. 3. Designation: BFV2 a. Description: High performance, high-pressure butteffly valve. Valve shall be suitable for corrosive service conditions. b. Operating Conditions: install where noted or shown. c. Design Requirements: 1) Valve shall provide drip-tight shutoff to the full valve rating on dead end or isolation service without a downstream flange. 2) Shaft shall be a single piece design. 3) Seal shall incorporate an externally adjustable packing gland. 4) Maximum Operating Pressure: 720 psig. 5) Rated Operating Temperature: 73" F. d. End Connections: Lugged, ANSI Class 300 standard drilling. e. Actuator: Manual or power, as shown on the Drawings and Valve Schedule. f. Manual Actuators: (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 19- 1) For 2-inch Valves: Lever actuator, IO-position with positive latching. 2) For Valves over 2-inches: Rotary manual actuator. g. Materials: Body: Type 316 stainless steel, ASTM A351 - Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex) for Pressure-Containing Parts, Grade CF8M. Disc: Type 316 stainless steel, ASTM A351 - Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex) for Pressure-Containing Parts, Grade CF8M. Shaft: 17-4 PH, ASTM A564 - Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes, Type 630. Seats: PTFE, replaceable. Seals: V-type packing, carbon graphitelbraided carbon. Bearings: Stainless steelhickel alloy. Fasteners: Type 316 stainless steel. h. Manufacturers: 1) Dezurik, BHP; 2) Bray, Series 43; 3) Or equal. 4. Designation: BFV3 a. Description: Low pressure, general service process isolation valve in sizes up to 24-inches. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Body: Single piece design. 2) Seats: Fully replaceable, covering all wetted portions of the valve body. Seats shall extend to the flange (Carlsbad Water) (Recycling Facility) (2-1-02) 151 00 -20- interface to provide sealing without the use of a gasket. Seats shall provide an internal seal with the disclshaft. 3) Shaft shall be single piece design. 4) Maximum Operating Pressure: 175 psig. 5) Rated Operating Temperature: 73" F. d. End Connections: Lugged, ANSI Class 150 standard drilling. e. Actuator: Manual or power, as shown on the Drawings and Valve Schedule. f. Manual Actuators: 1) For 2-inch Valves: Lever actuator, IO-position with positive latching. 2) For Valves over 2-inches: Rotary manual actuator. g. Materials: 1) Body: Cast iron: ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings, Class B. 2) Disc and Shaft: Aluminum Bronze; ASTM B148-954. 3) Seats: EPDM, food grade. 4) Stem Seal: 304 Stainless Steel ASTM A276 Type 304. 5) Fasteners: Type 316 stainless steel. h. Manufacturers: 1) Dezurik, BRS; 2) Bray, Series 31; 3) Or equal C. Ball Valves 1. Designation: BVI a. Description: PVC ball valve in sizes up to 2-inches. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -21 - b. C. d. e. f. 9. Operating Conditions: Install where noted or shown. Design Requirements: 1) Maximum Operating Pressure: 150 psig. 2) Rated Operating Temperature: 73' F. End Connections: Union inlet and outlet fittings with socket weld pipe interface for Schedule 80 PVC. Actuator: Manual, lever type. Materials: 1) Body: PVC. 2) Ball: PVC. 3) Stem: PVC. 4) Seats: EPDM, replaceable. 5) Seals: PTFE or Viton. Manufacturers: 1) George Fisher Plus; 2) Hayward; 3) Or equal. 2. Designation: BV2. a. Description: Three-piece stainless steel ball valve, in sizes up to 2-inches. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Maximum Operating Pressure: 1000 psig. 2) Rated Operating Temperature: 200' F. d. End Connections: 1000 WOG, FNPT. e. Actuator: Manual, lever type. (Carlsbad Water) 15100 (Recycling Facility) -22 - (2-1-02) f. Materials: 1) Body: Stainless steel, Type 316; ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes or ASTM A351 - Standard Specification for Castings, Austenitic, Austenitic-Ferritic (Duplex) for Pressure-Containing Parts, Grade CF8M. 2) Ball: Type 316 stainless steel. 3) Stem: Type 316 stainless steel. 4) Seats: Reinforced PTFE. 5) Seals: Reinforced PTFE. g. Manufacturers: 1) Milwaukee; 2) Contromatics; 3) Or equal. 3. Designation: BV3. a. Description: Three-piece brass ball valve, in sizes up to 2- inches. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Maximum Operating Pressure: 600 psig 2) Rated Operating Temperature: 200' F. d. End Connections: 600 WOG, conforming to MSS SP-110 - Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends. e. Actuator: Manual, lever type. f. Materials: 1) Body: Brass; ASTM B30 - Standard Specification for Copper Alloys in Ingot Form. 2) Ball: Hard Chrome plated brass ball (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -23- 3) Stem: Brass; ASTM B30 - Standard Specification for Copper Alloys in Ingot Form. 4) Seats: Glass reinforced Durafill. 5) Seals: PTFE. 6) Bolting: Type 316 stainless steel. g. Manufacturers: 1) Watts Series B-6000; 2) Or equal. D. Check Valves 1. Designation: DCVI a. Description: Molded-diaphragm type PVC check valve used in instrument bypass loops with 2-piece, union nut body. b. ' Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Maximum Operating Pressure: 150 psig 2) Rated Operating Temperature: 73 "F d. End Connections: FNPT. e. Check Mechanism: Asymmetric diaphragm. f. Materials: 1) Body: PVC, ASTM D1784, Type I, Gradel. 2) Diaphragm: EPDM. 3) Seats: PVC, ASTM D1784, Type I, Grade 1 4) Seals: Teflon. g. Shall be as manufactured by: 1) Plast-0-Matic, Series CKM; 2) Or Equal. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -24 - 2. Designation: BCV3. a. Description: Ball check valve integral to chemical injection quill; see equipment specification for requirements. 3. Designation: BCV4 a. Description: CPVC ball check valve in sizes up to I-inch. b. Operating Conditions: Install where noted or shown c. Design Requirements: 1) Design Pressure: 150 psig. 2) Design Temperature: 73 OF. d. End Connections: Union pipe fittings. e. Check Mechanism: Spring assisted ball. f. Materials: 1) Body: CPVC, normal impact class 23477-B, Type IV, Grade 1, Schedule 80; ASTM Dl784 - Standard Specification for Rigid Poly(Viny1 Chloride) (PVC) Compounds and Chlorinated Poly(Viny1 Chloride) (CPVC) Compounds. 2) Ball: Same as body. 3) Spring: Type 316 Stainless steel. 4) Seats: EPDM, food grade. 5) Seals: EPDM, food grade. g. Manufacturers: 1) AsahVAmerica Inc.; 2) Or Equal. 4. Designation: SCVl a. Description: Double-door, stainless steel wafer type check valve for general service in sizes up to 12-inches. b. Operating Conditions: Install where noted or shown. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -25- c. Design Requirements: 1) Maximum Operating Pressure: 275 psig 2) Rated Operating Temperature: 150' F 3) Rated Valve Coefficient (CV): Valve Size [inches] Minimum Cv 3 160 4 320 6 840 8 3000 12 2500 10 1500 Valve Size [inches] hAin I .-, I 12 d. End Connections: Wafer style, to fit between ANSI Class 150 flanges. e. Check Mechanism: Dual spring-assisted swing plates. f. Materials: 1) Body: Cast Iron, 2) Plates: Bronze 3) Shaft: Type 316 stainless steel, 4) Seals: EPDM, full face, secured to the valve plates by Type 316 stainless steel clamp plates and fasteners; field replaceable. 5) Fasteners: Type 316 stainless steel. g. Manufacturers: 1) Techno, Series 5051; 2) Mueller Steam Specialty; 3) Or equal 5. Designation: SCV2. a. Description: Double-door, stainless steel wafer type check valve for high-pressure service in sizes up to 12-inches. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 26 - b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Maximum Operating Pressure: 720 psig, 2) Rated Operating Temperature: 150' F 3) Rated Valve Coefficient (CV): ~~~~ ~~ Valve Sizeinches] Minimum Cv 3 160 4 320 6 840 8 1500 10 2500 12 3000 I I d. End Connections: Wafer style, to fit between ANSI Class 300 flanges. e. Check Mechanism: Dual spring-assisted swing plates. f. Materials: 1) Body: Type 316 stainless steel. 2) Plates: Type 316 stainless.steel. 3) Shaft: Type 316 stainless steel. 4) Seals: EPDM, full face, secured to the valve plates by Type 316 stainless steel clamp plates and fasteners; field replaceable. 5) Fasteners: Type 316 stainless steel. g. Manufacturers: 1) Techno, Style 5053-316; 2) Mueller Steam Specialty, Model 74; 3) Or equal. 6. Designation: SCV3. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 27 - a. b. C. d. e. f. Description: Double-door, stainless steel wafer type check valve for general service in sizes up to 12-inches. Operating Conditions: Install where noted or shown. Design Requirements: 1) Maximum Operating Pressure: 275 psig. 2) Rated Operating Temperature: 150' F 3) Rated Valve Coefficient (Cv): Valve Size [inches] Minimum Cv 3 3000 12 2500 10 1500 8 840 6 320 4 160 End Connections: Wafer style, to fit between ANSI Class 150 flanges. Check Mechanism: Dual spring-assisted swing plates. Materials: 1) Body: Type 316 stainless steel. 2) Plates: Type 316 stainless steel. 3) Shaft: Type 316 stainless steel. 4) Seals: EPDM, full face, secured to the valve plates by Type 316 stainless steel clamp plates and fasteners; field replaceable. 5) Fasteners: Type 316 stainless steel. Manufacturers: 1) Techno, Series 5051-316; 2) Mueller Steam Specialty, Model 72; 3) Or equal (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -28 - 7. Designation: SCV5. a. b. C. d. e. f. 9. Description: PVDF check valve in sizes 1 %-inches to 3- inches. 1) Valve shall be suitable for corrosive service conditions. 2) Valve shall be a self-closing design suitable for installation in any position and requiring minimum 1 .O psi differential for unseating. 3) Body shall be a three-piece union nut design Operating Conditions: Install where noted or shown. Design Requirements: 1) Maximum Operating Pressure: 150 psig. 2) Rated Operating Temperature: 150' F 3) Rated Valve Coefficient (CV): End Connections: FNPT Check Mechanism: Check mechanism shall consist of a spring-loaded poppet mechanism, which deflects under pressure to allow flow and returns to position to seal flow. Materials: 1) Body: PVDF 2) Seats: PVDF 3) Seals: Viton. 4) Spring: Corrosion resistant Teflon PFA encapsulated stainless steel. Manufacturers: 1) Plast-0-Matic Series CKS, 2) Or equal E. Vacuum Relief Valves 1. Designation: VBV4. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -29- a. Description: I-inch ball-spring type stainless steel vacuum relief valve used on RO Train pipe headers. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Valve shall be suitable for corrosive service conditions. 2) Relief mechanism shall consist of a spring-loaded ball. 3) Valve shall be suitable for direct flow, low-profile installation in vertical orientation in grooved fitting pipe cap. 4) Maximum Operating Pressure: 400 psig. 5) Rated Operating Temperature: 75 OF d. End Connections: MNPT for treading into header pipe cap. e. Materials: 1) Body: Type 316 stainless steel. 2) Retaining Ring: Type 316 stainless steel 3) Spring: Type 316 stainless steel. 4) Seals: Viton. f. Manufacturer: 1) Durabla Fluid Technologies, Model BSSV6, 2) Johnson, 3) Or equal. 2. Designation: VBV5. a. Description: Molded-diaphragm type PVC vacuum relief valve used in instrument bypass loops and chemical storage tanks with 2-piece. union nut body. b. Operating Conditions: Install where noted or shown c. Design Requirements: (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 30 - 1) Maximum Operating Pressure: 100 pSig 2) Rated Operating Temperature: 75' F 3) End Connections: FNPT 4) Relief Mechanism: Self-sealing asymmetric diaphragm d. Materials: 1) Body: PVC, ASTM D1784, Type I, Grade 1 2) Diaphragm: EPDM 3) Seats: PVC, ASTM D1784, Type I, Grade 1 4) Seals: Teflon e. Shall be as manufactured by Plast-0-Matic, Series VBM; Or equal. 3. Designation: VBVG. a. Description: Molded-diaphragm type PVDF vacuum relief valve for sizes 2 inches and smaller. 1) Valve shall be suitable for corrosive service conditions Relief mechanism shall consist of a spring loaded poppet seal. b. Operating Conditions: Install where noted or shown c. Design Requirements: 1) Maximum Operating Pressure: 100 psig 2) Rated Operating Temperature: 75' F 3) End Connections: FNPT 4) Relief Mechanism: Self-sealing asymmetric diaphragm d. Materials: 1) Body: PVDF 2) Diaphragm: Viton 3) Seats: PVDF (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 31 - 4) Seals: Viton 5) Spring: PFA encapsulated steel e. Shall be as manufactured by Plast-0-Matic, Series VBM; Or equal. F. Pressure Relief Valves 1. Designation: PRV4, a. Description: Chemical injection line safety relief valve. Furnished by the chemical pump supplier-see equipment specification for requirements. 2. Designation: PRV5. a. Description: Chemical transfer line safety relief valve. Relieves pressures up to 60 psig. Adjustable relief pressure. PVC body construction with flanged ends. Relief pressure adjustable by a set screw and securable with a lock nut. Mechanical parts isolated from the process fluid. G. Pressure RegulatinglControl Valves 1. Designation: BPR3. a. Description: Chemical injection line backpressure regulator. Furnished by the chemical pump supplier-see equipment specification for requirements. H. Pressure Control Valves 1. Designation: PCV2 a. Description: Instrument sample service, PVC body pressure regulating valve. b. Operating Conditions: Install where noted or shown c. Design Requirements: 1) Maximum Operating Pressure: 150 psig 2) Rated Operating Temperature: 75' F d. End Connections: FNPT e. Adjustable Range: 5 to 75 psig (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 32 - f. Materials: 1) Body: PVC 2) Adjusting Nut, Stem and Spring: Type 316 stainless steel 3) Shaft: Teflon 4) Seals: Viton, rolling diaphragm style 5) Resilient Seat: Viton 6) Boiting: Type 316 stainless steel g. Shall be as manufactured by Plast-0-Matic, Series PR; Or equal I. Sample Valves 1. Designation: SI. a. Description: Two-piece 114-inch PVC sample valve with hose fitting outlet. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Maximum Operating Pressure: 150 psig 2) Rated Operating Temperature: 70' F d. End Connections: 1) Valve Body: FNPT x FNPT 2) Inlet/Outlet Fittings: MNPT inlet with hose outlet. e. Actuator: Manual, graduated handle. f. Materials: 1) Body: PVC, Type I, Grade 1; ASTM Dl784 - Standard Specification for Rigid Poly(Viny1 Chloride) (PVC) Compounds and Chlorinated Poly(Viny1 Chloride) (CPVC) Compounds. 2) Ball: Same as body. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 33 - 3) Stem: Same as body. 4) Seats: EPDM, replaceable 5) Seals: EPDM. g. Manufacturers: 1) Hayward, Universal Stopcock; 2) Or equal. J. Diaphragm Valves 1. Designation: DPVI a. Description: Chemical service, PVDF lined ductile iron weir type valve. b. Operating Conditions: Install where noted or shown. c. Design Requirements: I) Valve body shall be weir style. 2) Valve (including external coating) shall be suitable for the intended chemical service application. 3) Valve shall be complete with manual handwheel, permanently lubricated, with position indication and adjustable travel stop. 4) Maximum Operating Pressure: 175 psig. 5) Rated Operating Temperature: 120 "F d. End Connections: Flanged, raised face, ANSI Class 150 standard. e. Actuator: Manual. f. Materials: 1) Body: PVDF lined and coated ductile iron 2) Bonnet: PVDF coated cast iron, sealed. 3) Diaphragm: EPDM backed PTFE. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 34 - 4) Stem: Steel. 5) Compressor: Cast iron. 6) Tube Nut: Type 316 stainless steel, 7) Bonnet Seals: EPDM. 8) Bolting: Type 316 stainless steel. g. Manufacturer: 1) IT Dia-Flo, Model 2555; 2) Alfa LavallSaunders, Model 3450; 3) Or equal. 2. Designation: DPV2. a. Description: Chemical service, stainless steel weir type valve. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Valve body shall be weir style. 2) Valve shall be complete with manual handwheel, permanently lubricated, with position indication and adjustable travel stop. 3) Maximum Operating Pressure: 175 psig. 4) Rated Operating Temperature: 120 OF d. End Connections: Butt weld, Schedule 40; or Flanged, flat face, ANSI Class 150 standard. e. Actuator: Manual. f. Materials: 1) Body: Type 316 (316L for butt weld fittings) stainless steel. 2) Bonnet: PVDF coated cast iron, sealed 3) Diaphragm: EPDM backed PTFE (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 - 35 - 4) Stem: Steel. 5) Compressor: Cast iron. 6) Tube Nut: Bronze. 7) Bonnet Seals: EPDM. 8) Bolting: Type 316 stainless steel. g. Manufacturer: 1) ITT Dia-Flo, Model 2433/2466; 2) Alfa LavallSaunders, Model 2306 (modified)/3306; 3) Or equal. 3. Designation: DPV3. a. Description: Chemical service, PVDF weir type valve. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Valve body shall be weir style. 2) Valve shall be complete with manual handwheel, permanently lubricated, with position indication and adjustable travel stop. 3) Maximum Operating Pressure: 120 psig 4) Rated Operating Temperature: 140 "F d. End Connections: Spigot weld (un-pigmented); or Flanged, flat face, ANSI Class 150 standard. e. Actuator: Manual. f. Materials: 1) Body: PVDF. 2) Bonnet: Polypropylene. 3) Diaphragm: EPDM backed PTFE 4) Stem: Steel. (Carlsbad Water) 15100 (2-1-02) (Recycling Faciliiy) - 36 - 5) Compressor: Cast iron or PVDF. 6) Tube Nut: Bronze or Stainless steel 7) Bonnet Seals: EPDM. 8) Bolting: Type 316 stainless steel. g. Manufacturer: 1) 177 Dia-Flo, Model 244712487; 2) AsahVAmerica, Type 72/G; 3) Or equal. 4. Designation: DPV4. a. Description: Chemical service, polypropylene weir type valve. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Valve body shall be weir style. 2) Valve shall be complete with manual handwheel, permanently lubricated, with position indication and adjustable travel stop. 3) Maximum Operating Pressure: 11 0 psig. 4) Rated Operating Temperature: 120 OF d. End Connections: Spigot weld; or Flanged, flat face, ANSI Class 150 standard. e. Actuator: Manual. f. Materials: 1) Body: Polypropylene. 2) Bonnet: Polypropylene 3) Diaphragm: EPDM backed PTFE 4) Stem: Steel 5) Stem Bushing: Bronze (Carlsbad Water) 15100 (Recycling Facility) - 37 - (2-1-02) 6) Compressor: Cast iron or PVDF. 7) Tube Nut: Bronze or Stainless Steel. 8) Bonnet Seals: EPDM. 9) Bolting: Type 316 stainless steel. g. Manufacturer: 1) ITT Dia-Flo, Model 2444/2484; 2) AsahiIAmerica, Type 72/G 3) Or equal. K. Multiport Valves 1. Designation: MPVl a. Description: Stainless steel, 5-way rotating plug type valve. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Valve shall incorporate detent positioning (mechanical stops at 90" positions) and a 4-position numbered nameplate suitable for panel mounting. 2) Body shall be a two piece design. 3) Lever shall be asymmetric handle type. 4) Maximum Operating Pressure: 1000 psig. 5) Rated Operating Temperature: 450 OF. d. End Connections: 1000 WOG, %-inch FNTP. e. Actuator: Manual. f. Materials: 1) Body: Stainless steel, ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes, Type 316. 2) Rotor: Type 316 stainless steel (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -38- 3) Lever: Type 316 stainless steel. 4) Seats: PTFE. 5) Seals: Viton. g. Manufacturer: 1) Conant Controls, Model 5316; 2) Or equal. L. Needle Valves 1. Designation: NDVI a. Description: Needle type flow control valve integral to rotameter-type flow element; see equipment specification for requirements. M. Combination AirNacuum Valves 1. Designation: CAVI a. Description: Combination air/vacuum valve for non-corrosive service. b. Operating Conditions: Install where noted or shown. c. Design Requirements: 1) Minimum Pressure Rating: 1,000 psi 2) Rated Operating Temperature: 120' F d. Materials: 1) Body: ASTM A126-B cast iron 2) Seat Ring: Resilient Buna-N 3) Float Ball: Stainless steel e. Combination aidvacuum valves shall be of the single body, double orifice design. The large orifice assembly air and vacuum valve shall automatically exhaust air from a pipeline during the initial filling of the pipeline. The large orifice assembly shall not blow shut while exhausting air, even while venting air at sonic velocity. When all air has been exhausted (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -39- from the pipeline, the large orifice float ball shall be buoyed up to seat tightly against a resilient seat ring. The large orifice float ball shall remain tightly closed while the pipeline is under positive pressure. Should the pipeline pressure fall below atmospheric pressure (such as during draining or a line break), the large orifice float ball shall automatically fall away from the seat ring and permit air to enter the pipeline. f. The body inlet shall be baffled to protect the lower float from direct contact or the rushing air and water to prevent premature shutoff. The float ball shall be center-guided for positive shutoff in the seat. g. Units shall be a small orifice (air release) valve mounted on a large orifice air/vacuum valve of the proper type and size as noted on the Drawings. The small orifice will open to allow small pockets of air to escape automatically and independently of the large orifice. h. The small orifice valve shall be piped to the body of the large orifice valve by non-corrosive piping equal in size to the small orifice inlet connection. An isolating stop valve (with operator removed) shall be furnished between the small and large orifice valves. i. One piece units performing all functions may be utilized, as acceptable to the Engineer. Component valves shall be as previously specified and by one manufacturer. 1) Unit shall be APCO series 140/150 or equal by GA; Val- Matic or equal. 2.04 INSTRUMENTATION AND CONTROLS A. Requirements 1. The CONTRACTOR shall coordinate with respective manufacturer’s of mechanical and electrical systems associated with the valves furnished to ensure all required functionality is incorporated and resolve any signal and control interface discrepancies. 2. Where required, the CONTRACTOR shall furnish additional devices and interface components in accordance with requirements under Divisions 13 and 16. 