HomeMy WebLinkAboutUS Filter Wastewater Group Inc; 2002-08-12; 3675 Part 2 of 5City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
b. Verify Valve Tags
c. Verify PLC Communication
d. Verify PC or Operator Interface Communication
e. Verify temporary system interconnections
2. Commissioning Activities
a.
b.
C.
d.
e.
f.
g.
h.
i.
j.
k.
1.
m.
Verify Pumps for Rotation
Commission Compressed Air System
Commission Blower System
Test Membrane Integrity Test System
Test Vacuum System (if used)
Test Automatic Strainers
Test Modulating Valves
Test Chemical Feed Systems used for feed and backwash
Test Chemical Feed Systems used in Clean-In-Place
Test Level Switches in Tanks
Test Pressure Switches
Set Mechanical Seals in Pumps and Flush System.
Test and Calibrate Process Instruments
1) Flow Meters
2) Pressure Transmitters
3) Level Transmitters
4) Turbidity Meters
5) Chlorine Residual Analyzers
6) pW0W Meters
016M.COMMISSIONMG OFMEMBRANE EQUIPMENTOOC 01660-4 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEM
n.
0.
P.
9.
r.
S.
7) Conductivity Meters
8) Temperature Transmitters
Miscellaneous Equipment
Field Located Manual Valves
Field Located Automatic Valves
Manual Unit Valves
Automatic Unit Valves
Flush Piping Systems
3. Start Up Activities
a.
b.
C.
d.
e.
f.
g.
h.
i.
1.
k.
1.
Test Feed Flow / Pressure / Level Control System in Manual and Automatic
Mode
Test Filtrate Flow / Pressure / Level Control System in Manual and
Automatic Mode
Test Backwash Flow / Pressure / Level / Control System in Manual and
Automatic Mode
Test Membrane Regeneration / Chemical Washing Sequences in Manual
and Automatic Mode.
Place Filtration Units into Service in Manual and Automatic Mode
Check Start Up Sequence in Normal and Emergency Modes
Check Shut Down Sequence in Normal and Emergency Modes
Check Process Logic Interlocks.
Remove Temporary Interconnections
Install Membrane Modules
1) See Section 01620, Installation of Membrane Equipment.
Conduct Preliminary Operator Training
Place Membrane System In Operation
016MI.COMMISSIONMG OFMEMBRANE EQUIPMENT.DOC 01660-5 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT Carlsbad Recycling Facility
D.
E.
F.
G.
1) Verify Filtration Sequence
2) Verify Backwash Sequence
3) Verify Membrane Test Sequence
4) Verify Other MFEM Process Sequences
m. Chemically Clean Membrane Units
n. Conduct Formal Operator Training
As a part of the commissioning, the MFEM shall start-up and operate all support
systems provided by MFEM, including but not limited to chemical feed systems,
instrumentation, air compression equipment, and electric controls. This testing shall
demonstrate that there are no water or air leaks in the System, that the piping has been
installed and connected properly, that the electrical system is operating correctly, and
that the instrumentation has been properly calibrated.
The MFEM shall furnish all labor, materials, instruments, and incidental and
expendable equipment required for commissioning / placing the equipment into
operation. The MFEM shall retain the services of any manufacturers representatives as
required in the Procurement Documents to assist with the commissioning / placing into
operation of the Goods. The Costs of theses services shall be borne by the MFEM
The MFEM shall conduct a membrane integrity test on each Unit as described in
Paragraph 2.2.G of Section 11300, Hollow Fiber Membrane Filtration System
Equipment. The MFEM shall provide the Engineer with both the integrity test results
for each Unit and results documenting that each installed Unit has passed the integrity
test.
Upon completion of the commissioning by the MFEM, the Engineer shall review the
operation of the equipment to verify that the commissioning is complete. The Engineer
shall perform random tests to determine if the equipment is operating properly and
witness various operational sequences. The Engineer may initiate alarm conditions to
determine if the control system is functioning properly. Upon satisfactory completion
of the review, the Engineer shall submit to the MFEM a written “notice of substantial
completion”. In the case that the review identifies some items that must be corrected,
the Engineer shall prepare a list detailing the outstanding issues and the party
responsible for the correction.