2.05 SPARE PARTS (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -40 - A. 2.06 A. 6. C. D. E. F. 2.07 A. 2.08 A. Provide all manufacturer recommended spare parts for equipment furnished. SHOP PAINTING If not specified herein, coatings shall comply with the requirements of Section 09940. In case of a conflict, the requirements of this Section govern. If the manufacturer's requirement is not to require finished coating on any interior surfaces, then manufacturer shall so state and no interior finish coating will be required, if acceptable to the Owner's Representative. The exterior surface of various parts of valves, operators, floor-stands and miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease or other foreign matter and thereafter one shop coat of an approved rust-inhibiting primer shall be applied in accordance with the instructions of the paint manufacturer or other primer compatible with the finish coat provided. Unless otherwise noted, interior ferrous surfaces of all valves shall be given a fusion bonded epoxy coating per Section 09900. Ferrous surfaces obviously not to be painted shall be given a shop coat of grease or other suitable rust-resistant coating. Mounting surfaces shall be especially coated with a rust preventative. Special care shall be taken to protect uncoated items and plastic items, especially from environmental damage. SPECIAL TOOLS Provide all special tools required for normal maintenance. Tools shall be packaged in a steel case, clearly and indelibly marked on the exterior to indicate equipment for which tools are intended. LUBRICANTS Provide all lubricants required for equipment startup and initial operations. PART 3 - EXECUTION 3.01 DELIVERY AND INSTALLATION A. All valves and appurtenances shall be installed per these Specifications, the manufacturer's instructions and approved shop drawings in the (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -41 - B. C. 0. E. F. G. 3.02 A. B. locations shown, true to alignment and rigidly supported. Any damage to the above items shall be repaired to the satisfaction of the Owner before they are installed. Install all brackets, extension rods, guides, the various types of operators and appurtenances as required. Before setting these items, the CONTRACTOR shall check all Drawings and figures which have a direct bearing on their location. The CONTRACTOR shall be responsible for the proper location of valves and appurtenances during the fabrication of all CONTRACTOR supplied items on which valves are installed. All materials shall be carefully inspected for defects in construction and materials. All debris and foreign material shall be cleaned out of openings, etc. All valve flange covers shall remain in place until connected piping is in place. All operating mechanisms shall be operated to check their proper functioning and all nuts and bolts checked for tightness. Valves and other equipment that do not operate easily, or are otherwise defective, shall be repaired or replaced at no additional cost to the Owner. Unless otherwise noted, joints for valves and appurtenances shall be made up utilizing the same procedures as specified under the applicable type connecting pipe joint and all valves and other items shall be installed in the proper position as recommended by the manufacturer. The CONTRACTOR shall be responsible for verifying manufacturers' torque requirements for all valves. In horizontal pipe runs centered less that 4""' above the operating floor, orient valve stems as close to vertical as permitted by adjacent piping. In horizontal pipe runs centered between 4'6" and 6'-6 above the operation floor, orient the valve stems as close to horizontal as permitted by adjacent piping. In vertical pipe runs, orient the valve stems in the most accessible position for operation from the operating floor. COMMISSIONING See also Division 1. Take care not to over pressure valves or appurtenances during pipe testing. If any unit proves to be defective, it shall be replaced or repaired to the satisfaction of the Owner's Representative. No testing shall be performed until the manufacturer's service engineer has provided written certification that the installed equipment has been examined and found to be in complete accordance with the manufacturer's requirements. (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -42 - C. Functional Test: Prior to plant startup, all items shall be inspected for proper alignment, quiet operation, proper connection and satisfactory performance. All units shall be operated continuously while connected to the attached piping for at least 48 hours, without vibration, jamming, leakage, or overheating and perform the specified function. D. The various pipe lines in which the valves and appurtenances are to be installed are specified to be field tested. During these tests any defective valve or appurtenance shall be adjusted, removed and replaced, or otherwise made acceptable to the Owner's Representative. E. Various regulating valves, strainers, or other appurtenances shall be tested to demonstrate their conformance with the specified operational capabilities and any deficiencies shall be corrected or the device replaced or otherwise made acceptable to the Owner's Representative. 3.03 OPERATOR TRAINING A. The CONTRACTOR shall provide training of the Owner's operations and maintenance personnel for the valves and appurtenances supplied as specified in Section 01400. 3.04 ACCEPTANCE TESTING A. Acceptance testing of valves and related appurtenances will be conducted as part of the overall system acceptance testing as specified in Section 01650. 3.05 MANUFACTURERS ASSISTANCE A. Field Services 1. A factory trained field representative of valve and component manufacturers shall be present at the jobsite or other accepted location to certify proper installation and provide instruction to the Owner's personnel. End Of Section (Carlsbad Water) (Recycling Facility) (2-1-02) 15100 -43 - SECTION 15100 VALVE SCHEDULE i VALVESANDAPPURTENANCES I I - ~~ .. ~ ." "~t" ~~ ~ .. pipe material, pipe size, ~ ~~~~~~ -. . .~. ~ ~ ~~ ~~~ ~~ 15100 Valve Schedule Page A - 1 02/01/2002 "" 1~~ size. .. I Page A - 2 02/01/2002 i ~ "" - ~ "_ 1. Untagged valves shall match pipe material,ylpe-size, - - and pipe pressure rating " "" I Valve Tag Number Size (inches) Notes I 1 13 I RDD? - V- . . V-I 190-2 2 V-I 190-3 2 BVI - I V-I 190-5 2 BVI i v-1190-6 2 , BVI \I-1 1 an"m 1 I R\II ". BVI - ~ V-I 190-7 1 ~ BVI I I V-1190-18 1 12 BVI V-I 190-27 1 I2 i BVI VI 190-28 1 12 BVI VI 190-1 9 1 12 I BV1 v-I 1%" I '1 IMstch Size of pipeline Match si7e of pipeline ' pipeline Matcn me of niceline V-I 190-22 I " V-I 190-23 " BVI v-119c " " . Match size of pipeline IMatch size of pipeline IMatch size of pipeline i 'Match si7e nf pipeline r-r-~~ ~- - ~__ DR\/A I Matcn swe of pipeline ' pipeline Match +i7e nf pipeline "t-" RPR? I -4- . . ." - I V-I 182-5 1 BVI V-I 182-8 1 BVI I V-I 182-25 1 12 "" V-I 182-27 ~ 112 BV1 V-I 182-23 1 12 BVI " -~ ~ 1"" size of pipeline " ~- ~- ~.. ~~~. latch size of pipeline I 15100 Valve Schedule Page A - 3 02/01/2002 AND APPURTENANCES SECTION 15100 - "" VALVE SCHEDULE 7"- 1"- -~ i 15100 Valve Schedule Page A - 4 02/01/2002 15100 Valve Schedule Page B - 1 02/01/2002 SECTION 15100 J~_.---~VALVES AND APPURTENANCES I -- - ~ ~ "" VALVE SCHEDULE ." ~ General Notes: ! j pipe material, pipe size, __~~___~ I -~ i _".". Notes IV-0915-1 I 1/2 I BVI ~ V-0915-2 ~ 1 14 SI I 15100 Valve Schedule Page B - 2 02/01/2002 -~ "" SECTION 15100 ~~~ . VALVESANDAPPURTENANCES - VALVE SCHEDULE "" +-- ~~~. . .. ~ I 15100 Valve Schedule Page B - 3 02/01/2002 SECTION 15100 AND APPURTENANCES ~ -1 , VALVES VALVE SCHEDULE . . ". . " -~ ~~ " . - ~ - ." .. "" .~ - 1 I I " shall matci pipe material, bipFsize, ~ ~~ ~ ~ -. .. . - .. .. I" . " .. .. ." 15100 Valve Schedule Page B - 4 02/01/2002 ." ~.. SECTION 15100 VALVE SCHEDULE I VALVES AND APPURFNZCES . " "" ~ "" "" ~~ 15100 Valve Schedule Page B - 5 02/01/2002 VALVES ANDTPPURTENANCES SECTION 15100 ___ I VALVE SCHEDULE - "" "7" " ~- I 02/01/2002 SECTION 15100 - VALVESANDAPPURTENANCES 7""- ~ "~ VALVE SCHEDULE- " - ~- General Notes: 1"~ 1. Untagged valves shall match pipe material, pipesize, ~" and pipe pressure rating. j I 4- "" I ValveTaa 1 I Actuator I Number- I Size (inches)) Code I Notes V-1171-1 3 1 DPV2 1 /2 PRV4 " ~ " 15100 Valve Schedule Page B - 7 02/01/2002 - "~ SECTION 15100 - - i VALVES ~ AND APPURTENANCES VALVE SCHEDULE " - -. . ". .. . " General Notes: .- valve I Valve Tag Actuator Number Size (inches) Code Notes V-I 178-1 1 1 ~ DPV4 V-1178-12 DPV4 1 1 12 V-I 178-1 3 DPV4 ~ 1 12 V-1178-14 DPV2 I 1 12 V-I 178-1 5 DPV2 1 12 V-1178-16 DPV2 1 12 V-1178-17 DPV2 V-I 178-1 9 1 12 PRV4 1 12 V-I 178-1 8 DPV2 1 12 15100 Valve Schedule Page B - 8 02/01/2002 SECTION 15140 PIPE HANGERS AND SUPPORTS PART 1 - GENERAL 1.01 DESCRIPTION A. Description of Work 1. The Contractor shall furnish all labor, materials, equipment and incidentals and install a complete system of pipe hangers and supports including all metallic hanging and supporting devices for supporting non-buried piping as shown on the Drawings and as specified herein. Any deviations from the design shown on the drawings shall be in accordance with these Specifications. 2. The absence of pipe supports and details on the Contract Drawings shall not relieve the Contractor of the responsibility for providing them. 6. Reference Specifications 1. Section 09940 - Protective Coatings 2. Division 15 - Mechanical 1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC) A. Manufacturer's Qualifications 1. Pipe hangers and supports shall be fabricated and installed by experienced welders and fitters, using the best welding procedures available. Fabricated supports shall be neat in appearance without sharp corners, burrs, and edges. 2. All hangers, supports and appurtenances shall conform to the latest applicable requirements of ANSVASME 631.1 - Power Piping, except as supplemented or modified by the requirements of this Specification. 6. Reference Standards: Comply with the applicable provisions and recommendations of the following, except as otherwise shown and specified. 1. Manufacturer's Standardization Society (MSS) a. MSS SP-58, Pipe Hangers and Supports, Materials and Design (Carlsbad Water) (Recycling Facility) (1-25-02) 15140 -1 - b. MSS SP-69, Pipe Hangers and Supports, Selection and Application c. MSS SP-89, Pipe Hangers and Supports, Fabrication and Installation Practices d. MSS SP-90, Guidelines on Terminology for Pipe Hangers and supports 2. American Society for Testing and Materials (ASTM) a. ASTM A36, Structural Steel b. ASTM A276, Stainless Steel Bar Stock c. ASTM A307, Carbon Steel Externally and Internally Treaded Standard Fasteners d. ASTM A774, Stainless Steel Butt Weld Type Fittings e. ASTM A778, Welded, Unannealed Austenitic Stainless Steel Tubular Products 3. American National Standards Institute (ANSI) a. ANSVASME B31 .I, Power Piping 1.03 SUBMllTALS A. Submit to the Owner's Representative as provided in Section 01300, complete sets of shop drawings of all items to be furnished under this Section. Shop drawings shall include the following information: 1. Drawings of all pipe supports, hangers, anchors, and guides showing dimensions, spacing, material and accessories. 2. Calculations for all supports and anchors. 3. Complete layouts, schedules, location plans and complete total bill of materials for all pipe supports including the additional pipe supports required for the existing piping in the RO trench. 4. Provide detailed information on connectors, bolts and anti-seize compound. 1.04 PRODUCT DELIVERY STORAGE AND HANDLING (Carlsbad Water) (Recycling Facility) (I -25-02) 15140 -2- A. B. C. D. All supports and hangers shall be crated, delivered and uncrated so as to protect against any damage. All parts shall be protected so that no damage or deterioration shall occur during a prolonged delay from the time of shipment until installation is complete. Any finished metal surfaces not galvanized, not of stainless steel construction, or that are not coated, shall be grease coated, to prevent rust and corrosion. Other Coatings: Other than stainless steel or non-ferrous supports, all supports (including galvanized supports) shall receive protective coatings in accordance with the requirements of Division 9. PART 2 - PRODUCTS 2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE - NOT USED 2.02 EQUIPMENT DESIGN AND FABRICATION A. Fabrication and Material Requirements 1. General a. Where flexible couplings are require'.^ d at equipment, tanks, etc. the end opposite to the piece of equipment, tank, etc. shall be rigidly supported, to prevent transfer of force systems to the equipment. No fixed or restraining supports shall be installed between a flexible coupling and the piece of equipment. b. All pipe and appurtenances connected to the equipment shall be supported in a manner to prevent any strain from being imposed on the equipment or piping system. c. Where pipe hangers and supports come in contact with piping provide protection from galvanic corrosion by; wrapping pipe with 1II6-in thick neoprene sheet material or PVC coated hangers and supports except as shown on the'drawings. d. All uninsulated non-metallic piping, such as PVC and FRP, shall be protected from local stress concentrations at each support point. Protection shall be provided by 316 stainless steel protection shields. 2. Stainless Steel Piping Support System: (Carlsbad Water) (Recycling Facility) (1 -25-02) 15140 -3- a. For all stainless steel piping, pipe supports shall be 316 stainless steel with neoprene isolators between the pipe and support components. b. All stainless steel piping shall be isolated from all ferrous materials, including galvanized steel by use of neoprene sheet material and protection shields. 3. For all other pipe not specified above, use 316 stainless steel pipe supports. 4. Submerged Supports: a. All submerged piping, as well as piping, conduits, and equipment in hydraulic structures within 24 inches of the water level and piping trenches, shall be supported with support, assemblies, including framing, hardware, and anchors, constructed of Type 316 stainless steel, unless otherwise indicated. 5. Corrosive: a. All piping in chemical and corrosive areas shall be supported with support assemblies, including framing, hardware, and anchors, constructed of FRP with Type 316 stainless steel fasteners, unless otherwise indicated. 6. Anchor Bolts: a. Provide stainless steel bolts complying with ASTM A 320 - Standard Specification for SteeVAlloy Bolting Materials for Low Temperature Service, Type 316. b. When the size, length, or load carrying capactty of an anchor bolt or expansion anchor is not shown on the Drawings, the Contractor shall provide the size, length, and capacity required to carry the design load times a minimum safety factor of four. B. Equipment Design Requirements 1. Determine design loads as follows: a. Equipment anchors: use the design load recommended by the manufacturer and approved by the Owner’s Representative, b. Vibration allowances: included in the safety factor specified above. (Carlsbad Water) (Recycling Faciliiy) (1-25-02) 15140 -4- 2. Unless othelwise approved by the Owner's Representative, expansion anchors shall not be used. 3. The dimensions specified above shall be increased if necessaty to accommodate required anchor load capacity. 4. Code Compliance a. All piping systems and pipe connections to equipment shall be properly anchored and supported to prevent undue deflection, vibration, dislocation due to seismic events and line pressures, and stresses on piping, equipment, and structures. b. All supports and parts thereof shall conform to the requirements of ANWASME B31 .I - Power Piping, except as supplemented or modified below. c. Supports for plumbing piping shall be in accordance with the latest edition of the applicable plumbing code or local administration requirements. 5. Support Spacing a. Support spacing for all 4-inch and larger PVC pipe shall be a maximum of 6-feet. For PVC pipe less than 4-inch, support spacing shall be a maximum of 3-feet. b. Support shall be provided for all 316 stainless steel header assembly piping at each RO train. Support shall be in accordance with the specifications and as shown on the Contractor's approved shop drawings. c. The absence of pipe supports and details on the Drawings shall not relieve the Contractor of the responsibility for providing them. C. Manufacturers: 1. Basic Engineer's Inc., Pittsburgh, PA; 2. Bergen-Paterson Pipesupport Corp., Woburn, MA; 3. Grinnell Corp. (Supply Sales Company), Cranston, RI; 4. NPS Products, Inc., Westborough, MA; 5. Power Piping Company, Pittsburgh, PA; (Carlsbad Water) (Recycling Facility) (1-25-02) 15140 -5- 6. Unistrut Northeast, Cambridge, MA. 7. Or Equal. 2.03 EQUIPMENT AND COMPONENTS A. Structural Members 1. Wherever possible, pipes shall be supported from structural members. Where it is necessary to frame structural members between existing members, such supplementary members shall be provided by the Contractor at no additional cost to the Owner. 2. All supplementary members shall be in accordance with the requirements of the building code and the American Institute of Steel Construction and shall be acceptable to the Owner's Representative. B. Pipe Hangers 1, 2. 3. 4. 5. 6. Pipe hangers shall be capable of supporting the pipe in all conditions of operation, allowing free expansion and contraction of the piping, and preventing excessive stress on equipment. All hangers shall have a means of vertical adjustment after erection. Hangers shall be designed to prevent becoming disengaged by any movement of the supported pipe. Hangers subject to shock, seismic disturbances, or thrust imposed by the actuation of safety valves, shall include hydraulic shock suppressors. All hanger rods shall be subject to tensile loading only. Hangers Subject to Horizontal Movements: a. At hanger locations where lateral or axial movement is anticipated, suitable linkage shall be .provided to permit such movement. b. Where horizontal pipe movement is greater than 1/2-inch, or where the hanger rod deflection from the vertical is greater than 4 degrees.from the cold to the hot position of the pipe, the hanger rod and structural attachment shall be offset in such a manner that the rod is vertical in the hot position. (Carlsbad Water) (Recycling Facility) (1-25-02) 15140 -6- C. D. E. F. G. H. Spring-Type Hangers 1. Spring-type pipe hangers shall be provided for piping subject to vibration or vertical expansion and contraction, such as engine exhausts and similar piping. 2. All spring-type hangers shall be sized to the manufacturer's printed recommendations and the loading conditions encountered. 3. Variable spring supports shall be provided with means to limit misalignment, buckling, eccentric loading, or to prevent overstressing of the spring, and with means to indicate at all times the compression of the spring. 4. Supports shall be capable of accommodating at least 4 times the maximum travel due to thermal expansion. Thermal Expansion Provisions 1. Wherever expansion and contraction of piping is expected, a sufficient number of expansion loops or joints shall be provided, together with the necessary rolling or sliding supports, anchors, guides, pivots, and restraints permitting the piping to expand and contract freely in directions away from the anchored points. 2. All components shall be structurally suitable to withstand all loads imposed. Heat Transmission: Supports, hangers, anchors, and guides shall be so designed and insulated, that excessive heat will not be transmitted to the structure or to other equipment. Riser Supports: Where practical, risers shall be supported on each floor with riser clamps and lugs, independent of the connected horizontal piping, Supports for Freestanding Piping 1. Free-standing pipe connections to equipment such as chemical feeders and pumps shall be firmly attached to steel frames fabricated from angles, channels, or I-beams anchored to the structure. 2. Exterior, free-standing overhead piping shall be supported on fabricated pipe stands consisting of pipe columns anchored to concrete footings, with horizontal, welded steel angles and U-bolts or clamps securing the pipes. Special Considerations for Plastic Piping Systems (Carlsbad Water) (1 -25-02) (Recycling Facility) 15140 -7- 1. Any meters, valves, heavy equipment, and other point loads on PVC, FRP, and other plastic pipes, shall be supported on both sides, according to manufacturer's recommendations to avoid undue pipe stresses and failures. 2. To avoid point loads, all supports on PVC, FRP, and other plastic piping shall be equipped with extra wide pipe saddles or stainless steel shields. 1. Manufactured Supports 1. Where not specifically indicated, designs which are generally accepted as exempllfying good engineering practice and use stock or production parts, shall be utilized wherever possible. 2. Such parts shall be locally available, new, of best commercial quality, designed and rated for the intended purpose. PART 3 - EXECUTION 3.01 DELIVERY AND INSTALLATION A. General 1. All pipe supports, hangers, brackets, anchors, guides, and inserts shall be fabricated and installed in accordance with the manufacturer's printed instructions and ANWASME 831 .I, Power Piping. 2. All concrete inserts for pipe hangers and supports shall be coordinated with the formwork. 3. Apply anti-seize compound to all nuts and bolts. Supports without the approved compound shall be dismantled and correctly installed, at no cost to the Owner. B. Appearance and Accessibility 1. Pipe supports and hangers shall be positioned to produce an orderly, neat piping system. 2. All hanger rods shall be vertical, without offsets. (Carlsbad Water) (1-25-02) (Recycling Facility) 15140 -8- 3. Hangers shall be adjusted to line up groups of pipes at the proper grade for drainage and venting, as close to ceilings or roofs as possible, without interference with other work. 4. Installed systems shall not interfere with maintenance and operational access to any equipment installed under this Section, or any other Section of this Specification. 5. All pipes, horizontal and vertical, requiring rigid support shall be supported from the building structure by approved methods. Supports shall be provided at changes in direction and elsewhere as shown in the Drawings or specified herein. No piping shall be supported from metal stairs, ladders and walkways unless specifically directed or authorized by the Owner’s Representative. 6. Continuous metal inserts shall be embedded flush with the concrete surface. C. Painting 1. Paint hangers, supports, anchors, and similar devices as specified in Section 09940. 2. Clean and touch-up painting of field welds, bolted connections and abraded areas as specified in Section 09940. 3.02 COMMISSIONING A. All pipe support systems shall be tested for compliance with the Specifications. After installation, each pipe support system shall be tested in accordance with the respective piping pressure tests. + + END OF SECTION + + (Carlsbad Water) (1-25-02) (Recycling Facility) 15140 -9- L STEEL PIPE CLRYP TYPE-I ROJ. SWIVEL RINC TYPE-IO anm TYPE Q HANGERS AND SUPPORTS la ELACKW~TCH FIG 1-15140(AI Caremratlorn 1 ! 1 CONSIRNT SUPPORT TRRPEZE TIPE TYPE-64 HANGERS AND SUPPORTS L .... Division 16 Electrical Section 16050 ELECTRICAL Data Sheet 'ara- install equipment and wiring devices - -1 lnph Data Description (i. yes General furnished By Owner r NO r N~ -2.01 li Yes General Equipment Requirements F Units - -3 Listed or labeled by approved Cable identification with wire - 4.02 Yes testing laboratory r No li markers Heat shrink type with custom typed numbers r Seif-laminating write-on type Power Service Entrance -1 - G Yes Power Service Entrance required r NO devices Power entrance and metering I- Meter board, socket and test cabinet r Meter transformer cabinet Disconnect, ground, counduit and fittings r Other When "Other is selected, indicate alternative Underground materials required r Trenching and backfill r Ducts r Senice cables r Concrete r Other alternative When "Othef is selected, indicate pelephone Service Entrance .2 - heieDhone Service Entrance ic vOc - (requ'ired I(i. No . " (Carlsbad Water) (Recycling Facility) 16050 -1- t I I Telephone entrance box Conduit. weathered and termination termination board Underground conduit with plywood ~4flby4R[1.2mby1.2m] r 4 R by 8 R (1.2 m by 2.4 m] r Other When "Other is selected, indicate alternative Cable Products 301 - Yes Lighting Cable required r No Lighting Cable Types THHN-THWN Figure 1-16050 for 10 and 12 AWG, larger, XHHW Figure 2-16050 for 0 AWG and Figure 3-16050 for 8 AWG and r larger, MHN-THWN r largsr, RHKRHW-USE Figure 13-16050 for 8 AWG and '-3.02 L Yes 600 volt Power Cable required r No Power Cable types P Figure 2-16050 for XHHW r Figure 3-16050 for THHN-THHW r Figure 13-16050 for RHH-RHW-USE '-3.03 - Yes Instrument Cable required r No Instrument Cable types P Figure 5-16050 for single triad I7 Figure 4-16050 for single pair Figure 6-16050 for multiple pair and/or triad Multiconductor Control Cable required Yes Figure 816050 for 12 AWG THHN- Figure 7-16050 for 14 AWG THHN- Control Cable types r No ' THWN THWN Medium Voltage Power Cable r Figure 9-16050 for 8 kv EPR Medium Voltage Power Cable types required r Yes No Figure 10-16050 for 15 kV EPR (Carlsbad Water) (Recycling Facility) 16050 -2- bray Cable required Jr Yes 1 No Tray Cable types I- Figure 11-16050 for 3 cond XLP r Figure 12-16050 for 1 cond XHHW -3.07 - r Yes (Figure 14-16050) Metal Clad Lighting Cable required No Raceways 4 P Rigid steel conduit Raceways required r lntenediate metal conduit I7 Liquidtight flexible metal conduit r Utility (PVC) duct P Rigid nonmetallic (PVC) conduit F PVC coated rigid steel conduit r Electrical metallic tubing (EMT) r Rigid aluminum conduit (RAC) r Other alternative When "Other" is selected, indicate Lighting Panels 8 - Yes Lighting Panels required r No capacity at rated voltage Minimum breaker interrupting amp [AI 10,000 r 22,000 r Other When "other" is selected, indicate alternative Power Panels amp [AI ,9 - Yes Power Panels required (r NO ith neutral Yes r No Minimum breaker interrupting capacity at 240 volts r 10,ooo amp [AI r 22,000 65.000 Minimum breaker interrupting capacity at 277 volts C 14,000 amp [AI r 25,000 65,000 (Carlsbad Water) (Recycling Facility) 16050 -3- capacity at 480 volts c ~5.000 65,000 Buses F Insulated neutral F Ground bus r Remomble bond to neutral bus Transient Voltage Sume Suppression Suppression required - - 2-10 Transient Voltage Surge r Yes (i Mr. /Motor Starters (Motor Starters required Yes No Minimum NEMA size (3 phase) Size 0 Size I Minimum starter interrupting 14,000 capacity at 480 volts (3 phase) 25,000 I I I 65.000 Minimum starter interrupting 10,wo capacity at 240 volts (I phase) 22,000 Manual Starters \Manual Starters required IC Yes No Control Stations 2-13 Control Stations required Yes r No II Break Glass switches required (i hln I If "Yes" is selected, Emergency r Yes , ." Circuit Breakers 2-14 Circuit Breakers required r Yes I I No I I I IMinirnurn breaker interrupting I 14.000 bmp [AI I at 480 volts . I 25,000 .~ ~ 65,000 Disconnect Switches 2-15 Disconnect Switches required Yes (Carlsbad Water) (Recycling Facility) 16050 -4- 2-16 ransformers required r NO G Yes ~. Power Centers 2-17 r Yes Power Centers required G No Power Factor Capacitors 2-18 r Yes Power Factor Capacitors required G No Photoelectric Controls 2-20 G Yes Photoelectric Controls required r No (Relay Enclosures \Relay Enclosures required Is Yes r No Alarm Horn and Beacon 2-22 C Yes Alarm Horn and Beacon required i= No Heat-Traced Piping 2-23 r Yes Heat traced piping required G No Door Entry Switches 2-24 r Yes Door Entry Switches required G No ~~ I /Coordination Report 3-1 /Coordination Report required Yes Ir No /Power and TeleDhone Service I I Entrances Instailation 3-2 Ms. Diana Ames Electric Utilitv contact Derson and San Diego Gas 8 Electric Name of Electric Utility telephone number ' Name of Telephone Utility and telephone number Telephone Utility contact person Cable Installation 3-4 procedure required Underground cable pulling r Yes G No When "Yes" is selected, indicate Circuit Numbers. Cable insulation testing required r Yes 1s NO (Conduit Installation (Carlsbad Water) (Recycling Facility) 16050 -5- 3-5 t specified locations Rigid steel (Carlsbad Water) (Recycling Facility) 16050 -6- Section 16050 ELECTRICAL PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing and installation of all equipment and materials needed for the electrical requirements of this contract. It alSO covers conduit, wiring, and terminations for electrical equipment installed under Section 16100. This section covers the installation of electrical equipment furnished under other sections, except electrical items designated to be installed under those sections. When required, this section covers installation of equipment furnished by OWNER. Both inch-pound (English) and SI (metric) units of measurement are specified herein; the units of measurement shall be as indicated on the top of the Data Sheet. 14.01. Teninoloqy. When the phrase "as required" is stated in this section it shall mean "as required in the Data Sheet". 1-2. GENERAL. Electrical apparatus on all equipment shall be installed complete and placed in readiness for proper operation. Electrical materials furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. 1-2.01. General EauiDment Reauirements. When required, the General Equipment Requirements shall apply to all equipment provided under this section. 1-2.02. Coordination. Electrical work shall conform to the construction schedule and the progress of other trades. 1-2.03. Anchor Bolts and ExDansion Anchors. Unless otherwise specified or indicated on the drawings, all anchor bolts, nuts, and washers installed in the Electrical Building shall be hot-dip galvanized. All anchor bolts, nuts, and washers installed outdoors shall be Type 316 stainless steel. Anchor bolts shall be at least 3/4 inch [I9 mm] except a smaller size will be permitted to match (Carlsbad Water) 16050 (Recycling Facility) -7- NEMA standard size boltholes on motors and electrical equipment, subject to the Seismic requirements specified herein. When expansion anchors are indicated on the drawings, only an acceptable expansion anchor shall be used. Alternative anchoring systems may be used only when acceptable to ENGINEER. Expansion anchors shall be installed in conformity with the manufacturer's recommendations for maximum holding power, but in no case shall the depth of the hole be less than six bolt diameters. The minimum distance between the center of any expansion anchor and an edge or exterior corner of concrete shall be at least six times the diameter of the bolt. Unless otherwise indicated on the drawings, the minimum distance between the centers of expansion anchors shall be at least 12 times the diameter of the bolt. Nuts and washers for expansion anchors shall be as specified for anchor bolts. 1-2.04. Drawinas. Supplementing this section, the drawings indicate locations of equipment and enclosures and provide one-line and schematic diagrams regarding the connection and interaction with other equipment. 1-2.05 Seismic Consideration. The anchoring of equipment and materials shall be designed in accordance with the requirements for Seismic Zone 4 of UBC. 1-3. CODES AND PERMITS. All work shall be performed and materials shall be furnished in accordance with the NEC - National Electrical Code, the NESC - National Electrical Safety Code, and the following standards where applicable: ANSI ASTM Fed Spec KEA IEEE IES NEMA NFPA UL American National Standards Institute. American Society for Testing and Materials. Federal Specification. Insulated Cable Engineers Association. Institute of Electrical and Electronics Engineers. Illuminating Engineering Society. National Electrical Manufacturers Association. National Fire Protection Association. Underwriters' Laboratories. When required, equipment covered by this section shall be listed by UL, or by a nationally recognized third party testing laboratory. All costs associated with obtaining the listing shall be the responsibility of CONTRACTOR. If no third- (Carlsbad Water) (Recycling Facility) 16050 -8- party testing laboratory provides the required listing, an independent test shall be performed at CONTRACTOR'S expense. Before the test is conducted, CONTRACTOR shall submit a copy of the testing procedure to be used. 1-4. IDENTIFICATION. 1-4.01. Conduit. Conduits in manholes, handholes, building entrance pull boxes, junction boxes, and equipment shall be provided with identification tags. Identification tags shall be 19 gage [I mm] thick stainless steel, with 112 inch [13 mm] stamped letters and numbers as indicated on the drawings. Identification tags shall be attached to conduits with nylon tie wraps and shall be positioned to be readily visible. 14.02. Cable. Except for lighting and receptacle circuits, each individual wire in power, control, indication, and instrumentation circuits shall be provided with identification markers at the point of termination. The wire markers shall be of the heat-shrinkable tube type, with custom typed identification numbers. The wire numbers shall be as indicated on the equipment manufacturer's drawings. The wire markers shall be positioned to be readily visible for inspection. Power wires shall be color coded with electrical tape or colored wire jacket; white-N, black, and red for 120/240 volt, 3-wire; and gray-N, brown, orange and yellow for 480/277 volt, 4-wire circuits. 1-4.03. Motor Starters. Not used. 14.04. Control Stations. Control stations shall be provided with nameplates identifying the related equipment. Pilot controls and indicating lights shall have engraved or etched legends ("start", "stop", etc.) as indicated on the drawings. Nameplates shall be laminated black-over-white plastic, with 1/8 inch [3 mm] engraved letters, and shall be securely fastened to the control stations. 1-4.05. Circuit Breakers. Not used. 1-4.06. Disconnect Switches. All switches shall have front cover-mounted permanent nameplates that include switch type, manufacturer's name and catalog number, and horsepower [kW] rating. An additional nameplate, engraved or etched, laminated black-over-white plastic, with 1/8 inch [3 mm] letters, shall be provided to identify the associated equipment. Both nameplates shall be securely fastened to the enclosure. 1-5. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with complete engineering data covering the materials used, parts, (Carlsbad Water) 16050 (Recycling Facility) -9- devices, and accessories forming a part of the WORK PERFORMED BY THE CONTRACTOR, shall be submitted in accordance with the submittals section. The drawings and data shall include, but shall not be limited to, the following: Drawings and data. Seismic requirements. Operating manuals. Samples. 1-5.01. Submittal Identification. Information covering all materials and equipment 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. Lamp fixture descriptive sheets shall show the fixture schedule letter, number, or symbol for which the sheet applies. b. Equipment and materials descriptive literature and drawings shall show the specification paragraph for which the equipment applies. c. Sheets or drawings covering more than the item being considered shall have all inapplicable information crossed. d. A suitable notation shall identify equipment and materials descriptive literature not readily cross-referenced with the drawings or specifications. e. Schematics and 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. CONTRACTOR shall submit the name and qualifications of the Engineering and Testing Services firm proposed to perform the coordination study and the on site testing. Within 90 days after the Notice to Proceed, CONTRACTOR shall furnish a submittal for all types of cable and conduit to be provided. The submittal shall include the cable manufacturer and type, and sufficient data to indicate that the cable and conduit meet the specified requirements. In addition to the complete specifications and descriptive literature, a sample of the largest size of each type of cable shall be submitted for review before (Carlsbad Water) (Recycling Facility) 16050 -1 0- installation. Each sample shall include legible and complete surface printing Of the cable identification. 1-6. PROTECTION AND STORAGE. During construction, the insulation on all electrical equipment insulation shall be protected against absorption of moisture, and metallic components shall be protected against corrosion by strip heaters, lamps, or other suitable means. This protection shall be provided immediately upon receipt of the equipment and shall be maintained continuously. PART 2 - PRODUCTS 2-1. POWER SERVICE ENTRANCE. CONTRACTOR shall consult the local electric utility regarding their service installation requirements, and shall furnish the service equipment in compliance with these requirements. Refer to the switchboard one-line diagram. Provide all materials and labor as required by the utility for the complete service installation. When required, power service equipment shall include meter board, meter socket, meter test cabinet, metering transformer cabinet, disconnect means, grounding materials, and riser conduits and service entrance fittings required by the utility and for compliance with codes and regulations. When required for underground services, trenching and backfill, ducts, service cables, and concrete for duct banks and transformer pads shall be furnished. 2-2. TELEPHONE SERVICE ENTRANCE. Not used. 2-3. CABLE. All cables of each type (such as lighting cable or 600 volt power cable) shall be from the same manufacturer. All types of cable shall conform to the Cable Data Figures at the end of this section and as described herein. 2-3.01. Liahtina Cable. When required, lighting cable (Figure 1-16050 THHN-THWN) shall be provided only in lighting and receptacle circuits operating at 277 volts or less. Lighting and receptacle circuits, 8 AWG [IO mm2] or larger, shall be as specified for 600 volt, Figure 2-16050, XHHW power cable as required. 2-3.02. 600 Volt Power Cable. When required, cable in power, control, indication, and alarm circuits operating at 600 volts or less, except where lighting, multiconductor control, and instrument cables are permitted, shall be 600 volt, Figure 2-16050, XHHW power cable as required. 2-3.03. Instrument Cable. When required, cable for electronic circuits to instrumentation, metering, and other signaling and control equipment shall be two- or three-conductor instrument cable twisted for magnetic noise rejection and (Carlsbad Water) 16050 (Recycling Facility) -1 1- protected from electrostatic noise by a total coverage shield. Types of instrument cables shall be Figure 4-16050, single pair, or Figure 5-16050, single triad, as required. 2.3.04. Multiconductor Control Cable. When indicated on the drawings or when required, cable in control, indication and alarm circuits shall be multiconductor. Cable shall be Figure 7-16050, 14 AWG THHN-THWN as required. 2-3.05. Medium Voltaae Power Cable. Not used. 2-3.06. Trav Cable. Not used 2-3.07. Metal Clad Liahtinq Cable. Not used. 2-4. CONDUIT. When required, conduit and raceways shall be as described in the following paragraphs: 24.01. Riaid Steel Conduit. Rigid steel conduit shall be heavy wall, hot-dip galvanized, shall conform to Fed Spec WW-C-581 and ANSI C80.1, and shall be manufactured in accordance with UL 6. 2-4.02. Intermediate Metal Conduit (IMC). Not used 2-4.03. Liauidtiaht Flexible Metal Conduit. Liquidtight flexible metal conduit shall be hot-dip galvanized steel, shall be covered with a moistureproof polyvinyl chloride jacket, and shall be UL labeled. 2-4.04. Utilitv IPVC) Duct. Not used 2-4.05. Riaid Nonmetallic (PVC) Conduit. PVC conduit shall be heavy wall, Schedule 40, UL labeled for aboveground and underground uses, and shall conform to Fed Spec W-C-1094, NEMATC-2, and UL 651. 24.06. PVC-Coated Riaid Steel Conduit. The conduit shall be rigid steel. Before the PVC coating is applied, the hot-dip galvanized surfaces shall be coated with a primer to obtain a bond between the steel substrate and the coating. The PVC coating shall be bonded to the primed outer surface of the conduit. The bond on conduit and fittings shall be stronger than the tensile strength of the PVC coating. The thickness of the PVC coating shall be at least 40 mils (1000 pm]. A chemically cured two-part urethane coating, at a nominal 2 mil [50 pm] thickness, shall be applied to the interior of all conduit and fittings. The coating shall be sufficiently flexible to permit field bending the conduit without cracking or flaking of the coating. Every female conduit opening shall have a PVC sleeve extending one conduit diameter or 2 inches 150 mm], whichever is less, beyond the opening. The inside (Carlsbad Water) 16050 (Recycling Facility) -12- diameter of the sleeve shall be the same as the outside diameter of the conduit before coating. The wall thickness of the sleeve shall be at least 40 mils [IO00 pm]. All fittings, condulets, mounting hardware, and accessories shall be PVC-coated. All hollow conduit fittings shall be coated with the interior urethane coating described above. The screw heads on condulets shall be encapsulated by the manufacturer with a corrosion-resistant material. PVC coated rigid steel conduit shall be manufactured by Ocal, Perma-Cote, or Robroy. 2-4.07. Electrical Metallic Tubina (EMT). Not used. 2-4.08. Rioid Aluminum Conduit (RAC). Not used 2-5. WIRING DEVICES, BOXES, AND FITTINGS. Concealed conduit systems shall have flush-mounted switches and convenience outlets. Exposed conduit systems shall have surface-mounted switches and convenience outlets. 2-5.01. Conduit Boxes and Fittinos. a. Galvanized or cadmium plated, threaded, malleable iron, or aluminum when required, boxes and fittings shall be manufactured by Crouse-Hinds, Appleton, or 0 Z Gedney. b. Rigid PVC device boxes and fittings shall be manufactured by Carlon or Cantex. c. Sheet steel device boxes shall be manufactured by Appleton, Raco. or Steel City. d. PVC coated device boxes shall be manufactured by Ocal, Perma-Cote, or Robroy Industries. e. Hub arrangements on threaded fittings shall be the most appropriate for the conduit arrangement to avoid unnecessary bends and fittings. 2-5.02. Device Plates. a. Galvanized or cadmium-plated device plates shall be used on surface mounted outlet boxes where weatherproof plates are not required. b. Device plates on flush mounted outlet boxes where weatherproof plates are not required shall be AIS1 Type 302 stainless steel, Eagle "93nnn series", Hubbell "S series", or Leviton "840nn-40 (Carlsbad Water) (Recycling Facility) 16050 -13- series"; nylon or polycarbonate, Eagle "513nV series", Hubbell "Pn series", or Leviton "807nn-I series". c. Device plate mounting hardware shall be countersunk and finished to match the plate. d. Device plates for switches outdoors or indicated as weatherproof - shall have provisions for padlocking switches "On" and "Off", and shall be Appleton "FSK-lVS, Crouse-Hinds "DS185" or 0 Z Gedney "FS-1-WSCA. e. Device plates for receptacles indicated as weatherproof shall be Appleton "FSK-WRD", Crouse-Hinds 'WLRDl", or 0 2 Gedney "FS-1-WDCA. f. Flush-mounted, weatherproof plates shall be provided with adapter plates, Appleton "FSK-SBA or Crouse-Hinds "FS031". g. Device plates for ground fault interrupter receptacles outdoors or indicated to be weatherproof shall be Appleton "FSK-WGFI", Eagle "966, or 0 Z Gedney "FS-1-GFCA. h. Engraved device plates, where required, shall be manufactured by Leviton, or equal. I. Device plates on PVC conduit fittings shall be Carlon "E98 Series" or Cantex "513300 Series". 2-5.03. Wall Switches. a. Switches on ac lighting panel load circuits through 277 volts shall be 20 amperes, 120/277 volts, Eagle "2221V' through "2224V', Hubbell "HBL 12211" through "HBL 12241", or Leviton "1221-21" through "1224-21". b. Switches for pulse control of lighting contactors shall be 15 amperes, 120Q77 volts, momentary, double-throw, center "Off', Eagle "1220V', Hubbell "15561" or Leviton "1256-1". 2-5.04. ReceDtacies. a. Standard convenience outlets shall be duplex, three-wire, grounding, 20 amperes, 125 volts, Eagle "5362V', Hubbell "53621" or Leviton "5362-1" for 120 volt circuits, and 250 volts, Eagle "5462V', Hubbell "54621" or Leviton "5462-1" for 240 volt circuits. b. Ground fault circuit interrupter receptacles shall be duplex, 20 amperes, 125 volts, Eagle "GF8300V', Hubbell "GF53621" or (Carlsbad Water) 16050 (Recycling Facility) -14- Leviton "8899-1". c. Welding receptacles shall be 30 amperes, 600 volts, 3 phase, with grounding conductors connected through a fourth pole, Appleton "ACRE3034-100, Crouse-Hinds "AR348 plus "ARRC33" and "AR30 or Leviton " 430M15W'. One matching plug, Appleton "ACP3034BC", Crouse-Hinds "APJ3485" or Leviton "430P5W' with appropriate woven grip and plug cap, shall be furnished for the cable size directed by the OWNER. d. Welding receptacles shall be 60 amperes, 240 volts, 3 phase, with grounding. conductors connected through a fourth pole, Appleton "ACRE6035-150, Crouse-Hinds "AREA6485" or Leviton "460M19W. One matching plug, Appleton "ACP6034BC", Crouse-Hinds "APJ6485" or Leviton "460P9W' with appropriate woven grip and plug cap, shall be furnished for the cable size directed by OWNER. 2-5.05. Soecial Outlets. Clock outlets shall be Eagle "93632, Hubbell "5235' or Leviton "5261-CH". 2-6. JUNCTION BOXES, PULL BOXES. AND WIRING GUlTERS. indoor boxes (larger than switch, receptacle, or fixture type) and gutters shall be constructed of sheet steel and shall be galvanized after fabrication. Similar enclosures outdoors shall be provided with neoprene gaskets on the hinged doors or removable covers. Box and gutter sizes, metal thickness, and installation details shall comply with the National Electrical Code. Indoor junction boxes in corrosive areas indicated on the drawings shall be NEMA Type 4X, ABS or stainless steel, manufactured by Hoffman Engineering Co., or equivalent. Outdoor pull boxes shall be NEMA Type 4X stainless steel manufactured by Hoffman Engineering Co.. or equivalent. Bolt-on junction box covers 3 feet [900 mm] square or larger, or heavier than 25 Ibs [ll kg], shall have rigid handles. Covers larger than 3 by 4 feet [900 by 1200 mm] shall be split. Where indicated on the drawings, junction boxes with a removable side opposite the underground conduits shall be provided over building ends of underground conduit banks. Boxes shall be at least Code size, including space for full size continuations of all underground conduits not originally continued. Conduit arrangement shall leave maximum space for future conduits. 2-7. LIGHTING FIXTURES. Lighting fixtures shall be furnished as described in the fixture schedule and as indicated on the drawings. Lighting fixtures shall be (Carlsbad Water) (Recycling Facility) 16050 -1 5- furnished complete with lamps. Pendant fixtures shall have swivel type box covers and threaded conduit pendants unless otherwise specified. 2-7.01. Electronic Ballasts. Electronic ballasts furnished with fluorescent type lighting fixtures shall be CBM certified as meeting requirements of ANSI C82.11 with a THD level of not more than 10 percent. 2-8. LIGHTING PANELS. Unless otherwise specified, each lighting panel shall be a dead-front, 120/208 volt, three phase panelboard with circuit breakers, in accordance with the drawings and the following: 2-8.01, Cabinet. The panel shall have a surface-mounted enclosure with a NEMA designation as shown on the panelboard schedule. The enclosure shall have a hinged trim (cover). Breaker operating handles shall be accessible through a latched, lockable, door. At the completion of the contract, a neatly printed or typed directory listing the panel and circuit identities shall be mounted inside the door. 2-8.02. Circuit Breakers. Circuit breakers shall be thermal-magnetic, bolt-in, individually front replaceable, and shall indicate "On", "Ow', and "Tripped". Breakers indicated as multiple-pole shall be common trip. Breakers shall have interrupting ratings not less than 10,000 or 22,000 amperes as required. Handle clips to prevent casual operation of breakers shall be provided for 10 percent (at least two) of the breakers and applied to the circuits directed. Breakers and provisions for future breakers shall be provided in the quantities, number of poles, and ampere ratings indicated on the drawings. 