+ + END OF SECTION + +
016M).COMMISSIONl?4G OF MEMBRANE EQUIPMEN’LWC 0 1660-6 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 01670
ACCEPTANCE TESTING OF MEMBRANE EQUIPMENT
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work:
1. This Specification outlines the requirements for acceptance testing of the
membrane filtration equipment.
2. In addition to testing services required by this Section, the MFEM shall perform
all other testing services required by the Specifications.
B. Reference Specifications:
1. Section 11300, Hollow Fiber Membrane Filtration System Equipment
C. Coordination
1. The MFEM shall coordinate all services and activities required by this Section
with the Installation Contractor and the Engineer.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QMQC) - NOT USED
1.03 SUBMITTALS
A. Upon completion of the acceptance testing, the MFEM shall submit to the District a
written report detailing the results of the acceptance testing, including a copy of all
field notes, test logs and performance data.
PART 2 - PRODUCTS (NOT USED)
PART 3 - EXECUTION
3.01 ACCEPTANCE TESTING
A. Upon receipt of the written “notice of substantial completion”, the MFEM shall
perform an acceptance test on the System in coordination with the Installation
Contractor. Each Unit shall be tested concurrently but evaluated separately for
performance.
B. The purpose of the acceptance testing is to demonstrate that equipment is:
01670,ACCEPTANCE TESTMG OF MEMBRANE EQUIPMENT.DC€ 01670-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Properly installed.
2. Ready to be placed into service by the District.
3. In compliance with the service conditions, performance requirements, material
specifications, and all other requirements of the Procurement Documents.
The MFEM shall furnish all materials, instruments, and incidental and expendable
equipment required for acceptance testing, except where otherwise specified.
Throughout the acceptance testing period, a representative of the MFEM shall be
present on site during normal working hours and available via means of a pager or
cellular communication during non-working hours in case of an emergency.
The MFEM shall coordinate system acceptance testing with the Installation Contractor.
The District or an authorized representative of the District will be present to witness the
acceptance testing.
The MFEM shall maintain detailed logs and records regarding the progress of the
testing on a 12-hour interval basis. Reporting shall include both a narrative summary
of operations as well as a record of system setpoints and operating parameters. Any
changes to operations or process upset conditions shall be detailed in the report.
Testing shall be conducted on the complete MF train with membrane module pressure
vessels installed for a period of up to 72-hours of cumulative operation, during which
the MF system shall be operated and adjustments made to demonstrate that the
equipment and controls operate as a functional system as intended.
The major acceptance criteria for the 72-hour performance test shall be that the train
and ancillary systems operate as intended without major mechanical or electrical
problems and with minimal operator attention. Observed deficiencies in operation of
the system shall be corrected to the satisfaction of the Engineer at no cost to the
District.
The test shall be considered complete when, in the opinion of the Engineer, the
complete treatment system has operated in the manner intended at plant design capacity
for 72 hours without significant interruption. This period is in addition to any training,
functional, or performance test periods specified elsewhere. A significant interruption
will require the test then in progress to be stopped and restarted after corrections are
made.
1. Significant Interruption: May include any of the following events:
a. Failure of MFEM to maintain qualified onsite startup personnel as
scheduled.
C.
D.
E.
F.
G.
H.
I.
J.
01670.ACCEPTANCE TESlTNG OF MEMBRANE EQUIPMENT.M)C 01670-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Failure of any equipment item or treatment subsystem furnished by MFEM
to meet specified performance requirements for more than 2 consecutive
hours.
c. Failure of any critical equipment unit, system, or subsystem that is not
satisfactorily corrected within 5 hours after failure.
d. Failure of non-critical unit, system, or subsystem that is not satisfactorily
corrected within 8 hours after failure.
e. As may be determined by the Engineer.