2-8.03. Buses. The panel shall have main and neutral buses insulated from the cabinet, and a ground bus. Buses shall be copper, with ampere ratings and main lugs or breaker as indicated. The ground bus shall be similar to a neutral bus and shall have a good ground connection to the cabinet, a removable bond to the neutral bus, clamp type lugs for the ground cable in each supply conduit, and connections for a ground cable in each load conduit. 2-9. POWER PANELS. Unless otherwise specified, each power panel, with or without a neutral as required, shall be dead-front, 3 phase panelboard with circuit breakers, in accordance with the drawings and the following: 2-9.01. Cabinet. The panel shall have a surface-mounted enclosure with a NEMA designation appropriate for the location where it will be installed. The enclosure shall have a door with latch and lock. At the completion of the contract, a neatly printed or typed directory listing the panel and circuit identities shall be mounted inside the door. The panel enclosure shall be 20 inches wide, Square D type NF, or equivalent. 2-9.02. Circuit Breakers. Circuit breakers shall be thermal-magnetic, bolt-in, individually front replaceable, and shall indicate "On", "Of?', and 'Tripped". Breakers indicated as multiple-pole shall be common trip type, Breakers up to (Carlsbad Water) 16050 (Recycling Facility) -1 6- 240 volts shall have interrupting ratings not less than 10,000, 22,000 Or 65,000 amperes as required. Breakers for 277 volts shall have interrupting ratings not less than 14,000, 25,000 or 65,000 amperes as required. Breakers for 480 volts shall be rated 600 volts, with interrupting ratings not less than 14,000, 25,000 or 65,000 amperes at 460 volts as required. Handle clips to prevent casual operation of breakers shall be provided for 10 percent (at least two) of the breakers and applied to the circuits directed. 2-9.03. w. The panel shall have 3 phase buses, a neutral bus insulated from the cabinet, andlor a ground bus as required. Buses shall be copper, with ampere and voltage ratings and main lugs or breakers as indicated. The ground bus shall be similar to a neutral bus and shall have a good ground connection to the cabinet, a removable bond to the neutral bus as required, clamp type lugs for the ground cable in each supply conduit, and connections for a ground cable in each load conduit. 2-10. TRANSIENT VOLTAGE SURGE SUPPRESSION. Not used. 2-1 1. SEPARATELY ENCLOSED MOTOR STARTERS. Not used. 2-12. SEPARATELY ENCLOSED MANUAL STARTERS. Not used. 2-13. CONTROL STATIONS. Control stations shall be provided as indicated on the one-line diagrams or schematics or as required by the equipment furnished. Pilot devices shall be heavy-duty, oiltight, and shall perform the functions indicated. Indoor control stations shall have NEMA Type 13 enclosures. Control stations outdoors or indicated to be weatherproof shall have NEMA Type 4 stainless steel enclosures with protective caps on the control devices. Control stations in NEC Class I, Division 2, Group D hazardous areas shall have NEMA Type 7 enclosures, or be factory sealed type, Appleton N2 Series. 2-13.01. Emeraencv Break-Glass Switch. Not used, 2-14. SEPARATELY ENCLOSED CIRCUIT BREAKERS. Not used. 2-15. DISCONNECT SWITCHES. Unless otherwise indicated on the drawings, each disconnect switch shall be 3 pole, nonfusible, 600 volts, with a continuous current rating as indicated on the drawings. Switches located indoors shall have NEMA type enclosure designations as required by the locations where they will be installed. Switches located outdoors shall have NEMA Type 4 enclosures. Switches in chlorine rooms, or in other areas where contact with caustic substances may occur, shall have NEMA Type 4X enclosures of AIS1 Type 316 stainless steel or of molded reinforced polyester. Switches shall have high conductivity copper, visible blades; nonteasible, positive, quick-make, quick-break mechanisms; and switch assembly plus (Carlsbad Water) (Recycling Facility) 16050 -1 7- operating handle as an integral pat? of the enclosure base. Each switch shall have a handle whose position is easily recognizable and which can be locked in the "Ow' position with three padlocks. The "On" and "Off' positions shall be clearly marked. All switches shall be UL listed and horsepower [kilowatt] rated, and shall meet NEMA KSI-1990. Switches shall have defeatable door interlocks that prevent the door from being opened while the operating handle is in the "On" position. 2-16. LIGHTING AND AUXILIARY POWER TRANSFORMERS. Separately mounted transformers shall be provided in the phases, kVA, and voltages indicated on the drawings. Transformers shall be self-air-cooled, dry type, wall- or floor-mounted, and enclosed for wiring in conduit. Transformers installed outdoors shall be the non-ventilated, epoxy-resin encapslated type without exception. Transformers shall have at least two full capacity voltage taps. 2-17. POWER CENTERS. Not used 2-18. POWER FACTOR CORRECTION CAPACITORS. Not used. 2-20. PHOTOELECTRIC CONTROLS. Photoelectric controls shall be weatherproof, swivel adjustable, with built-in time delay to prevent accidental turnoff by momentary brightness. The photocell shall be rated 1800 VA, 120 volts ac, and shall be field adjustable from 1 ft/c [I1 lux] turnon to 15 Wc [I61 lux] turnoff. 2-21. RELAY ENCLOSURES. Relay enclosures shall be furnished as indicated on the drawings. The enclosure shall have a NEMA designation appropriate for the location where it will be installed. Pilot devices shall be heavy duty, oiltight construction. Relays and timers shall have 120 volt, 60 Hz coils rated for continuous duty in 40 C ambient and 10 ampere, 120 volt ac contacts. Intrinsically safe relays shall be installed within the enclosures in accordance with NEC requirements and shall be Gems "Safe-Pak", BNV "Series 53, or equal, 2-22. ALARM HORN AND BEACON. Not used 2-23. HEAT-TRACED PIPING. Not used 2-24. DOOR ENTRY SWITCHES, Not used. 2-25. TIME CLOCKS. Provide a 24-hour digital timer Rated 12OVAC, with one channel SPDT contacts rated 20 amperes inductive at 12OVAC. The timer shall have the following features: - A minimum of 20 set points per day. - Leap year automatic adjustment. Daylight saving automatic adjustment. (Carlsbad Water) (Recycling Facility) 16050 -18- - Manual override to the next scheduled ON or OFF set point when - LCD display. automatic operation resumes. - Battery backup to retain programming for a minimum or 175 hours. Provide Tork model DG180, or equivalent. Coordinate set points requirements with the Owner and provide programming of the timer. PART 3 - EXECUTION 3-1. COORDINATION STUDY. CONTRACTOR shall commission a coordination study of relays, fuses, circuit breakers, and all other protective devices and shall submit a coordination report as specified herein. The study shall include the entire distribution system, or the portion of the system indicated as required, starting with the smallest -- 480 volt, 3 phase, 60 Hz -- circuit protective device on the load end, to the nearest protective device on the power company's line side. The study shall include, but shall not be limited to, the following: A short circuit evaluation. Utility line and transformer impedance shall be obtained from San Diego Gas & Electric. A tabulation of all protective relay and circuit breaker trip settings and recornmended sizes and types of medium-voltage fuses. Motor starting profiles for all 50 horsepower (37 kw] and larger motors. Transformer damage curves and protection, evaluated in accordance with ANSlllEEE C57.109. Coordination curve(s) from the power company, if available. An Engineering and Testing Services firm acceptable to ENGINEER shall conduct the coordination study. CONTRACTOR shall be responsible for obtaining the following: The coordination curves for relays, fuses, and circuit breakers. Transformer damage curves. Motor data. Other applicable information for all new and existing electrical equipment. (Carlsbad Water) (Recycling Facility) 16050 -19- CONTRACTOR shall Coordinate with the power company to obtain the required protective device curves and shall be responsible for all the field work associated with obtaining the necessary data on existing relays, circuit breakers, fuses, and transformers to be included in the coordination study. The available 3 phase, symmetrical fault current at the point of service shall be obtained from the Power Company. The coordination report shall be bound in a standard 8-1/2 by 11 inch [210 by 275 mm] three-ring binder and shall be submitted in accordance with the submittals section. Final selection of all protective device settings or sizes shall be subject to review and acceptance by ENGINEER. 3-2. POWER AND SERVICE ENTRANCE INSTALLATION. CONTRACTOR shall consult the local electric utility regarding their service installation requirements, and shall install the service equipment in compliance with these requirements. CONTRACTOR shall coordinate details and timing of service entrance installations with the utili. 3-3. TELEPHONE SERVICE ENTRANCE INSTALLATION. Not used. 3-4. CABLE INSTALLATION. 3-4.01. General. Except as otherwise specified or indicated on the drawings, cable shall be installed according to the following procedures, taking care to protect the cable and to avoid kinking the conductors, cutting or puncturing the jacket, contamination by oil or grease, or any other damage. a. Stranded conductor cable shall be terminated by lugs or pressure type connectors. Wrapping stranded cables around screw type terminals is not acceptable. b. Stranded conductor cable shall be spliced by crimp type connectors. Twist-on wire connectors may be used for splicing solid cable and for terminations at lighting fixtures. c. Splices may be made only at readily accessible locations. d. Cable terminations and splices shall be made as recommended by the cable manufacturer for the particular cable and service conditions. All shielded cable stress cone terminations shall be IEEE Class 1 molded rubber type. Shielded cable splices shall be tape or molded rubber type as required. Shielded cable splices and stress cone terminations shall be made by qualified splicers. Materials shall be by 3M Company, PlymouthlBishop, or Raychem Electric Power Products. (Carlsbad Water) (Recycling Facility) 16050 -20- e. f. 9. h. I. 1. k. I. Cable shall not be pulled tight against bushings nor pressed heavily against enclosures. Cable-pulling lubricant shall be compatible with all cable jackets; shall not contain wax, grease, or silicone; and shall be Polywater "Type J" . Cables operating at more than 3,000 volts shall be fiteproofed in all cable vaults, manholes, and handholes. Fireproofing shall be done with a half-lapped layer of 3M "Scotch 77 Arc-Proofing Tape", anchored at each end with a double wrap of 3M "Scotch 69 Glass Cloth Tape" or with equivalent tape by Anixter Brothers or PlymouthlBishop. Where necessary to prevent heavy loading on cable connections, in vertical risers, the cable shall be supported by Kellems, or equal, woven grips. Spare cable ends shall be taped, coiled, and identified. Cables shall not be bent to a radius less than the minimum recommended by the manufacturer. For cables rated higher than 600 volts, the minimum radius shall be 8 diameters for nonshielded cable and 12 diameters for shielded cable. All cables in one conduit, over 1 foot [305 mm] long, or with any bends, shall be pulled in or out simultaneously. Circuits to supply electric power and control to equipment and devices are indicated on the one-line diagrams. Conductors in designated numbers and sizes shall be installed in conduit of designated size. Circuits shall not be combined to reduce conduit requirements unless acceptable to ENGINEER. 3-4.02. Underaround Cable Pullina Procedure. Not used. 3-4.03. Cable Insulation Test. Not used 3-5. CONDUIT INSTALLATION. Except as otherwise specified or indicated on the drawings, conduit installation and identification shall be done according to the following procedures. 3-5.01. Installation of Interior and Exposed Exterior Conduit. This section covers the installation of conduit inside structures, above and below grade, and in exposed outdoor locations. In general, conduit inside structures shall be concealed. Large conduit and conduit stubs may be exposed unless otherwise specified or indicated on the drawings. No conduit shall be exposed in water chambers unless so indicated on the drawings. (Carlsbad Water) (Recycling Facility) 16050 -21- Unless otherwise indicated on the drawings, CONTRACTOR shall be responsible for routing the conduit to meet the following installation requirements: a. b. C. d. e. f. 9. h. I. 1. k. Conduit installed in all exposed indoor locations, except Corrosive areas indicated on the drawings, and in floor slabs, walls, and ceilings of hazardous (classified) locations, shall be rigid steel as required. Exposed conduit shall be rigidly supported by hot-dip galvanized hardware and framing materials, including nuts and bolts. Conduit installed in floor slabs and walls in non-hazardous locations shall be rigid PVC Schedule 40. Conduit installed in all exposed outdoor locations shall be PVC-coated rigid steel, rigidly supported by PVC-coated mounting hardware and framing materials. Nuts and bolts shall be stainless steel. All damaged coatings shall be repaired according to the manufacturer's instructions. Final connections to dry type transformers, to motors without flexible cords, and to other equipment with rotating or moving parts shall be liquidtight flexible metal conduit with watertight connectors installed without sharp bends and in the minimum lengths required for the application, but not longer than 6 feet [I .8 m] unless otherwise acceptable to Engineer. Terminations and connections of rigid steel and intermediate metal conduit shall be taper threaded. Conduits shall be reamed free of burrs and shall be terminated with conduit bushings. Exposed conduit shall be installed either parallel or perpendicular to structural members and surfaces. Two or more conduits in the same general routing shall be parallel, with symmetrical bends. Conduits shall be at least 6 inches 1150 mm] from high temperature piping, ducts, and flues. Rigid PVC Schedule 40 conduit shall have supports and provisions for expansion as required by NEC Article 347. Metallic conduit connections to sheet metal enclosures shall be securely fastened by locknuts inside and outside. Rigid PVC Schedule 40 conduit shall be secured to sheet metal device boxes using a male terminal adapter with a locknut inside or by using a box adapter inserted through the knockout and (Carlsbad Water) (Recycling Facility) 16050 -22- cemented into a coupling. Conduits in walls or slabs, which have reinforcement in both faces, shall be installed between the reinforcing steel. In slabs with Only a single layer of reinforcing steel, conduits shall be placed under the reinforcement. Conduits that cross structural joints where structural movement is allowed shall be fitted with concretetight and watertight expansion/ deflection couplings, suitable for use with metallic conduits and rigid PVC Schedule 40 conduits. The couplings shall be Appleton type DF, Crouse-Hinds type XD, or 0-Z type DX. Conduit shall be clear of structural openings and indicated future openings. Conduits through roofs or metal walls shall be flashed and sealed watertight. Conduit installed through any openings cut into concrete or masonry structures shall be neatly grouted. Conduits shall be capped during construction to prevent entrance of dirt, trash, and water. Exposed conduit stubs for future use shall be terminated with galvanized pipe caps. Concealed conduit for future use shall be terminated in equipment or fitted with couplings plugged flush with structural surfaces. Where the drawings indicate future duplication of equipment wired hereunder, concealed portions of conduits for future equipment shall be provided. Horizontal conduit shall be installed to allow at least 7 feet [2.1 m] of headroom, except along structures, piping, and equipment or in other areas where headroom cannot be maintained. PVC-coated rigid steel conduit shall be threaded and installed as recommended by the conduit manufacturer's installation procedure using appropriate tools, All conduits that enter enclosures shall be terminated with acceptable fMings that will not affect the NEMA rating of the enclosure. Nonmetallic conduit, which turns out of concrete slabs or walls shall be, connected to a 90 degree elbows of metallic conduit before it I. m. n. 0. P. q. r. S. t. U. v. W. X. (Carlsbad Water) (Recycling Facility) 16050 -23- emerges, y. Conduits that turn out of concrete floor slabs shall be given a heavy coat of coal tar paint extending 2 inches [50 rnrn] on each side of the point of turn-out, or a three lap wrap of 4 inch [IO0 mm] wide 3M Company 51 tape applied over a coat of 3M No. 34548 primer. aa. Power conductors to and from adjustable frequency drives shall be installed in steel conduit. 3-5.02. Underqround Conduit Installation. All excavation, backfilling, and concrete work shall conform to the respective sections of these specifications. Underground conduit shall conform to the following requirements: a. All underground conduits shall be concrete encased unless indicated otherwise on the drawings. Concrete encasement installed under roadways shall be reinforced as indicated on the drawings. b. Concrete encased conduit shall be rigid schedule 40 (PVC) conduit as required. Conduits shall have end bells where terminated at walls. All joints shall be solvent welded in accordance with the recommendations of the manufacturer. c. Concrete encasement on exposed outdoor conduit risers shall continue to 6 inches [I50 mrn] above grade, with top crowned and edges chamfered. d. Conduit and concrete encasement installed underground for future extension shall be terminated flush at the bulkhead with a coupling and a screw plug. The termination of the duct bank shall be reinforced with bars 100 diameters long that shall be terminated 2 inches [50 mm] from the bulkhead. Matching splice bars shall be 50 bar diameters long. Each longitudinal bar shall be provided with a Lenton "Form Saver" coupler and plate or a Dayton "Superior DBR coupler at the bulkhead. The coupler shall be threaded to accept a dowel of like diameter in the future. Threads shall be protected with screw-in plastic caps. A 1-3/4 by 314 inch [45 by 20 mm] deep horizontal shear key shall be formed in the concrete encasement above and below the embedded conduits. After concrete placement. conduit and bar connector ends shall be cleaned and coated with two coats of thixotropic coal tar. e. Underground conduits indicated not to be concrete encased shall be rigid Schedule 40 PVC. (Carlsbad Water) (Recycling Facility) 16050 -24- Underground conduit bend radius shall be at least 2 feet (600 mm] at vertical risers and at least 3 feet [900 mm] elsewhere. Underground conduits and conduit banks shall have at least 2 feet [600 mm] of earth cover, except where indicated otherwise. Underground conduit banks through building walls shall be cast in place, or concreted into boxouts, with water stops on all sides of the boxout. Water stops are specified in the cast-in-place concrete section. Underground nonmetallic conduits, which turn out of concrete or earth in outdoor locations, shall be connected to 90 degree elbows of PVC-coated rigid steel conduit before they emerge. Conduits not encased in concrete and passing through walls, which have one side in contact with earth, shall be sealed watertight with special rubber-gasketed sleeve and joint assemblies or with sleeves and modular rubber sealing elements. Underground conduits shall be sloped to drain from buildings to manholes. Each 5 kV or higher voltage cable, each 250 mcm [I20 mm2] or larger cable, and each conduit group of smaller cables shall be supported from manhole walls by Kindorf "D-990 or Unistrut "P-3259 inserts, with Kindorf "F-721-24" or Unistrut "P-2544" brackets and Unistrut "P1753" or "P1754" fiberglass reinforced polyester cable saddles. Telephone cables shall not be installed in raceways, conduits, boxes, manholes, or handholes containing other types of circuits. Intercommunication and instrument cables shall be separated the maximum possible distance from all power wiring in pull-boxes, manholes, and handholes. 3-5.03. Sealina of Conduits. After cable has been installed and connected, conduit ends shall be sealed by forcing nonhardening sealing compound into the conduits to a depth at least equal to the conduit diameter. This method shall be used for sealing all conduits at handholes, manholes, and building entrance junction boxes, and for 1 inch [25 mm] and larger conduit connections to equipment. Conduits entering chlorine feed and storage rooms shall be sealed in a junction box or conduit body adjacent to the point of entrance. (Carlsbad Water) (Recycling Facility) 16050 -25- Conduits entering hazardous (classified) areas and submersible or explosion proof enclosures shall have Appleton "Type ESU" or Crouse-Hinds "EYS" sealing fittings with sealing compound. 3-5.04. Reuse of Existina Conduits. Not used. 3-6. WIRING DEVICES. BOXES, AND FllTlNGS INSTALLATION. Metallic and nonmetallic conduit boxes and fittings shall be installed in the following locations: 3-6.01. Conduit Boxes and Fittinas, a. Galvanized or cadmium plated, threaded, malleable iron boxes and fittings shall be installed in concrete walls, ceilings, and floors; in the outdoor faces of masonry wails; and in all locations where weatherproof device covers are required. These boxes and fittings shall also be installed in exposed rigid steel and intermediate metal conduit systems. b. Galvanized or cadmium plated sheet steel boxes shall be installed in the indoor faces of masonry walls, in interior partition walls, and in joist supported ceilings. c. Rigid PVC device boxes shall be installed in exposed nonmetallic conduit systems. d. PVC coated boxes and fittings shall be installed in PVC coated conduit systems. e. Telephone conduit shall be provided with separate junction boxes and pull fittings. 3-6.02. Device Plates. Oversized plates shall be installed where standard-sized plates do not fully cover the wall opening. 3-6.03. Wall Switches. a. Wall switches shall be mounted 3'4" [I .05 m] above floor or grade. b. After circuits are energized, all wall switches shall be tested for proper operation. 3-6.04. Receptacles. a. Convenience outlets shall be 18 inches [450 mm] above the floor b. Convenience outlets outdoors and in garages; in basements, unless otherwise required. (Carlsbad Water) (Recycling Facility) 16050 -26- shops, storerooms, and rooms where equipment may be hosed down; shall be 4 feet [I .2 m] above floor or grade. the floor. correct polarity and each GFCl receptacle shall be tested for proper operation. c. Welding receptacles shall be surface-mounted 4 feet [I .2 m] above d. After circuits are energized, each receptacle shall be tested for e. Conduit and wire for convenience outlet installation is not shown on the drawings and shall be sized, furnished, and installed by the Contractor. Conductors shall be minimum 12 AWG and conduit shall be minimum % inch for convenience outlet installation. 3-6.05. SDecial Outlets. a. Wall thermostats shall be 4'-6 [I .35 m] above the floor unless otherwise required. Thermostats on exterior walls shall be suitably insulated from wall temperature. b. Telephone outlets shall be 18 inches [450 mm] above the floor unless otherwise required. Telephone outlets outdoors and in garages; in basements, shops, storerooms, and rooms where equipment may be hosed down; shall be 4 feet [1.2 m] above floor or grade. c. Clock outlets shall be located 7 feet I2.1 m] above the floor. 3-7. EQUIPMENT INSTALLATION. Except as otherwise specified or indicated on the drawings, the following procedures shall be used in performing electrical work. 3-7.01. Settina of EauiDment. All equipment shall be installed level and plumb. Sheet metal junction boxes, equipment enclosures, sheet metal raceways, and similar items mounted on water- or earth-bearing walls shall be separated from the wall by at least 114 inch [6 mm] thick corrosion-resistant spacers. 3-7.02. Sealina of EauiDment. All outdoor substation, switchgear, motor control center, and similar equipment shall be permanently sealed at the base, and all openings into equipment shall be screened or sealed with concrete grout to keep out rodents and insects the size of wasps and mud daubers. Small cracks and openings shall be sealed from inside with silicone sealant, Dow-Corning "795" or General Electric "SCS1200. 3-8. GROUNDING. The electrical system and equipment shall be grounded in compliance with the NFPA National Electrical Code and the following requirements: (Carlsbad Water) (Recycling Facility) 16050 -27- a. All ground conductors shall be at least 12 AWG [4 mm21 soft drawn copper cable or bar, bare or green-insulated in accordance with the National Electrical Code. b. Ground cable splices and joints, which will be inaccessible after completion of construction, shall meet the requirements of IEEE 837, and shall be Cadweld "Exothermic" or Burndy "Hyground". c. Ground cable through exterior building walls shall enter within 3 feet [900 rnm] below finished grade and shall be provided with a water stop. Unless otherwise indicated, installation of the water stop shall include filling the space between the strands with solder and soldering a 12 inch [300 mm] copper disc over the cable. d. Ground cable near the base of a structure shall be installed in earth and as far from the structure as the excavation permits, but not closer than 6 inches [150 mm]. e. Lighting fixtures and receptacles shall be grounded by a copper ground conductor in addition to the conduit connection. f. Ground connections to equipment and ground buses shall be made with copper or high conductivity copper alloy ground lugs or clamps. Connections to enclosures not provided with ground buses or ground terminals shall be made with clamp type lugs inserted under permanent assembly bolts or under new bolts drilled and inserted through enclosures, other than explosion proof, or by grounding locknuts or bushings. Ground cable connections to anchor bolts; against gaskets, paint, or varnish; or on bolts holding removable access covers will not be acceptable. g. The grounding system shall be bonded to the station piping by connecting to the first flange inside the building, on either a suction or discharge pipe, with a copper bar or strap. The flange shall be drilled and tapped to provide a bolted connection. h. Ground conductors on equipment shall be formed to the contour of the equipment and firmly supported. i. Ground rods not described elsewhere shall be 34 inch [I9 mm] in diameter by 10 feet [3 m] long, with a copper jacket bonded to a steel core. 3-9. LIGHTING FIXTURE INSTALLATION. The drawings indicate the general locations and arrangements of the lighting fixtures. Fixtures in rows shall be aligned both vertically and horizontally unless otherwise specified. Fixtures shall (Carlsbad Water) (Recycling Facility) 16050 -2%- be clear of pipes, mechanical equipment, structural openings, indicated future equipment and structural openings, and other obstructions. Conduit and wire for lighting fixture installation is not shown on the drawings and shall be sized, furnished and installed by the Contractor. Circuits to emergency lighting units, exit signs, and fixtures indicated to be night lights shall not be switched. Circuits to fluorescent lighting fixtures indicated to have emergency battery packs shall include an additional un-switched hot conductor. Conductors shall be minimum 12 AWG and conduit shall be minimum 3/r” for lighting fixture installation. 3-10. POWER FACTOR CORRECTION CAPACITOR INSTALLATION. Not used. 3-1 1. MODIFICATIONS TO EXISTING EQUIPMENT. Not used. End of Section (Carlsbad Water) (Recycling Facility) 16050 -29- STANDARD SPECIFICATIONS REFERENCE: UL 83, ICEA S-95-658 (NEMA WC701 CONDUCTOR: Soli, uncoated copper. Maximum operating tempmature Wt dry, 75% wet INSULATION: Polyvinyl chloride, UL 83. Type THHN and TWN. lCm s-95658. SHIELD: None. JACKET: Conduclor: Nylon. 4 mils (100 !xnJ mmimum thickness, UL 83. FACTORY TESTS: Cable shall meet the requirements of UL 83 for Type THHN and TWN. Cable Detaib Size Number of Conductor Insulation Strands Thickness. Maximum Outaide Diameter AWG mm' in. In. mm 12 4.0 1 0.015 380 0.17 4.32 I1 10 I 6.0 I 1 I 0.020 I 510 I 0.20 I 5.08 Y The average thickness shall be not ks than that Indicated above The mlnlmum thickness shall not be less than 90 percent of the values indlcated above A durable marking shall be provlaed on the surface of Ihe cable at lnlervals not exceeding 24 inches (600 rnm). Marking shall include rnanufacturefs name. TWN or THHN, wnducror rue. and 600 von. I 600 Volt, Single Conductor Lighting Cable (600-1-PVC-THHN-THWN) (Carlsbad Water) (Recycling Facility) 16050 -30- . STANDARD SPECIFICATIONS REFERENCE: ICEA S-95-658 (NEMA WC 70). CONDUCTOR: Conwntriotay. Uncoated copper: strand Class 8. Normal maximum operating temperature 9O'C. INSULATION: Cross-linked thermosetting polyethylene, ICEA S-95.658, Paragraph 3.6 SHIELD: None. JACKET: None. FACTORY TESTS: Cable shall meet the requirements of ICEA S-95.658. Cable Daalls Size Number Conductor Insulation Maximum Outside Dlamebr of Strands Thickness. AWG or kcm 'The average thickness shall be not less than that indicated above. The minimum thickness shall be not less than 90 percent of the values indicated above. A durable marking shall be provided on the surface of the cable at intervals not exceeding 24 inches (600 mm). Marking shall include manufacturer's name, XLP. XHHW, conductor size, and voltage class. 600 Volt, Single Conductor LightinglPower Cable (600-1-XLP-NONE-XHHW) BLACK & VEATCH 11 Cable Data 11 Figure 2-16050 (Carlsbad Water) (Recycling Facility) 16050 -31- STANDARD SPECIFICATIONS REFERENCE: UL 62. UL 1277 CONDUCTOR: 16 AwG (1.5 mm'). ?-strand. concentric-lay, uncoated copper. Maximum operating temperature 9o'C dry, 75'C wet. INSULATION: Polyvinyl chloride, not less than 15 milr (380 pin) average thickness: 13 mils (330 pin) minlmum thickness. UL 62. Type TFN. IAY: Twisted pair with 1-1/2 inch to 2-112 inch (38.10 mm - 63.5 mm) lay. SHIELD: Cable assembly. combination aluminum-polyester tape and 7-strand. 20 AWG (0.5 mml) minimum sue, tinned copper drain wire, shleld applied to achleve 100 percent cover over insulated conductors. JACKET: Conductor: Nylon, 4 mils (100 pn) minimum thickness, UL 62. Cable assembly: Black. flame-retardant polyvinyl chloride. UL 1277. applied over tape-wrapped cable Core. CONDUCTOR One conductor black, one conductor white. IDENTIFICATION: FACTORY TESTS: Insulated conductors shall mset the requirements of UL 62 for Type TFN. Assembly jacket shall meet the requirements of UL 1277. Cable shall meet the verlicaktray flame test requirements of UL 1277. Cable Details Assembly Jecka Thickness. wide Diameter Maximum in. in. mm Sinpb Pair 0.045 1140 0.34 8.64 80 percant of the value indicated above. The average thickness shall be not less than that indicated above. The minimum thickness shall be not less than A durable mahing shall be provided on the surfaca of the cable at intervals not exceeding 24 inches (600 mm). Marking shall include manufactureh name, Type TC. Type TFN, conductor sue. single pair, and voltage class. 11 BLACKEL VEATCH 11 Cable Data II Figure 4-16050 (Carlsbad Water) (Recycling Facility) 16050 -32- REFERENCE: UL 62, UL 1277. STANDARD SPECIFICATIONS CONDUCTOR: 16AWG (1.5 mm'). 7-strand. concentric-lay. uncoated copper. Maximum operating temperature 9o'C INSUATION: Polyvinyl chloride, not less than 15 mils (380 Inn) average thickness; 13 mils (330 V) minimum dry, 7% wet. thickness. UL 62, Type TFN. SHIELD: tinned copper drain wire, shield applid to achieve 100 percent cover over insulated conductors. Cable assembly, combination aluminurnpolyester tape and 7-strand, 20 AWG (0.5 mm4 minimum size, Cable assembly: Black. flame-retardant polyvinyl chloride, UL 1277, applied over tape-wrapped cable Conductor: Nylon, 4 mils (100 pm) minimum thicknew, UL 62. core. LAY: Twisted pair with 1-1i2 inch to 2-1Q inch (38.10 mm - 63.5 mm) lay. JACKET: CONDUCTOR One conductor black, one conductor white, one conductor red. IDENTIFICATION: FACTORY TESTS: Insulated conductors shall meet the requimnents of UL 62 for Type TFN. Assembly Jacket shall mdet the requiremento of UL 1277. Cable shall meet the vertical-tray flame test requirements of UL 1277. Cable Details Assembly Jacket Thicknod Oumlde DIameter Maximum In. rn in. mm Single Triad 0.045 1140 0.35 8.87 I I I i I The average thickness shall be not Iks than that indicated above. The minimum thickness shall be not less than 80 percent of the value indicated above. A durable marking shall be provided on the surface of the cable at intervals not exding 24 inches (600 mm). Marking shall Include manufactunts name, Type TC. Type TFN, conductor slze, single triad, and vokage Class. 11 600 Volt, Single Triad, Shielded Instrument Cable (600-SlNGLE-TRIAD-SH-INSTR) 11 BLACK6 VEATCH 1 Cable Data u Figure 5-16050 (Carlsbad Water) (Recycling Facility) 16050 -33- STANDARD SPECIFICATIONS REFERENCE: UL 83. UL 1277. KEA s-58479. CONDUCTOR: 14 AWG (2.5 mml), 7 or 19 strands, concentriclay. uncoated copper. Maximum operating tempentUR 9o'C dry. 75.C wet. INSULATION: Polyvinyl chloride, not lea^ than 15 mils (380 m) average thickness; 13 mils (330 pnn) minimum thickness. UL 83. Type THHN and TMNN. Conductor: Nylon, 4 mils (100 m) minimum thickness. UL 83. Cable assembly: Black, Rame-retardant polyvinyl chloride, UL 1277, applied over tapewrapped cable core. CONDUCTOR ICEA 5-58-679, Method 1, Table 2 or ICEA S-58679, Method 3. Table 2. White IDENTIFICATION: or green wnductors shall not be provided. A durable marking shall be pmvided on the surfam of the cable a! intewals not excaeding 24 inch- (600 mm). Marking shall include manufaciureh name, Type TC. Type TWWN or THHN. conduaor size, number of conductors. and vonage (Carlsbad Water) (Recycling Facility) 16050 -34- Section 16150 ADJUSTABLE FREQUENCY DRIVES Data Sheet - Para- graph Units Data Desciption General Driven equipment specification 11213 1-4. point of common coupling. Submit harmonic calculations at (i Yes r No 1-4 r yes Submit detailed harmonic testing plan. G No Performance Requirements Load characteristics. G Variable toque r Constant toque Required minimum speed. C 120 wlt. 1-phase, 60 Hz Drive voltage. Drive Characteristics rpm 1200 IC 240 wlt, 1-phase, 60 Hz c 208 wlt, 3-phase, 60 Hz c 240 mlt, 3-phase. 60 HZ 480 wlt, 3-phase. 60 Hz Enhanced or non-standard features. (Carisbad Water) (Recycling Facility) 16150 -1- Harmonic Analysis Existing facility loads to be included Switchboard SWB-1 in harmonic calculation and testmg Short circuit current at utility Available from SDGBE interface. all equipment powered from the Total maximum running amperes of 870 amperes utility connection. 2 Operation from standby generator. C Yes (i No Three Dhase fault current at the bus Available from coordination studv as I I ]Power entry. .. 8 I..."."" ((i. Drive top r Drive bottom I [Power exit. IC Drie top c Drive bottom Drive enclosure type. (i NEMA Type 1 r NEMA ~ype 12 r Other When "Othe? is selected. indcate alternative. 2-3.04. Conformal waling on clrcuit boards. (i yes C No Shop painting. r GI-~Y color Manufactureh standard color r Corrosion resistant coating required r resistant coating required Guarantee of hydrogen sulfide bptional Equipment r Yes ,z No 2-4.04 IsolationNoltage matchlng r Yes No transformers. \ 2-4.05. Furnish power factor correctlon c Yes capacitors for constant speed motors. When "Yes" is selected. lndlcate constant speed motor tag numbers. power factor correctlon capacttor When "Yes" is selected lndlcate r Indoor enclosure type. I: No r Outdoor (Carlsbad Water) (Recycling Facility) 16150 -2- Testing Controls, Accessories, and hut thermal-magnetic molded- r 14.000 ase circuit breaier interrupting 42,000 1Elapsed time meter. Yes r NO r NO 2-5.01. PID set point control selection @ Yes required. Maximum noise level. Additional features. (MPR) Motor protection relay. r Yes - li MO I I Secondary factory testing with AFD C Yes . .. nd driven equipment in place. No Field Services and Testing 3-3 Installation supervision required. (i Yes r No Number of working davs for 1 Each linstallation supervisor. (Number of roundtrips for installation 11 (Each -~ supervisor. 3-4.02. Harmonic distortion test. r Yes No 3-5. Training. (i Yes r No Number of OWNER personnel to be5 trained. Each Number of working days required 2 Each for training. Number of round trips required for 2 Each training. (Carlsbad Water) (Recycling Facility) 16150 -3- Section 161 50 ADJUSTABLE FREQUENCY DRIVES PART 1 - GENERAL 1-1, SCOPE. This section covers pulse width modulated (PWM) type adjustable frequency drives (AFD) for the equipment and locations as required. AFDs shall meet the design conditions and features as required. AFD's shall be designated and shall be located as required. 1-1.01. Terminology. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-2. GENERAL. Equipment provided under this section shall be fabricated and assembled in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Equipment provided under this Section shall be fabricated as specified in this Section and as shown on the schematics and one line diagrams on the Contract Drawings. Unless otherwise indicated on the drawings, one adjustable frequency drive, complete with all required control components, shall be furnished for each motor. AFDs shall be manufacturedlassembled in their entirety at the manufacturer's factory. Systems fabricated or assembled in whole or in part by parties other than the drive manufacturer will not be acceptable, 1-2.01. Coordination. The design of the adjustable frequency drive shall be coordinated with the driven equipment. The Contractor shall coordinate the collection of data and the design effort to limit harmonics to the levels specified. Verification of this coordination shall be submitted as required in the submittals paragraph. 1-2.02. General EauiDment Requirements. When required, the General Equipment Requirements shall apply to all equipment furnished under this section. 1-2.03. Dimensional Restrictions. Layout dimensions will vary between manufacturers and the layout area indicated on the drawings is based on typical values. The supplier shall review the contract drawings, the manufacturer's (Carisbad Water) (Recycling Facility) 16150 -4- layout drawings and installation requirements, and make any modifications required for proper installation subject to acceptance by ENGINEER. 1-2.04. Workmanship and Materials. Equipment supplier shall guarantee all equipment against faulty or inadequate design, improper assembly or erection, defective workmanship or materials, and leakage, breakage, or other failure. Materials shall be suitable for service conditions. All equipment shall be designed, fabricated, and assembled in accordance with recognized and acceptable engineering and shop practice. Individual parts shall be manufactured to standard sizes and thicknesses so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable. Equipment shall not have been in service at any time prior to delivery, except as required by tests. 1-2.05. Abbreviations. Reference to standards and organizations in the Specifications shall be by the following abbreviated letter designations: AIS1 ANSI AWG IEEE NEC NEMA UL American Iron and Steel Institute American National Standards Institute American Wire Gage Institute of Electrical and Electronics Engineers National Electrical Code National Electrical Manufacturers Association Underwriters' Laboratories 1-2.06. Governina Standards. The adjustable frequency drive shall be designed, constructed, and tested in accordance with the applicable standards of NEMA. ANSI, UL, and IEEE, and shall be designed for installation in accordance with the NEC. The drives shall be UL or ETL listed. 1-2.07. Nameplates. All devices mounted on the face of the drive shall be provided with suitable nameplates. Push buttons, selector switches, and pilot lights shall have the device manufacturer's standard legend plate. All other devices shall have an engraved, laminated plate, with at least 3/16 inch [5 mm] high, black lettering on a white background. 1-3. DESC,RIPTION. The AFD shall produce an adjustable ac voltagelfrequency output and shall be equipped with an output voltage regulator to maintain correct output VlHz despite incoming voltage variations. (Carlsbad Water) (Recycling Facility) 16150 -5- 1-3.01. Six-Pulse Drives. Each drive, for motors rated below 100 horsepower, shall be of the pulse-width modulated type and shall consist of a full-wave diode or gated-open SCR bridge. The rectifier shall convert incoming fixed voltage and fixed frequency to a fixed dc voltage. The pulse-width modulation technology shall be of the space vector type, implemented in a microprocessor that generates a sine-coded output voltage. The drive inverter output shall be generated by insulated gate bipolar transistors (IGBT) which shall be controlled by six identical base driver circuits. The drive shall not induce excessive power losses in the motor. The worst case RMS motor line current measured at rated speed, torque, and voltage shall not exceed 1.05 times the rated RMS motor current for pure sine wave operation. 1-3.02. Eiahteen-Pulse Drives. Not Used. 14. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with complete engineering data covering the materials used, parts, devices, and accessories forming a part of the drive shall be submitted in accordance with the submittals section. The drawings and data shall include, but shall not be limited to, the following: a. b. C. d. e. f. 9. h. I. 1. Name of manufacturer. Types and model numbers, Rated drive input kVA and output kVA. Percent efficiency at 100 percent speed and 60 percent speed. Maximum Btu [kJ] heat release data and verification of the drive cooling requirements. Total weight and lifting instructions, height, mounting, and floor space required. Panel interior and front and side exterior view details showing maximum overall dimensions of all transformer, bypass contactor, ac line filter, ac line reactor, and drive compartments. Schematics, including all interlocks. Wiring diagrams, including all internal and external devices and terminal blocks. Locations and sizes of electrical connections, ground terminations, and shielded wires. (Carlsbad Water) (Recycling Facility) 16150 -6- .,.. k. I. rn.. n. 0. P. q. r. S. List of diagnostic indicators. List of fault and failure conditions that the drive can recognize and indicate for simultaneous occurrence. List of standard features and options. List of spare parts to be furnished. Input line protection model numbers and manufacturer's data sheets. Output filter model number and manufacturer's data sheets. When required, certification of conformal coating on all printed circuit boards. Provide verification that coordination with the pumplmotor supplier has been made. When required, harmonic calculations by the drive manufacturer at the points of common coupling. Detailed drawings and information showing how protection is applied to comply with harmonic limits. 1-5. OPERATION AND MAINTENANCE DATA AND MANUALS. Adequate operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals section. Operation and maintenance manuals shall include the following: a. b. C. d. e. f. Manufacturer's operation and maintenance manual for each size of adjustable frequency drive. Manufacturer's standard manuals for each size and type of bypass contactor, transformer, line reactor, and filter. Schematics, wiring diagrams, and panel drawings in conformance with construction record. Model numbers and up-to-date cost data for spare parts. Troubleshooting procedures, with a cross-reference between symptoms and corrective recommendations. Connection data to permit removal and installation of recommended smallest field-replaceable parts. (Carlsbad Water) (Recycling Facility) 16150 -7- g. Information on testing of power supplies and printed circuit boards and an explanation of the drive diagnostics. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. 1-6. SPARE PARTS. The drive manufacturer shall provide spare parts for each type and size of drive supplied. The spare parts shall include at least one complete set of all plug-in components for each size and type of drive, and shall include the following: Power fuses Control fuses Indicating lights Rectifier power semiconductors Inverter power semiconductors One of each type printed circuit board and gate firing board Other field-replaceable component parts Spare parts shall be suitably packaged, as specified herein, with labels indicating the contents of each package. Spare parts shall be delivered to OWNER as directed. PART 2 - PRODUCTS 2-1. ACCEPTABLE MANUFACTURERS. All drives shall be pulse-width modulated type, as manufactured by Cutler-Hammer, Robicon, or Toshiba, without exception. The products of other manufacturers will not be acceptable. All adjustable frequency drives shall be a product of the same manufacturer. 2-2. PERFORMANCE AND DESIGN REQUIREMENTS. 2-2.01. Performance. The adjustable frequency drive controller shall be of sufficient capacity and shall produce a quality output waveform for stepless motor control from 10 to 100 percent of base speed. The adjustable frequency drive shall be suitable for either constant torque (CT) or variable torque (VT) loads as required. The adjustable frequency drive shall meet the following ratings and parameters: (Carlsbad Water) (Recycling Facility) 16150 -0- input voltage and frequency Minimum drive efficiency Ambient temperature Relative Humidity Displacement Power Factor Drive service factor Over current capability VoltslHz ratio Acceleration/deceleration time Output speed regulation Output frequency stability 460 volts (*lo percent); 3 phase, 60 Hz (i2 Hz); imbalance, 2 percent maximum. Continued operation with additional momentary 25 percent voltage dip of 0.5 second duration from nominal input voltage level. 95 percent at 100 percent speed, 90 percent at 60 percent speed. -10 to 40°C. 0 to 95 percent non-condensing. 95 percent or higher throughout the entire operating speed range, measured at drive input terminals. 1 .o. 11 0 percent for 1 minute for variable torque: 150 percent for 1 minute for constant torque. Voltage varies as the square of frequency over the entire range of the unit for variable torque drives, constant over the entire range of the unit for constant torque drives; except under voltage boost condition. Adjustable over a range that meets the requirements of the drive equipment. 0.5 percent. 