2. The following events will not be considered cause for significant interruption:
a. Loss of feedwater delivered to the MF system for reasons beyond the
control of the MFEM.
b. Loss of power to the plant for reasons beyond the control of the MFEM.
c. Inability of the product water distribution system to accept water produced
by the MF system.
d. As may be determined by the Engineer.
K. During the acceptance testing, the System shall perform in accordance with the
guaranteed product water quality as specified in Article 2.01-B-4 of Section 11300,
Membrane Filtration (MF) System Equipment, General
L. Compliance and Release from On-Site Obligations: After the acceptance testing period,
the Engineer and District will meet with the MFEM to determine compliance with the
Procurement Documents. At that time, if it is determined that the MFEM has fulfilled
the requirements of the Procurement Documents, the MFEM will be released from the
obligation of an on-site presence. This will complete the acceptance test.
M. Successful completion of acceptance testing and receipt of the revised operations and
maintenance manuals shall be required for acceptance of the equipment.
++ ENDOF SECTION ++
01670.ACCEPTANCETESTMG OF MEMBRANE EQULPMENT.DOC 01670-3 AF'RIL '27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 01680
OPERATIONS ASSISTANCE DURING CORRECTION PERIOD
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work:
1. The MFEM shall provide Operations Assistance to the District for the Membrane
Filtration System Equipment during the correction period.
2. The Operations Assistance shall consist of a minimum of six site visits by the
MFEM.
3. The required assistance shall commence approximately one month after
completion of the Acceptance Testing as described in Section 01670, Acceptance
Testing of Membrane Equipment.
4. All tests or work by the MFEM during the correction period whether specifically
mentioned or not are to be included in the MFEM’S bid.
B. Coordination
1. The MFEM shall respond to the District’s request for operations assistance
promptly and be at the Point of Delivery within 48 hours of the request. The
duration of each visit shall be for a minimum of two days.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
A. Manufacturers Field Services
1. The service representative shall be an employee of the MFEM. The MFEM shall
make every attempt to send the same representative for each of the site visits for
operations assistance. The MFEM shall send one of the two Service Engineers
involved with the commissioning of the System.
PART 2 - PRODUCTS (NOT USED)
PART 3 - EXECUTION
3.01 MANUFACTURERS FIELD SERVICES
01680.OPERATIONS ASSISTANCE DURING CORRECTION PERlOD.ooCo168O-1 APRIL 27,2001
C&lsbad Recycling Facility
MF EQUII”ENT PROCUREMENT
A. The MFEM’S Project Engineer shall visit the site approximately one month before the
end of the correction period to resolve any outstanding issues. The MFEM shall correct
any items identified by the District or the Engineer during final inspection and resolve
said items prior to the issuance of the Notice Of Acceptability by the Engineer,
+ + END OF SECTION + +
01680.OPERATIONS ASSISTANCE DURING CORRECTION PERIOD.DOCO~~~O-~ APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 01730
OPERATION AND MAINTENANCE MANUALS
PART 1 - GENERAL
1.01 DES"TION
A. Description of Work
1. Provide operation and maintenance manuals for use by the District's personnel
for: '
a. All equipment and systems.
b. All valves and related accessories.
c. All instruments and control devices.
d. All electrical gear.
2. Training or start-up on any system, process, or piece of equipment shall not be
permitted until preliminary operation and maintenance manuals and lesson plans
for training are approved by the Engineer.
B. Coordination
1. The MFEM shall coordinate the Operational and Maintenance Manuals provided
to them from component equipment suppliers. The MFEM shall develop an
Operational and Maintenance Manual for the equipment and systems designed
and provided by the MFEM under this contract.
C. Special Considerations
1. Definitions
a. The term "operation and maintenance data" includes all product related
information and documents which are required for preparation of the plant
operation and maintenance manuals, as well as all data which is required for
inclusion by current regulations of any participating government agency.