0.5 percent of nominal. 2-2.02. Adiustments. The following drive adjustments shall be provided: Maximum speed. Minimum speed. (Carlsbad Water) (Recycling Facility) 16150 -9- Linear acceleration time. Linear deceleration time. VoltslHz ratio; linear, squared, and automatic settings. Voltage boost Process follower gain, offset, and bias. Torque limit. Critical frequency avoidance with adjustable bandwidth. 2-2.03. Fault Protection. Design of the power circuit shall include provisions for protection against fault conditions as follows. 2-2.03.01. but Protection. High speed current limiting fuses rated 200,000 AIC, specifically designed for solid state applications. Solid state instantaneous overcurrent trip set at 180 percent. Adjustable over voltage and under voltage protection with automatic restart. Phase loss and reverse phase trip with manual restart. 2-2.03.02. Internal Protection. AC line, phase-to-phase transient voltage surge suppression utilizing metal oxide varistors. Drive shall meet the requirements of IEEE C62.41. Power device snubbers. Power devices rated 2.5 times line voltage. Instantaneous overcurrent. Static overspeed (overfrequency) protection. DC bus over voltage trip. DC bus discharge circuit with an indicator lamp, for protection of personnel. (Carlsbad Water) (Recycling Facility) 16150 -1 0- Individual transistor overtemperature and overcurrent protection. Control logic circuit malfunction indication. 2-2.03.03. Outaut Protection. Inverse-time motor overload protection adjustable from 10 percent to 100 percent. Overvoltage protection. Overfrequency protection. Short circuit protection (three phase, phase to phase, and ground fault Protection). Protection against opening or shorting of motor leads. Static overspeed protection. Stall protection on overload with inverse time Over current trip, adjustable current limit from 10 percent to 120 percent. 2-2.04. Harmonic Distortion Abatement. The electrical system shall be provided with the necessary equipment to protect the drive and the power system ahead of the drive from harmonic distortion, as described below. The drive shall operate satisfactorily when connected to a bus supplying other solid-state power conversion equipment which may be causing up to 10 percent total harmonic voltage distortion and commutation notches up to 36,500 volt- microseconds. Harmonic distortion abatement equipment shall be provided to bring the facility and its electrical system into compliance with IEEE 519, 1992 at the points of analysis defined below and indicated on the Contract Drawings. The supplier shall review the existing facility loads and shall take note of the equipment listed in the data sheet. All distortion reports and/or testing shal1,include the existing facility loads. The maximum total harmonic distortion (THD and TDD) allowed at the points of analysis shall include harmonics from the existing equipment as well as the harmonics from equipment provided under this Section. Current Distortion Limits. Maximum allowable total and individual harmonic current distortion limits for each odd harmonic shall not exceed limits set forth in IEEE 519, 1992. The utility connection shall be the primary point of analysis for current distortion. The values of utility short circuit current at the utility interface and the total maximum running amperes of all equipment powered from the utility connection shall be as indicated on the Data Sheet. (Carlsbad Water) (Recycling Facility) 16150 -1 1- 2-2.04.02. Voltaqe Distortion Limits. Individual or simultaneous operation of the drives shall result in a maximum total harmonic voltage distortion of 5 percent on the bus feeding the drives. The point(s) of analysis for harmonic Voltage distortion testing shall be the nearest electrical bus on the supply side of each drive. The three phase fault current at the bus feeding the drives shall be derived from the short circuit and coordination study as specified in Section 16050. 2-3. CONSTRUCTION 2-3.01, Fabrication and Assembly. The adjustable frequency drive system shall be shop assembled in a single enclosure using interchangeable plug-in printed circuit boards and power conversion components wherever possible. Shop assembly shall be performed by the drive manufacturer; systems fabricated or assembled in whole or in part by parties other than the drive manufacturer will not be acceptable. Changes to the drive manufacturer's product by a distributor or system integrator are not allowed. Input line reactors, fuses, circuit breakers, and filters, where required, shall be mounted within the drive enclosure, without exception. Isolation/voltage matching transformers, where required, may be enclosed separately from the remaining drive equipment. 2-3.02. Wiring. Internal cabinet wiring shall be neatly installed in wireways or with wire ties where wireways are not practical. If wire ties are used, the wire bundles shall be held at the back panel with a screw-mounted mounting base. Bases with a self-sticking back are not acceptable. Power entry and exit for the drive shall be through the top or bottom of the drive as required. Terminal blocks shall be nonbrittle, interlocking, track-mounted type, complete with a marking strip, covers, and pressure connectors. Screw terminals will not be acceptable. A terminal shall be provided for each conductor of external circuits, plus one ground for each shielded cable. In freestanding panels, 8 inches [200 mm] of clearance shall be provided between terminals and the panel base for conduit and wiring space. Not less than 25 percent spare terminals shall be provided. Terminals shall be labeled to agree with the identification on the submittal drawings. Each control loop or system shall be individually fused, clearly labeled, and located for ease of maintenance. All grounding wires shall be attached to the sheet metal enclosure with a ring tongue terminal. The surface of the sheet metal shall be prepared to ensure good conductivity and corrosion protection. (Carlsbad Water) (Recycling Facility) 16150 -12- Wires shall not be kinked or spliced and shall be color coded or marked on both ends. The markings or color coding shall agree with the submittal drawings. With the exception of electronic circuits, all interconnecting wiring and wiring to terminals for external connection shall be stranded copper, insulated for at least 600 volts, with a moisture-resistant and flame-retardant covering rated for at least 90°C. 2-3.03. Enclosures, The drive shall consist of factory mounted and wired components within a dead front enclosure, as required. The complete drive package, including accessories, shall fit into the space indicated on the drawings. Freestanding panels shall be suitable for mounting on a concrete pad and shall include provisions for anchoring to the supporting structure. Suitable lifting facilities shall be provided for handling and shipment. Relays, terminals, and special devices inside the control enclosure shall have permanent markings to match the identification on the manufacturer's wiring diagrams. 2-3.04. Printed Circuit Boards. When required, all printed circuit boards shall be sprayed on both sides with a conformal coating. The conformal coating shall be a part of the AFD manufacturing process and shall be selectively applied to the circuit board connections only. Heat sinks and resistors on the circuit board shall not be coated. Conformal coating shall be Konform "C416" or HumiSeal. All plug-in type boards shall be mechanically held at the circuit board connector. Compression fit only at the connector will not be acceptable. 2-3.05. ShoD Painting. All iron and steel surfaces, except machined surfaces and stainless steel, shall be shop cleaned in accordance with the coating manufacturer's recommendations, and finished with the drive manufacturer's standard coating. Finish color shall be the manufacturer's standard color. Dry film thickness of the finish coat shall be at least 4 mils [lo0 pm]. Field painting, other than touch up, will not be required. A sufficient quantity of additional coating material and thinner shall be furnished for field touch up of damaged coatings. 2-4. OPTIONAL EQUIPMENT 2-4.01. BvDass Switch. Not Used. 2-4.02. AC Line Reactors. When required, the AFD shall be supplied with an input ac line reactor. AC line reactors shall be designed to address performance issues of NEMA MG1-20.55 and to provide proper transient protection of the (Carlsbad Water) (Recycling Facility) 16150 -1 3- AFD input power devices. AC Line reactors shall be factory mounted and wired within the AFD enclosure. AC line reactors shall be K-rated per IEEE C57-110 and shall be TCI Model KLR, or equal. 2-4.03. Harmonic Filters. When harmonic filters are required to Comply with the total harmonic distortion limits specified herein, the AFD manufacturer shall design and provide the required filters. The harmonic filters shall utilize an interlocking contactor that shall be automatically operated by the AFD run circuit. The AFD manufacturer shall be responsible for the complete filter unit, including the filter contactor. Harmonic filters shall be TCI Harmonic Guard Series, or equal. 2-4.04. IsolationNoltaqe Matchino Transformers. Not Used, 2-4.05. Power Factor Correction CaDacitors. Not Used. 2-4.06. Output dV/dt Filters. When required, output filters shall be installed inside the drive enclosure on the inverter output. Output filters shall consist of a minimum 1.5 percent impedance reactor, in conjunction with a resistor and capacitor network, to form a damped low-pass filter. Use of output reactors alone is not acceptable. Output filters shall be TCI Model KLC, or equal. 2-5. CONTROLS. 2-5.01. Features. Each drive shall include the following features in addition to those indicated on the drawings: a. A door mounted membrane keypad with integral 2-line, 24 character minimum LCD display that is capable of controlling the AFD and setting drive parameters. The keypad module shall be programmed with factory set drive parameters in nonvolatile EEPROM or FLASH memory and shall be resettable in the field through the keypad. The keypad module shall contain a self-test software program that can be activated to verify proper keypad operations. b. Microprocessor-based regulator. Nonvolatile memory modules shall have a useful life of at least 20 years without requiring battery or module replacement. c. Input thermal-magnetic molded-case circuit breaker disconnect with interrupting capacity rated in RMS symmetrical amperes as required, and labeled in accordance with UL standard 489. The disconnect shall be mounted inside the controller enclosure and shall have door interlocks and a handle with provisions for padlocking in the "Of?' position. (Carlsbad Water) (Recycling Facility) 16150 -14- d. e. f. 9. h. I. j. k. I. m. n. 0. P. Input line high-speed, current limiting fuses rated 200,000 amperes interrupting and specifically designed for solid-state applications. Manual speed adjustment. Indications of power "On", drive "Run", and drive "Fault". Indication of these parameters shall be provided by pilot lights that utilize 6 volt LED lamps with built-in transformers. Lamps shall be easily replaceable from the front of the indicating light. Elapsed time meter when required. Speed indication - calibrated in percent rpm. Control circuits of not more than 115 volts supplied by internal control power transformers. Control power transformers shall have additional capacity as required by external devices indicated on the drawings. Control power transformers shall be equipped with two primary leads fused, one secondary lead fused, and one secondary lead grounded. Automatic controller shutdown on overcurrent, overvoltage, undervoltage, motor overtemperature and other drive fault conditions. Controller shutdown shall be manually reset type. Terminals shall be provided for control wiring from motor temperature switches, or a motor protection relay located in the drive enclosure. Diagnostic indicators that pinpoint failure and fault conditions. Indicators shall be manually reset to restore operation after abnormal shutdown. Accept a remote 4-20 mA speed control signal. Process control output for remote 4-20 mA speed indication, rated 0 to 100 percent speed. Spare interlock contacts rated 5 amperes at 120 volts ac, wired separately to the unit terminal board. One NO and one NC isolated spare interlock shall be furnished with each drive. Additional interlock contacts shall be provided as indicated on the drawings. Drive fault and run status contacts for remote indication, rated 5 amperes at 120 volts ac. Speed droop feature which reduces the speed of the drive on transient overloads. The drive shall return to set speed after the (Carlsbad Water) (Recycling Facility) 16150 -15- 9. r. S. t. U. V. transient is removed. If the acceleration or deceleration rates are too rapid for the moment of inertia of the load, the drive shall automatically compensate to prevent drive trip. Heavy duty, oil-tight pilot devices of the 30.5 mm type. Individual adjustable speed profile settings for start. stop, entry, slope, and minimum and maximum speed points. Coast, controlled ramp, or dc injection selectable modes of stopping. PID setpoint control selection when required. Adjustable PWM carrier frequency. The inverter output section shall be provided with adjustable PWM carrier frequency from 500 Hz to at least 10 kHz. When required, noise level of installed equipment shall not exceed the dB values indicated on the Data Sheet as measured by an appropriate calibrated instrument. The required sound level limit shall be met at a minimum of four locations, each not more than 3 feet [0.9 m] above the floor and not more than 10 feet [3 m] from the equipment. This requirement shall apply to all drives, motors, filters, reactors, and transformers supplied with the drive. 2-5.02. Diaanostics. Diagnostic indicators on the face of the drive shall display the type of fault responsible for drive shutdown, warning, or failure. If two or more faults occur simultaneously, the diagnostic segment shall record or indicate each condition. The drive shall be capable of storing 10 events with a time and date stamp for each event. 2-5.03. Motor Protection Relay. Not Used. 2-6. ACCESSORIES. 2-6.01. Special Tools and Accessories. Equipment requiring periodic repair and adjustment shall be furnished complete with all special tools, instruments, and accessories required for proper maintenance. Equipment requiring special devices for lifting or handling shall be furnished complete with those devices. 2-7. TESTING. All power switching components shall be prerun under anticipated operating temperature and load conditions. 2-7.01. Factorv Testinq. After the drive system has been assembled at the manufacturer's facility, it shall be tested for at least 24 hours before it is shipped. (Carlsbad Water) (Recycling Facility) 16150 -16- The complete drive system, including all peripherals, shall be factory tested under simulated operating conditions, including normal operating sequences and fault conditions. Contact closure inputs and simulated driven-outputs shall be connected to the system inpuffoutput modules. A test report summary indicating satisfactory final test results shall be submitted to ENGINEER before shipment of the equipment. 2-7.02. Secondarv Factorv Testing. Not Used. PART 3 - EXECUTION 3-1, PREPARATION FOR SHIPMENT. All equipment shall be suitably packaged to facilitate handling and to protect against damage during transit and storage. All equipment shall be boxed, crated, or otherwise completely enclosed and protected during shipment, handling, and storage. All equipment shall be protected from exposure to the elements and shall be kept dry at all times. Painted surfaces shall be protected against impact, abrasion, discoloration, and other damage. Painted surfaces that are damaged prior to acceptance of equipment shall be repainted to the satisfaction of ENGINEER. Grease and lubricating oil shall be applied to all bearings and similar items Each item of equipment shall be tagged or marked as identified on the Equipment Data Sheet. Complete packing lists and bills of material shall be included with each shipment. 3-2. INSTALLATION CHECK. An experienced, competent, and authorized representative of the manufacturer shall visit the site of the Work and inspect, check, adjust if necessary, and approve the equipment installation. The representative shall be present when the equipment is placed in operation and shall revisit the jobsite as often as necessary until all trouble is corrected and the equipment installation and operation are satisfactory in the opinion of ENGINEER. The manufacturer's representative shall furnish a written report certifying that the equipment has been properly installed and lubricated; is in accurate alignment; is free from any undue stress imposed by connecting piping or anchor bolts; and has been operated under full load conditions and that it operated satisfactorily. 3-3. INSTALLATION SUPERVISION. The equipment manufacturer shall furnish a qualified field installation supervisor during the equipment installation. Such services shall be included in the contract price for the number of days and round trips to the site as required. (Carlsbad Water) (Recycling Facility) 16150 -17- Manufacturers' installation supervisor shall observe, instruct, guide, and direct CONTRACTOR'S erection or installation procedures as required. The equipment manufacturer will be provided with written notification 10 days prior to the need for such services. 3-4. FIELD TESTING. 3-4.01. Field AcceDtance Testinq. After installation of the system at the site of the work and checkout by the drive manufacturer, a field acceptance test shall be conducted jointly by the drive manufacturer and the manufacturer of the driven equipment. The field acceptance test shall consist of repeating the factory acceptance testing procedure and an additional 5 days of similar testing, during which the system shall run continuously without loss of basic functions. Functional tests shall demonstrate satisfactory operation of all interlocks, alarms, and normal operating sequences. The drive manufacturer shall use suitable test equipment to identify and correct malfunctions. Failure of redundant equipment will not be considered as downtime, provided that automatic failover occurs as specified herein and, that in the opinion of ENGINEER, the failure was not caused by deficiency in design or installation. Repeated failure of any component shall be cause for the acceptance test to be terminated and restarted. 3-4.02. Harmonic Distortion Test. Not Used. 3-5. TRAINING OF OWNER'S PERSONNEL. The number of employees of OWNER, as required, shall be trained in the proper operation, troubleshooting, and maintenance of the equipment. Training shall be conducted by a qualified representative of the drive manufacturer and shall consist of at least 16 hours of combined classroom and hands-on instruction. Training shall be conducted at a place and time mutually agreeable to OWNER and the drive manufacturer. End of Section (Carlsbad Water) (Recycling Facility) 16150 -10- Section 16220 GENERAL PURPOSE INDUCTION MOTORS Data Sheet IPara- IDescription IData lunits graph General Tag Numbers of Driven Equipment. Each 2 Number of Motors required. P-1604-1-1, P-1604-2-1 1-2.02. C yes General Equipment Requirements. r No 1-4 @ Yes Operation and maintenance manuals required. Spare Pats r No 1-5. r Yes Required. =No When "Yes" is selected, indicate what spare parts are required. Service Conditions Altitude. C Below 3,300 [l,OOO] C Abow 3,300 [l.OOO] If "Above" is selected, indicate elevation. Ambient temperature. @ 40'c r 50°c c Other When "Other" is selected, indicate ambient temperature. Locations. r Indoor F Abow Grade Performance and Design Requirements 16220 -1- Project Rev. 10/1612000 Print Date 2/1/2002 Std. Rev. 3.3, 3/1/2000 Motor voltage. I ! r 115 wit, 1-phase, 60 Hz C 200 Wlt, 3-phase. 60 Hz r 230 wit, I-phase, 60 Hz C 230 mlt, 3-phas.e. 60 Hz G 460 mlt. 3-phase, 60 Hz r 2300 mlt. 3-phase. 60 Hz C 4000 mlt. 3-phase, 60 Hz Arrangement. C Horizontal With Non- 6 Vertical solid shafl C Vertical hollow shaft Reverse Ratchet Speed. C Constant speed C 2 speed, 1 winding C 2 speed. 2 winding G C Variable speed (other) Variable speed (adjustable frequency drive) When "Variable speed (other)" is selected, indicate type 2-2.02. Enclosure. C Open dnp proof li Totally enclosed-fan cooled C Explosion pmf Totally enclosed-fan cooled rated for Class I, Diwsion 2 area r wp1 r WP~ r Other When "Othef is selected. Indicate alternative. 2- Area classifications. Non-Hazardous 2.02.03 r Class I. Group C 8 D, Diusion 1 C Class I. Group C & D. Diusion 2 IC Other 1 bhen "Othef is selected. tndicate I class, group, and dlvlslon 2- Special features. 2.02.04 2-2.14. Efficiency. C Premium Efhciency r Encapsulated Winding r Sebere Duty-Chemical SeNlce 16220 -2- Project Rev. 10/16/2000 Print Date 2/1/2002 Std. Rev. 3.3, 3/1/2000 hhen "Other" is selected, indicate I I alternative. Service factor. r 1.0 c 1.15 insulation class and temperature (by resistance method). r Class F with 800~ rise at 1.0 SF c Loaded Starting condition. Starting Requirements Class with rise at 1,15 rise above 40°C design ambient r Class H with 105'C rise at 1.0 SF r Unloaded Starting method. C Full Voltage C Reduced Voltage, Auto-transformer C Reduced Voltage, Solid-state Accessory Equipment -2.11. c Yes Space heaters required. No -2.03. Main conduit box sized for. p Main Motor Leads Space heater leads r CT for Ammeter r Ground Lug Mounted Inside r Stress Cones r Surge Protection L Auxiliary conduit box required. (i Yes r No .2.12. c Temperature switches Temperature sensing devices. C RTDs When "RTDs" are selected, indicate requirement. 6 Stator RTDS r I Thrust bearing RTD r 1 Each thrust and guide bearing r 2 Each thrust and guide bearing Miscellaneous. r NonSpak Fan F DrainlBreather "- NEMA P flange Base i 16220 -3- Project Rev. 1011 6/2000 Print Date 2/1/2002 Std. Rev. 3.3, 3/1/2000 Section 16220 GENERAL PURPOSE INDUCTION MOTORS Data Sheet Para- Units Data Description graph General Tag Numbers of Driven Equipment. Each 2 Number of Motors required. P-1621, P-1629 1-2.02. li Yes General Equipment Requirements. - r No 1” Yes Operation and maintenance manuals required. Spare Parts r No 1-5 r Yes Required. (Carlsbad Water ) (Recycling Facility) 16220 -1- I (r ZOO w~t. %phase. 60 HZ I (r 230 wlt. 1-phase, 60 Hz I Ir 230 Loit. 3-phase, 60 HZ I (li. 460 wlt, 3-phase, 60 Hz I (r 2300 wlt, 3-phase. 60 Hz r 4000 wlt. 3-phase, 60 Hz rrangement. (i Horizontal I (r Vertical solid shaft r Vertical hollow shaft [Speed. (i Constant speed I Ir 2 speed, 1 winding I \r 2 speed. 2 winding Variable speed (adjustable frequency drie) r Variable speed (other) selected, indicate type. When "Variable speed (other)" is -2.02. - Enclosure. r Open drip proof G Totally enclosed-fan cooled C Explosion proof Totally enclosed-fan cooled rated for Class I, Diwsion 2 area r wp1 r WPZ r Other alternative. When "Other" is selected, indicate 2- Area classifications. 2- Non-Hazardous C Class I, Group C B D, Diwsion 1 C Class I, Group C 8 D, Diwsion 2 r Other When "Other" is selected, indicate class, group, and division. 2 Special features. r Encapsulated Winding 2.02.04 Seere DutyChemical SeMce Premium Efficiency Other (Carlsbad Water ) (Recycling Facility) 16220 -2- When "Othef is selected, indicate Service factor. F 1.0 - alternative. r 1.15 Insulation class and temperature (by resistance method). rise above 40°C design ambient F Class F with 8o'C rise at 1.0 SF Starting Requirements Starting condition. Loaded r Class F with 90°C rise at 1.15 SF C Class H with 105°C rise at 1.0 SF Ir Unloaded tarting method. C Full Voltage Reduced Voltage, Auto-transformer Main Motor Leads Space heater leads CT for Ammeter Ground Lug Mounted Inside 1 Thrust bearing RTD r 1 Each thrust and guide bearing r 2 Each thrust and guide bearing Miscellaneous. R DrainlBreather Non-Spark Fan (Carlsbad Water ) (Recycling Facility) 16220 -3- Section 16220 GENERAL PURPOSE INDUCTION MOTORS PART 1 - GENERAL 1-1. SCOPE. This section covers single and three-phase, small (fractional) and medium (integral) horsepower, alternating current motors rated 500 horsepower and less (NEMA MG1-1998). Motors shall meet the following requirements, and the design conditions and features as required. Motors shall be designated with the driven equipment and shall be located as required. 1-2. GENERAL. Motors furnished under this section shall be fabricated, and assembled in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by the ENGINEER. 1-2.01. Terminoloqy. When the phrase " when required" is stated in this section it shall mean "as required in the attached Data Sheet ". 1-2.02. General Eauipment Requirements. When required, the General Equipment Requirements shall apply to all equipment furnished under this section. 1-2.03. Abbreviations. Reference to standards and organizations shall be indicated by the following abbreviated letter designations: AFBMA Antifriction Bearing Manufacturers Association ANSI American National Standards Institute IEEE Institute of Electrical and Electronics Engineers NEC National Electrical Code NEMA National Electrical Manufacturers Association UL Underwriters' Laboratories (Carlsbad Water ) (Recycling Facility) 16220 -4- 1-2.05, Governina Standards. Motors furnished under this section shall be designed, constructed, and tested in accordance with the latest version of NEMA MGI and IEEE 112, Test Method 6. 1-2.06. NameDlates. All motor nameplate data shall conform to NEMA MG 1 requirements. 1-3. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with complete engineering data covering the materials used, parts, devices, and accessories forming a part of the motor shall be submitted in accordance with the submittals section. The drawings and data shall include, but shall not be limited to, the following: Motors Name of manufacturer. Type and model. Type of bearing and method of lubrication. Rated size of motor, hp [kWJ, and service factor. Temperature rise and insulation rating. Full load rotative speed. Net weight. Efficiency at full, 3/4, and 1/2 load. Full load current. Locked rotor current Space heater wattage, where applicable, Motor temperature switch data, where applicable. RTD data, where applicable 1-4. OPERATION AND MAINTENANCE DATA AND MANUALS. When required, adequate operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals section. Operation and maintenance manuals shall include the following: (Carlsbad Water ) (Recycling Facility) 16220 -5- a. Assembly, installation, alignment, adjustment, and checking instructions. b. Lubrication and maintenance instructions. c. Guide to troubleshooting. d. Parts lists and predicted life of parts subject to wear. e. Outline, cross-section, and assembly drawings; engineering data; and wiring diagrams. f. Test data and performance curves, where applicable. 1-5. SPARE PARTS. Not Used. PART 2 - PRODUCTS 2-1. SERVICE CONDITIONS. Service conditions for motors shall be as required for driven equipment. Motors shall be designed for special conditions such as area classification, altitude, frequent starting, intermittent overload, high inertia, mounting configuration, or service environment as required. Manufacturer's standard motor may be supplied on appliances, tools, and unit heaters, in which case a redesign of the unit would be required to furnish motors of other than the manufacturer's standard design. Unless specified otherwise, all motors shall be designed for full voltage starting and to operate from an electrical system that may have a maximum of 5 percent voltage distortion according to IEEE 519. Where required, motors utilizing a reduced-voltage, autotransformer starter shall be capable of reduced-voltage starting at a 65 percent tap setting. When powered from an adjustable frequency drive (AFD), motors shall be inverter duty and specifically selected for service with an adjustable frequency type speed controller and shall be derated as required to compensate for harmonic heating effects and reduced self-cooling capability at low speed operation. Each motor shall not exceed a Class 6 temperature rise when operating in the installed condition at load with power received from the adjustable frequency drive. All motors driven by AFDs shall be supplied with full phase insulation on the end turns and shall meet the requirements of NEMA MG 1, Part 31. In addition to the requirements of NEMA MG 1, Part 31, motors (Carlsbad Water ) (Recycling Facility) 16220 -6- shall be designed to be continually pulsed at the motor terminals with a Voltage Of 1600 volts ac. 2-2. PERFORMANCE AND DESIGN REQUIREMENTS. Design and construction of each general-purpose motor shall be as specified herein and as required. Motor voltage, arrangement, service factor, insulation class, and drive system shall be as required. 2-2.01, Nameplate Horsepower. Motor nameplate horsepower [kw shall be equal to or greater than the maximum load imposed by the driven equipment. 2-2.02. Enclosures. All motors shall be self-ventilated. All self-ventilated open type motors, including those with dripproof, splashproof, and weather protected enclosures, and the fan covers of totally enclosed fan cooled motors shall meet NEMA MG 1 requirements for a fully guarded machine. 2-2.02.01. Totallv Enclosed Motors. Totally enclosed motors shall be furnished with drain holes and rotating shaft seals. Frames, bearing brackets, external terminal housings, and fan covers for fan cooled motors shall be cast iron. External cooling fans for fan cooled motors shall be fabricated of brass, bronze, aluminum alloy containing not more than 0.2 percent copper, malleable iron, or plastic. All plastic fans shall be fabricated of a reinforced thermosetting plastic and shall be UL approved. 2-2.02.02. Outdoor Motors. Outdoor motors shall have NEMA weather protected enclosures. All exposed metal surfaces shall be protected, where practical, with a corrosion resistant polyester coating. Exposed uncoated surfaces shall be of a corrosion resistant metal. Enclosure exterior and interior surfaces, air gap surfaces, and windings shall be protected with a corrosion resistant alkyd enamel, polyester, or epoxy coating. 2-2.02.03. Motors for Hazardous Locations. Motors for hazardous locations shall be in accordance with the NEC and of the correct type enclosures for the particular service as specified in NEMA MG 1. Motors shall meet the requirements of UL 674. 2-2.02.04. Encapsulated Windings. Not Used. 2-2.02.05. Severe Dutv Chemical Service Motors. When required, motors shall be provided with a totally enclosed, fan-cooled enclosure with special corrosion- MGI-1.27.2 and IEEE 841. resistant finish and encapsulated windings meeting the requirements of NEMA 2-2.03. Conduit Boxes. Externally mounted conduit boxes shall be in accordance with NEMA MG 1. The conduit boxes shall be diagonally split for easy access to the motor leads, and designed for rotation in 90-degree (Carlsbad Water ) (Recycling Facility) 16220 -7- increments. A gasket shall be furnished between the halves of the box. Conduit openings in the main conduit box shall match the size and quantity of conduits indicated on the one line drawings. Motor conduit boxes shall be oversized at least one size larger than NEMA standard. The main conduit box shall be sized for all indicated accessory leads. Size shall be increased as required for stress cone terminations and current transformers. When required, each motor shall have auxiliary terminal boxes with terminal leads grouped in boxes for all external connections. Terminal boxes shall be oversized and shall have terminals and conduit hubs sized for the cables and conduit indicated on the drawings. Motors furnished in NEMA 320 frame series and larger shall have conduit boxes designed and constructed to permit motor removal after installation without disconnecting raceways. 2-2.04. &&. Motor power leads shall be wired into the motor terminal housing. Unless otherwise specified, space heater leads shall be wired into the motor terminal housing. All motor leads and their terminals shall be permanently marked in accordance with the requirements of NEMA MG 1, Part 2. Each lead marking shall be visible after taping of the terminals. All motors rated 100 horsepower and larger, all motors furnished with unidirectional blowers, and all vertical motors shall have the direction of rotation marked by an arrow mounted visibly on the stator frame near the terminal housing, or on the nameplate, and the leads marked for phase sequence TI, T2, T3, to correspond to the direction of rotation and supply voltage sequence. Leads for dual-voltage rated or for multispeed motors shall be easily connected or reconnected in the terminal housing for the operating voltage or for the specified speeds. Permanent instructions for making these connections shall be furnished inside the terminal housing or on the motor frame or nameplate. 2-2.05. Terminals. Cable type leads shall be provided with Burndy Type YA or acceptable equal compression type connectors. 2-2.06. Groundina Connections. All motors, including those with resilient mountings, shall be furnished with a ground connection. 2-2.07. Bearinos. All bearings shall be self-lubricating, shall have provisions for relubrication, and shall be designed to operate in any position or at any angle. Motor bearings shall be antifriction type with Llo life rating of 40,000 hours in accordance with AFBMA Standards. (Carlsbad Water ) (Recycling Facility) 16220 -8- All bearing mountings shall be designed to prevent the entrance of lubricant into the motor enclosure or dirt into the bearings, and shall be fitted with pipes, drain plugs, and fittings arranged for safe, easy relubrication from the outside of the motor while the motor is in service, as necessary. 2-2.08. Rotors. All induction motors shall have squirrel-cage rotors adequately sized to avoid overheating during acceleration of the motor and driven equipment. Rotors shall be dynamically balanced to 0.08 in./sec or less. 2-2.09. Shafts. Shafts shall be furnished with corrosion resistant treatment or shall be of a corrosion resistant material. 2-2.10. Toraue Characteristics. Motors rated 200 horsepower and less shall have torques and locked-rotor current in accordance with NEMA MG 1, Part 12. 2-2.1 1. Motor SDace Heaters. When required, motors shall be provided with a space heater element sized to prevent condensation on the core and windings. The space heaters shall be isolated or so located as to prevent heat damage to adjacent painted surfaces and shall be suitable for 120 volt, 60 Hz, single phase power supply. 2-2.12. Temperature Sensina Devices. When required, each motor shall be furnished with at least one automatic reset winding temperature switch per phase. Temperature switch contacts shall be normally closed and rated 5 amperes at 120 volts ac. The contacts shall be wired in series with the end leads brought out to a separate motor terminal box. Switches shall be as recommended by the motor manufacturer. 2-2.13. Assembly. All motors shall be completely assembled with the driven equipment, lubricated, and ready for operation. 2-2.14. Efficiency. When required, motors shall be premium efficiency type and shall have a NEMA nominal efficiency nameplate value equal to or greater than values indicated in the following table. Efficiency shall be determined in accordance with IEEE 112, Test Method B. When premium efficiency is required, vertical motors shall be premium efficiency type and shall have efficiency values equal to or greater than those indicated in the following table minus 0.50. (Carisbad Water ) (Recycling Facility) 16220 -9- Motor Nominal Efficiency Values Nominal Efficiency Values --___ - - - " -. Open Drlp Enclosure TEFC Enclosure ~ . ." kW hp ~ 3600 1800 1200 900 3600 1800 1200 900 rpm rpm rpm rprn rpm ' rprn rpm rpm ~~ .............................. .. - 0.7 1 84.0 83.0 80.5 75.0 75.5 81.5 81.5 75.5 1.1 1.5 82.5 84.0 84.5 78.0 82.5 ' 84.0 86.5 80.0 1.5 2 84.0 84.0 86.5 86.5 84.0 , 84.0 87.5 . 85.5 ... .. - " ......... " ..... " .~ ........ ...... .. . ~ ........... ..... "" ... _" (Carlsbad Water ) (Recycling Facility) 16220 -1 0- - Motor Nominal Efficiency Values Nominal Efficiency Values Open Drip Enclosure - TEFC Enclosure -. " ~ kw ' hp ' 3600 1800 1 1200 ' 900 ' 3600 . 1800 1200 900 rpm rpm rpm rpm rpm rpm rpm rpm 298 , 400 95.4 95.4 . 95.4 95.4 336 450 ' 95.8 95.8 95.4 95.4 373 500 ' 95.8 95.8 95.4 95.8 . . " ". ." 2-3. ACCESSORIES, 2-3.01. SDecial Tools and Accessories. Motors requiring periodic repair and adjustment shall be furnished complete with all special tools, instruments, and accessories required for proper maintenance. Each motor shall be provided with lifting eyebolts or lugs and appropriate fittings for adding bearing lubricant. Grease lubricated units shall be provided with a means of venting the casing. Oil lubricated units shall be provided with constant level oilers or with sight glasses arranged to indicate operating and static oil levels. 24. ANCHORS. CONTRACTOR shall furnish suitable anchors for each item of equipment as required for driven equipment. 2-5. SHOP PAINTING. Exposed surfaces shall be finished, thoroughly cleaned, and filled as necessary to provide a smooth, uniform base for coating. Electric motors shall be shop primed or finished with an oil-resistant enamel or universal type primer suitable for top coating in the field with a universal primer and aliphatic polyurethane system. 2-6. BALANCE. All rotating parts shall be accurately machined and shall be in as nearly perfect rotational balance as practicable. Excessive vibration shall be sufficient cause for rejection of the equipment. The mass of the unit and its distribution shall be such that resonance at normal operating speeds is avoided. In any case, the unfiltered vibration displacement (peak-to-peak), as measured at any point on the machine, shall not exceed the limits as required .At any operating speed, the ratio of rotative speed to the critical speed of a unit or its components shall be less than 0.8 or more than 1.3. (Carlsbad Water ) (Recycling Facility) 16220 -1 1- PART 3 - EXECUTION 3-1, INSTALLATION. Each motor will be installed in accordance with the Equipment Installation, Section 1106OC. End of Section (Carlsbad Water ) (Recycling Facility) 16220 -12- Section 16425 SWITCHBOARDS Data Sheet I I I 1-4 (i Yes Operation and maintenance manuals required. r No (Spare parts. 1-6. kdination'study. 1~ Yes r No Time current curves required for: R Mein breaker r ?e breaker I7 Largest feeder breaker Smallest breaker System Characteristics Voltage, phase. V r 240, 3 phase 480, 3 phase r Other wltage alternative value. When "Other is selected, indicate Frequency. r 50 Hz 60 Hz Number of wires. r 3 wire 4 wire (Carisbad Water) (Recycling Facility) 16425 -1- I onstruction Features €MA enclosure type. (i- NEMAType 1 C NEMA Type 3R walk-in r NEMA Type 3R non-walk-in lain bus rating. amp [AI r 400 r 600 r 800 r 1600 r 2500 r 3000 r 1200 (i- 2000 C 4000 Connected. (i- Front " Front Access. r Rear r Rear Install against wall. (i- Yes r NO Section bottom type. (5 Open r Baniered Busing 2-2.02 r Pad (i- Bus Neutral connection. Bus fault rating (symmetrical). amp [AI r 50,000 (i- 75,000 r 1oo.000 r 200,ooo Incoming Line Section@) Number of incoming line sections. r 1 "2 Service entrance rated. (i- Yes r No Incoming cables. r TOP (i- Bottom 2- 2- Cable pull box required. r Yes (i- No (Carlsbad Water) (Recycling Facility) 16425 -2- . .~ I - 2- 2.04.03 G Yes Pqwer utility metering requirements. ?No 2 c Yes Incoming line metering. 2.0L1.04 r NO - 2- r Yes If "Yes" is selected, indicate if metering is to be compatible with Metering System Software and Network in Section 16050. suppression. No 2 Transient voltage surge G Yes 2 r Yes Busway entry compartment. 2 provisions. 2.04.01 Yes Cable pull box Utility Seal No 2.04.02 G No - - - Fixed mounted insulated case power Solid-state electronic trip F Short time delay (electronic trip) I be. Molded case Fixed mounted insulated case power Drawout insulated case power Operation. Manual Electrical (Carlsbad Water) (Recycling Facility) 16425 -3- Breaker trip features (molded case) ," Magnetic/thenal trip r Solid-state electronic trip r Short time delay (electronic trip) Ground fault protection Distribution Section 2-2.06. Distribution breakers required. G Yes /r No Type. c Molded case C Fixed mounted insulated case power C Drawout insulated case power Breaker trip features (molded case). IJ Magnettc/thennal trip F Solid-state electronic trip F Short time delay (electronic trip) F Ground fault Drotection I I I able exit. IF TOP IF Bottom Operation. Manual r Electrical 2-2.07. Molded Case Circuit Breakers MCB mounting. r Indtidually r Panel Individual main (tie) with panel MCB fault current (symmetrical). r 35,000 amp [AI r 5o.ooo c 65.000 r 100,000 r 5o.ooo r 65.000 r 1oo.000 Environmental Conditions Location. G lnslde buildmg (Carlsbad Water) (Recycling Facility) 16425 -4- (Carlsbad Water) (Recycling Facility) 16425 -5- Section 16425 SWITCHBOARDS PART 1 - GENERAL 1-1. SCOPE. This section covers switchboard equipment, which shall be furnished as specified herein and as indicated on the drawings. Switchboards shall meet the following requirements, and the design conditions and features as required. Switchboards shall be designated and shall be located as required. 14.01. 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. 1-2.01. General EauiDment Reauirements. When required, the General Equipment Requirements shall apply to all equipment furnished under this section. 1-2.02. Dimensional Restrictions. Layout dimensions will vary between manufacturers, and the layout area indicated on the drawings is based on typical values. The supplier shall review the contract drawings, the manufacturer's layout drawings and installation requirements, and make any modifications required for proper installation subject to acceptance by ENGINEER. 1-2.03. WorkmanshiD and Materials. Equipment supplier shall guarantee all equipment against faulty or inadequate design, improper assembly or erection, defective workmanship or materials, and leakage, breakage, or other failure. Materials shall be suitable for service conditions. All equipment shall be designed, fabricated, and assembled in accordance with recognized and acceptable engineering and shop practice. Individual parts shall be manufactured to standard sizes and thicknesses so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable. Equipment shall not have been in service at any time prior to delivery, except as required by tests. (Carlsbad Water) (Recycling Facility) 16425 -6- 1-2.04. Abbreviations. Reference to standards and organizations in the Specifications shall be by the following abbreviated letter designations: AIS1 American Iron and Steel Institute ANSI American National Standards Institute AWG American Wire Gage IEEE Institute of Electrical and Electronics Engineers NEC National Electrical Code NEMA National Electrical Manufacturers Association UL Underwriters' Laboratories 1-2.05. Governina Standards. All equipment furnished under this section shall be designed, constructed, and tested in accordance with all the applicable standards of ANSI, NEMA, and UL. includina. but not limited to, NEMA PB 2 and UL 891 (switchboards); NEMA AB1 and UL 489 (molded-case circuit breakers); ICs-6 (enclosures); and NEMA PD 2.2 (Ground Fault Protection). When required, equipment covered by this section shall be listed by UL or a nationally recognized third-party testing laboratory. All costs associated with obtaining the listing shall be the responsibility of CONTRACTOR. In the event no third-party testing laboratory provides the required listing, an independent test shall be conducted at CONTRACTOR'S expense. Before the test is conducted, CONTRACTOR shall submit a copy of the testing procedure to ENGINEER. 1-2.06. Namedates. When required, each switchboard section shall have a nameplate permanently affixed to it, listing the following information: Name of manufacturer System voltage Main bus rating Type Manufacturer's shop order number and date In addition, each circuit breaker and instrument on the front of the switchboard shall have a suitable nameplate. Each incoming line section shall be furnished with a nameplate to indicate the power source or substation from which it is fed. The nameplates for the distribution circuit breakers shall indicate the equipment fed through the breaker. Nameplates shall be black and white laminated (Carlsbad Water) (Recycling Facility) 16425 -7- phenolic material or suitable size, and shall be engraved with 3/4 inch 119 mml high letters for section and circuit breaker identity and 118 inch [3 mm] letters for other information. The engraving shall extend through the black exterior lamination to the white center. Each control device and each control wire terminal block connection inside the units shall be identified with a permanent nameplate or painted legend to match the identification on the manufacturer's wiring diagram. 1-2.07. System Characteristics. The equipment will be connected to a system as required. 1-2.08. Seismic Consideration. The manufacturing and anchoring/support of equipment and materials shall be designed in accordance with the requirements for Seismic Zone 4 of UBC. 1-3. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with complete engineering data covering the materials used, parts, devices, and accessories forming a part of the switchboard, shall be submitted in accordance with the submittals section. The drawings and data shall include, but shall not be limited to, the following: Switchboard Elevation, plan, conduit entrance locations, and weight. Circuit breaker time-current characteristic curves. Nameplate legends and equipment schedule Single-line and control wiring interconnection diagrams, Metering section details Shop test report. Installation report. Seismic requirements. When transient voltage surge suppressors are required, submittals shall include manufacturer's catalog and specification data, including device dimensions, weight, material composition, and connection diagrams Documentation shall be provided showing the file number of compliance with UL 1449 listing requirements and results of independent, third party NRTL certification of listed surge ratings. The test results submitted shall include UL file number, date or (Carlsbad Water) (Recycling Facility) 16425 -0- report, product covered, electrical ratings, voltages, phases, modes of protection, nomenclatures, and UL 1449 ratings with and without disconnect device. 1-4. OPERATION AND MAINTENANCE DATA AND MANUALS. When required, adequate operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals section. Operation and maintenance manuals shall include the following: a. Assembly, installation, alignment, adjustment, and checking instructions. b. Lubrication and maintenance instructions. c. Guide to troubleshooting. d. Parts lists and predicted life of parts subject to wear e. Outline, cross-section, and assembly drawings; engineering data; and wiring diagrams. f. Test data and performance curves, where applicable. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. 1-5. SPARE PARTS. Spare parts shall be provided as required Spare parts shall be suitably packaged, as specified herein, with labels indicating the contents of each package. Spare parts shall be delivered to OWNER as directed. 1-6. COORDINATION STUDY. When required, a coordination study of the power distribution system will be conducted as specified in the electrical section. The equipment manufacturer shall provide the following information to ENGINEER with the initial equipment drawing submittal: Protective relay coordination curves for each solid-state trip device. Time current curves shall be provided for circuit breakers as required. Data for all devices with adjustable settings shall be submitted, with all literature necessary to determine the appropriate settings. This shall include, but shall not be limited to, Operation Manuals for each type of adjustable trip device, (Carlsbad Water) (Recycling Facility) 16425 -9- 1-7. DELIVERY, STORAGE. AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. PART 2 - PRODUCTS 2-1. ACCEPTABLE MANUFACTURERS. The switchboard shall be manufactured by Cutler-Hammer, General Electric, Siemens Energy 8 Automation, or Square D, without exception. 2-2. CONSTRUCTION. All equipment furnished under this section shall be designed and constructed in accordance with the following requirements: 2-2.01, Enclosure. The switchboard shall be of deadfront, modular type construction with the required number of vertical sections bolted together to form one rigid, metal-enclosed unit as required. All sections shall be aligned in both front and rear. The switchboard frame shall be of formed UL gauge steel, rigidly bolted together to support all cover plates, buses, and circuit breakers. Steel base channels shall be bolted to the frame. Each section shall have a removable top plate and when required, an open or a barriered bottom for installation and termination of conduit. All front covers shall be removable with a single tool and all doors shall be hinged, with removable hinge pins. 2-2.02. w. The main a bus shall be tin-plated copper and shall be of sufficient size to limit the temperature rise to 65"C, based on UL tests. End sections shall be predrilled for units to be added in the future. 2-2.02.01. Neutral Bus. When required, a tin-plated copper neutral bus shall be provided through all vertical sections and shall be rated full capacity. 2-2.02.02. Neutral Pad. Not Used. 2-2.03. Ground Bus. The ground bus shall extend the entire length of the switchboard and shall be firmly secured to each vertical section. A ground lug shall be provided at each end of the ground bus for connection to building grounding system with 4/0 AWG bare copper cables. Other ground lugs for feeder circuits shall also be supplied as indicated on the drawings. 2-2.04. lncomina Line Sections. Incoming line sections shall be provided as shown on the one-line diagram and when required shall have all necessary components for a cable pull box, a busway entry compartment, a power utillty metering compartment, an OWNER metering compartment, or a main breaker. 2-2.04.01. Cable Pull Box. Not Used (Carlsbad Water) (Recycling Facility) 16425 -1 0- 2-2.04.02. Buswav Entrv Compartment. Not Used. 2-2.04.03. Power Utilitv Meterina Compartment. When required, this compartment shall meet the requirements of the local utility and shall be provided with a sealable hinged door. Busses shall include provisions for mounting utility company current transformers and potential transformers or bus taps. 2-2.04.04. Incoming Line Metering Compartment. When required, the incoming line section@) shall be provided with a microprocessor-based, digital power meter. Current transformers and potential transformers shall be provided for input of current and voltage signals to the metering package. Currents, voltages, active power, reactive power, power factor, watt-hours, frequency, and demand values shall be available for display. Total harmonic distortion waveforms shall also be available. The following alarm features shall be provided: undervoltage, power factor leading or lagging, kvar limit, voltage sequence reversal, underfrequency, and overcurrent. The metering package shall be capable of RS 485 serial communication for remote monitoring. The digital power meters shall be Cutler-Hammer "IQ Analyzer", Multilin "PQM", Square D "PowerLogic Model 2350, Allen-Bradley "Power Monitor II", or Basler "Energy Transducer" with built- in face display. Sufficient lengths of communication cable shall be provided for connection of metering units within the switchboard and as indicated on the drawings. The unit shall have two isolated 4-20 ma selectable outputs. 2-2.04.05. Transient Voltaae Surae Suppression. When required, transient voltage surge suppressors (TVSS) shall be provided and installed integral to each switchboard assembly. Units shall be UL 1449 listed for installation into switchboards. TVSS devices shall be designed, manufactured, tested, and installed in accordance with the following standards: ANSlllEEE C62.41-1991 and C62.45-1987. NEMA LS1-1992 Guidelines. NFPA 20,70, 75, and 780. UL 1449 2"d Edition and 1283. Each NSS device shall be configured for permanent connection, The TVSS device shall be provided with the manufacturer's standard disconnecting means. In-line, series connected components shall not be acceptable. Each NSS device shall utilize metal oxide varistors (MOV) connected in parallel. 2-2.04.05.01. Device Performance (Carlsbad Water) (Recycling Facility) 16425 -1 i- The minimum total surge current and withstand capability with Compliance to ANSIAEEE C62.41 and NEMA LS1 shall be: L-L L-N L-G N-G Switchboards 240,000 A 120,000 A 120,000 A 120,000 A The maximum UL 1449 Edition SVR for the device must not exceed the following (inclusive of disconnect): L-L L-N L-G N-G Switchboards 1500 V 800 V 800 V 800 V Each unit shall have a maximum continuous operating voltage (MCOV) greater than 115 percent of the nominal system operating voltage for L-L, L-N, L-G, and N-G. Each unit shall be capable of suppressing a Category B3 impulse at less than 500 volts. Each unit shall be UL 1283 listed as an electromagnetic interference filter. Electromagnetic filtering shall provide insertion loss with a system noise attenuation of 55 dB from 100 kHz to 100 MHz when tested per 50 Ohm insertion loss method as defined by MIL 220A. Each unit shall incorporate 200 kAlC rated fusing and shall monitor all modes of protection inclusive of N-G and provide indicator lights (one green and one red LED) on the front cover of the enclosure and an indicator light on each module (inclusive of N-G) to individually monitor each module for failure. 2-2.04.05.02. Testing. CONTRACTOR shall provide the following test data for each unit: a. Third party testing from a nationally recognized testing laboratory (NRTL) verifying that the total surge current can be passed through the fuse with no charring, flames, or projection of materials. Testing of the fuse only will not be acceptable for this requirement. Testing shall indicate the lowest possible surge that can disrupt the fusing. b. Third party, NRTL testing verifying the fault current withstand rating of the fusing employed. Testing shall be conducted in both high and low impedance fault conditions and shall confirm no charring, flaming, or projection of materials. c. Life cycle testing per ANSlllEEE C62.41 and C62.45 with fusing in place for category C3 transients (20 kV at 1.2 x 50 microseconds (Carlsbad Water) (Recycling Facility) 16425 -12- and 10 kV at 8 x 20 microseconds). 2-2.04.06, Main Breaker. When required, each incoming line section shall include a molded case, fixed mounted insulated case, or drawout insulated case power circuit breaker with a current rating as indicated on the drawings. Internal control power transformers shall be provided to furnish control power for insulated case power circuit breakers. Compression type terminals shall be provided for terminating the number and size of copper conductors indicated on the drawings. 2-2.05. Tie Breaker Section. Not Used. 2-2.06. Distribution Section. The distribution section shall be provided to house branch circuit breakers as indicated on the drawings. Circuit breakers shall be molded case (individually mounted or panel mounted as required), fixed mounted insulated case, or drawout insulate case as required. Circuit breakers shall be removable from the front without disturbing adjacent units. The switchboard shall contain space for future units as indicated on the drawings. 2-2.07. Molded Case Circuit Breakers. Molded case circuit breakers shall be individual or panel mounted as required. Circuit breakers shall be rated to interrupt and withstand an available fault current at the system line voltage as required. Circuit breakers shall be operated by a toggle-type handle and shall have a quick-make, quick-break, over-center switching mechanism that is mechanically tripfree. When required, circuit breakers shall be thermal magnetic or shall be furnished with a solid-state electronic trip unit complete with built-in current transformers. The ampere rating of the trip unit shall be as indicated on the drawings. The trip unit shall have adjustable settings for continuous amperes, instantaneous pickup, and short-time pickup. When required, the trip unit shall be provided with additional short delay trip time adjustment for better system coordination. Circuit breakers indicated to be rated less than 100 amperes shall be thermal-magnetic types. When required, built-in ground fault protection shall have adjustable pick-up ratings not exceeding 1,200 amperes, time delay adjustable from 0.1 to 0.5 seconds, and a neutral ground fault current transformer. The solid-state electronic trip breakers shall have built-in test points for testing long delay, instantaneous, and ground fault functions of the breaker by means of a 120 volt ac operated test kit. 2-2.08. Insulated Case Power Circuit Breakers. Not used. (Carlsbad Water) (Recycling Facility) 16425 -1 3- 2-2.09. Shop Paintinq. All iron and steel surfaces, except machined Surfaces and stainless steel, shall be shop painted with the manufacturer's standard coating. Finish color shall be ANSI 61. Field painting, other than touchup painting, will not be required. A sufficient quantity of additional coating material and thinner shall be furnished for field touch up of damaged coatings. When required, the underside of equipment to be installed in exposed outdoor locations shall be thoroughly cleaned and coated with an automotive type undercoating material. The coating shall be thick enough to withstand normal handling during shipping and installation. The underside is defined as the surfaces in contact with the floor or pad and other surfaces not readily accessible for field painting. The coating may be factory or field applied. 2-3. ACCESSORIES 2-3.01. Special Tools and Accessories. Equipment requiring periodic repair and adjustment shall be furnished complete with all special tools, instruments, and accessories required for proper maintenance. Equipment requiring special devices for lifting or handling shall be furnished complete with those devices. 2-4. SHOP TESTS. After the equipment has been completely assembled, it shall be shop tested for general operating conditions, circuit continuity, and high potential and other standard tests for the particular class of equipment as defined by industry standards. Four certified copies of the test results shall be submitted to ENGINEER before the equipment is shipped. PART 3 - EXECUTION 3-1. INSTALLATION. Installation will be in accordance with 16100 3-2. FIELD QUALITY CONTROL. 3-2.01. Installation Check. When required, an experienced, competent, and authorised representative of the manufacturer shall visit the site of the Work and inspect, check, adjust if necessary, and approve the equipment installation. The representative shall be present when the equipment is placed in operation in accordance with Section 01650, and shall revisit the job site as often as necessary until all trouble is corrected and the equipment installation and operation are satisfactory in the opinion of ENGINEER. The representative shall verify that the settings of all protective devices are as recommended in the coordination study, make all adjustments, approve the installation, and test the ground fault system. The ground fault system testing shall satisfy the requirements of the National Electrical Code, (Carlsbad Water) (Recycling Facility) 16425 -14- The manufacturer's representative shall furnish a written report certifying that the equipment has been properly installed and lubricated: is in accurate alignment; is free from any undue stress imposed by connecting conduit or anchor bolts; and has been operated under full load conditions and that it operated satisfactorily. All costs for these services shall be included in the Contract Price for the number of days and round trips to the site as required. 3-2.02. Field Installation Suwrvision. When required, the equipment manufacturer shall furnish a qualified field installation supervisor during the equipment installation. Such services shall be included in the Contract Price for the number of days and round trips to the site as required. Manufacturers' installation supervisor shall observe, instruct, guide, and direct CONTRACTORS erection or installation procedures as necessary. The equipment manufacturer will be provided with written notification 10 days prior to the need for such services. End of Section (Carlsbad Water) (Recycling Facility) 16425 -15- Section 16480 600 VOLT CLASS MOTOR CONTROL CENTERS Data Sheet bara- (Description IData JUnits graph General Location of MCC's. required. G yes, General Equipment Requirements 1-2.01 MCC-2 MCC Designations. Electrical Room 1.1 2 400 Amps and 1200 Amps Quantity of MCC's required. - r NO. or labeled by approved testing r No. 1-2.06 E Permanent name plates required. Nameplates. C Name plates by othen. 1-4 G yes. Operation and maintenance manuals required. r NO. 1-5 E Yes. Coordination Study. 1-s Spare Parts. c NO. 1-6 r M~,~ breaker. Time current curves required for r ne breaker. Largest breaker in combination starter. F Smallest breaker. System Characteristics Voltage. VM C 240, 3 phase. G 480, 3 phase. r Other wltage (Carlsbad Water) (Recycling Facility) ~ 16480 -1- When "Other voltage" is selected, indicate the alternative. Frequency. 6' 60. r 50. Number of wires. I; 3 wire. r 4 wire. Construction Features NEMA wiring class. I; I. r IS r 11s. NEMA wiring type. r A. I; 20 pool. .2.01 - I; Yes. Physical metal barrier between sections. r no. Horizontal bus bar rating. fi 600. r 800. r 1000. r 1200. r woo. r 2000. c 2500. I I ertical bus bar rating. li 300. r 600 I C Manufacturer standard I I Neutral connection. r BUS. - 04.01 Hz [Hz] in. [mm] - amp IAI amp [AI " (Carlsbad Water) (Recycling Facility) 16480 -2- I Prig. . If? 65,000 r 100,ooo. Service Entrance rated. r Yes. IC No I I I Cable entry. c TOP. Jr Bottom. G Both. NEMA enclosure type. (i NEMA Type 1 Gasket&. I I Ir NEMA ~ype 12 Industrial. I Ir NEMA Type 3R walk-in. I r NEMA Type 3R non-walk-in. Components 2-2.06 Combination magnetic Starters. F Yes. r NO. contacts. If "yes" is selected, indicate spare F one NO spare contact, F One NC spare contact. If "yes" is selected, indicate overload (i Bimetallic oefload =lays, type. (C Eutectic Alloy oerbad relays. I r Heaterless owrload relays. \Combination solid state starters. yes. l(i No If "yes" is selected, indicate spare r one NO spare contact. contacts. r One NC spare contact. auxiliary contactor for power factor If "yes" is selected, indicate if C Yes. correction capacitor is required. c NO. (i No. (Carlsbad Water) (Recycling Facility) 16480 -3- Yes -wired fur external power (Carlsbad Water) (Recycling Facility) 16480 4- (If "Yes" is selected. indicate number 11 [Each 1 ~~ lof days. Ilf "Yes" is selected, indicate number 11 ]Each ~~ of round trips. 3-2.02 c yes. Installation supervision required. C No. If "Yes" is selected, indicate number of days. If "Yes" is selected, indicate number of round trips. (Carlsbad Water) (Recycling Facility) 16480 -5- Section 16480 600 VOLT CLASS MOTOR CONTROL CENTERS PART 1 - GENERAL 1-1. SCOPE. This section covers motor control center equipment which shall be furnished and installed as specified herein and as indicated on the drawings. Motor control centers shall meet the following requirements, and the design conditions and features as required. Motor control centers shall be designated and shall be located as required, 1-1.01. Terminoloay. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless ENGINEER notes exceptions. 1-2.01. General EQuiDment Requirements. When required, the General Equipment Requirements shall apply to all equipment provided under this section. 1-2.02. Dimensional Restrictions. Layout dimensions will vary between manufacturers and the layout area indicated on the drawings is based on typical values. The supplier shall review the contract drawings, the manufacturer's layout drawings and installation requirements, and make any modifications required for proper installation subject to acceptance by ENGINEER. 1-2.03. Workmanship and Materials. Equipment supplier shall guarantee all equipment against faulty or inadequate design, improper assembly or erection, defective workmanship or materials, and leakage, breakage, or other failure. Materials shall be suitable for service conditions. All equipment shall be designed, fabricated, and assembled in accordance with recognized and acceptable engineering and shop practice, Individual parts shall be manufactured to standard sizes and thicknesses so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable. Equipment shall not have been in service at any time prior to delivery, except as required by tests. (Carlsbad Water) (Recycling Facility) 16480 -6- 1-2.04. Abbreviations. Reference to standards and organizations in the Specifications shall be by the following abbreviated letter designations: AIS1 American Iron and Steel Institute ANSI American National Standards Institute AWG American Wire Gage IEEE Institute of Electrical and Electronics Engineers NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association UL Underwriters' Laboratories 1-2.05. Governinq Standards. All equipment furnished under this section shall be designed, constructed, and tested in accordance with NEMA ICs 3 and UL 845. When required, equipment covered by this section shall be listed by UL or a nationally recognized third-party testing laboratory. All costs associated with obtaining the listing shall be the responsibility of the CONTRACTOR. In the event, no third-patty testing laboratory provides the required listing; an independent test shall be performed at the CONTRACTORS expense. Before testing, the CONTRACTOR shall submit a copy of the testing procedure that will be used in evaluating the equipment. 1-2.06. Nameplates. When required, nameplates with unit description and designation of each control or indicating device shall be provided on all hinged doors. Nameplates shall be black and white laminated phenolic material of suitable size, and shall be engraved with 318 inch [lo mm] high letters for compartment identity and 3/16 inch [5 mrn] letters for other information. The engraving shall extend through the black exterior lamination to the white center. Each control device and each control wire terminal block connection inside the units shall be identified with permanent nameplates or painted legends to match the identification on the manufacturer's wiring diagram. 1-2.07. Svstern Characteristics. This equipment will be connected to a system as required. (Carlsbad Wafer) (Recycling Facility) 16480 -7- 1-2.08 Seismic Consideration. The manufacturing and anchoringlsupport of equipment and materials shall be designed in accordance with the requirements for Seismic Zone 4 of UBC. 1-3. SUBMITTALS. Complete assembly, foundation, and installation drawings, together with complete engineering data covering the materials used, parts, devices, and accessories forming a part of the motor control center shall be submitted in accordance with the submittals section. The drawings and data shall include, but shall not be limited to, the following: Motor Control Center Elevation, plans, and weight. Unit wiring diagrams showing devices, connections, and terminal designations. Interconnection diagrams. Control schematic diagrams, Seismic requirements. Circuit breaker time-current characteristic curves. 14. OPERATION AND MAINTENANCE DATA AND MANUALS. When required, adequate operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals section. Operation and maintenance manuals shall include the following: a. Assembly, installation, alignment, adjustment, and checking instructions. b. Lubrication and maintenance instructions, c. Guide to troubleshooting d. Parts lists and predicted life of parts subject to wear. e. Outline, cross-section, and assembly drawings; engineering data; and wiring diagrams. f. Test data and performance curves, where applicable. (Carlsbad Water) (Recycling Facility) 16480 -8- The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. 1-5. SPARE PARTS. Spare parts shall be provided as required Spare parts shall be suitably packaged, as specified herein, with labels indicating the contents of each package. Spare parts shall be delivered to OWNER as directed. 1-6. COORDINATION STUDY. When required, a coordination study of the power distribution system will be conducted in accordance with the electrical section. The initial equipment drawing submittal shall include the circuit breaker coordination curves for the largest circuit breaker utilized in a combination starter, and the smallest circuit breaker provided as a part of the motor control center assembly. 1-7. DELIVERY, STORAGE, AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. PART 2 - PRODUCTS 2-1. ACCEPTABLE MANUFACTURERS. The equipment shall be manufactured by Allen-Bradley, Cutler-Hammer, General Electric, Siemens Energy & Automation, or Square D, without exception. 2-2. CONSTRUCTION. Each control center shall conform to the arrangement, one-line diagram, schematics, and requirements indicated on the drawings or specified herein. Wiring shall be NEMA Class I, IS, II, or IIS as required. Wiring shall be NEMA Type A, B, or C as required. 2-2.01. Vertical Sections. The control center shall consist of standardized, freestanding structures bolted together to form a single dead-front panel assembly containing combination motor control units; feeder units; transformers; lighting panels; and metering, relaying, and interlocking, and miscellaneous control devices, as indicated on the drawings. A removable lifting angle shall be mounted on the top of each shipping group. Removable front and rear bottom channel sills shall extend the full width of the motor control center. Each vertical section shall be 90 inches [2250 mm] high and not less than 20 inches [500 mm] wide. When required, sections shall be 15 inches [375 mm] or 20 inches [500 mm] deep. Each 20 inch wide standard section shall have all necessary hardware and busing for modular plug-in units to be added and moved (Carlsbad Water) (Recycling Facility) 16480 -9-