Required operation and maintenance data shall include, but not be limited
to, the following:
1) Detailed, written operating instructions for each product andor piece
of equipment, including equipment function; operating
01730.OPERATIONANDMAINTENANCEMANUAIS.WC 01730-1 APRIL 27,2001
City of carisbad
MF EQUIPMENT PROCUREMEW
Carlsbad Recycling Facility
characteristics; limiting conditions; operating instructions for startup,
normal and emergency conditions; regulation and control; and
shutdown.
2) Detailed, written preventive maintenance instructions as described in
Paragraph l.O1.D of this Section.
3) Recommended spare parts lists, by generic title and identification
number, and local sources of supply for parts.
4) Written explanations of all safety considerations relating to operation
and maintenance procedures.
5) Name, address, and phone number of manufacturer, manufacturer's
local service representative, and all sub-contractors employed by the
MFFiM.
6) Copies of all approved Shop Drawings (including circuit diagrams,
schematics, and functional drawings) warranty bond(s), and service
contract(s).
7) Factory Test Reports were applicable.
8) Disassembly, reassembly, installation, alignment, adjustment, and
checkinghnspection instructions.
9) Written reference to equipment tag number as specified under Section
01600, Field Tests of Equipment.
b. The term "preventive maintenance instructions" includes all information and
instructions required to keep a product or piece of equipment properly
lubricated, adjusted, and maintained so that the item functions reliably
throughout its full design life. Preventive maintenance instructions shall
include, but not be limited to, the following:
1) Written explanations with illustrations for each preventive
maintenance task.
2) Recommended schedule for execution of preventive maintenance
tasks.
3) Lubrication charts.
4) Table of alternative lubricants naming at least two alternate lubricant
manufacturers, with applicable product numbers, for each application.
5) Troubleshooting instructions.
01130.OPERATJON AND MANTENANCEMANUALS.E€C 01730-2 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEW
6) List of required maintenance tools and equipment.
c. The term component equipment supplier is used to describe manufacturer
Goods purchased by the h4FEM and incorporated into the MF System.
1.02 QUALITY CONTROL 1 QUALITY ASSURANCE (QNQC) - NOT USED
1.03
A.
B.
C.
SUBMIl-rALS
General: The MFEM shall submit preliminary equipment operation and maintenance
manuals and training lesson plans for approval by the Engineer within 30 days prior to
delivery of the Goods. Final equipment operation and maintenance manuals and
equipment and training lesson plans, as approved by the Engineer, shall be submitted
30 days prior'to the commencement of training andor start-up on any system, process,
or piece of equipment.
Number of Copies: The MFEM shall submit eight preliminary copies of each required
operation and maintenance manual and lesson plan and a CD containing the operational
and maintenance manual.
Format Requirements:
1. Use 8-112-inch by 11-inch paper of high rag content and quality. Larger drawings
or illustrations are acceptable if neatly folded to the specified size in a manner
which will permit easy unfolding without removal from the binder. Provide
reinforced punched binder tab or fly-leaf for each product.
2. All text must be legible, type-written or machine printed originals or high quality
copies.
3. Each page shall have a binding margin of approximately 1-112 inches and be
punched for placement in a three ring loose-leaf binder, which shall be provided
by the "EM along with the submittal. Identify each binder with the following:
a. Title "OPERATING AND MAINTENANCE INSTRUCTIONS",
b. Title of Project.
c. Identity of general subject matter covered.
4. Use dividers and indexed tabs between major categories of information such as
operating instructions, preventive maintenance instructions, etc. When necessary,
place each major category in a separate binder.
5. Provide a complete table of contents in each binder.
01130.OFZRATIONANDMAOUl€NANCEMANUALS.DOC 01730-3 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
6. Identify products by their functional names in the table of contents and at least
once in each chapter or section. Thereafter, abbreviations and acronyms may be
used if their meaning is explained in a table in the back of each binder. The use
of model or catalog numbers or letters for identification shall not be acceptable.
7. Indicate all components of the equipment on catalog pages by highlighting or
some other clearly definable medium for ease of identification.
D. After the acceptance testing has been completed the MFEM shall revise and resubmit
the Operational and Maintenance Manuals for the project eight final copies of each
required operation and maintenance manuals and a CD of the information.
PART 2 - PRODUCTS (NOT USED)
PART 3 - EXECUTION (NOT USED)
++ END OFSECTION ++
0173O.OPERATION ANDMAWTENANCEMANUALS.DC€ 01730-4 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
SECTION 0 1 73 1
TRAINING OF OPERATIONS AND MAINTENANCE PERSONNEL
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide the services of factory-trained specialists to instruct the
District's operations and maintenance personnel in the recommended operation
and the preventive maintenance procedures for all equipment provided under the
Procurement Documents.
2. The MFEM shall provide a combination of classroom and field training. All
training shall be conducted at a location designated by the District. Each class
shall be limited to no more than ten (10) trainees. If the District requires more
than ten (10) individuals to be trained, additional classes shall be conducted by
the MFEM to accommodate all personnel in groups with no more than (10)
trainees.
3. The MFEM shall allow any and all training sessions to be videotaped by the
District. All training material shall be provided to the District in electronic format.
4. Instruction of the District's personnel shall commence within five days after the
equipment has been started, preliminary operation and maintenance manuals have
been turned over to the District, and commissioning has been completed.
5. Training shall be performed by the MFEM and component equipment suppliers,
a. The MFEM shall be responsible for the training on the design and operation
of the equipment and systems provided. This includes:
1) Membrane Filtration System
2) Membrane Filtration Units
3) Clean In Place System
4) Backwash and Chemical Washing Systems
5) Process Instrumentation
APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
6) PLC Equipment (including software functionality)
7) Supervisory Control Equipment (including software functionality)
b. Component Equipment Suppliers: The MFEM shall retain the services of
manufacturers representative(s) for training of the following equipment
provided by the MFEM.
1) Pumps
2) Compressors
3) Blowers
4) Other equipment provided by the MFEM where the MFEM is not
qualified to provide authorized factory level training.
B. Coordination:
1. The MFEM shall coordinate training services at times acceptable to the Engineer,
with a minimum of seven (7) days prior notice.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
A. The qualifications of specialists shall meet the requirements of this Section and are
subject to approval by the Engineer.
1.03 SUBMITTALS
A. The MFEM shall develop and submit to the Engineer and District a Training Lesson
Plan. Specific components and procedures shall be identified in the proposed Lesson
Plan.
1. Lesson Plans: Proposed lesson plans for scheduled instruction shall he submitted
thirty (30) days prior to the commencement of training. Lesson plans shall be
approved by the Engineer a minimum of seven (7) days prior to scheduled
instruction. All training material shall be provided to the District in electronic
format.
2. Credentials: Credentials for the MFEM's designated instructor(s) shall be
submitted thirty (30) days prior to the commencement of training. Credentials
shall include a brief resume and specific details of the instructor's pertaining hotb
to personal experience operating and maintaining the specified equipment and
conducting operation and maintenance for the same equipment.
01731.TRAMMG OF OPERATIONS AND MAlNTENANCEPERSONNEL.DOCO173 1-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
3. The MFEM’s proposed lesson plans shall detail specific instruction topics.
Training aids to be utilized in the instruction shall be referenced and attached
where applicable to the proposed lesson plan. “Hands-on” demonstrations
(referred to Paragraph 1.05.C) planned for the instruction shall be described in the
lesson plan.
4. The MFEM shall indicate the estimated duration of each segment of the training
in the lesson plan.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING - NOT USED
1.05 SPECIAL PROJECT CONSIDERATIONS
A. Scheduling
1. The training sessions shall be scheduled to accommodate the District’s
requirements.
B. Training Aids
1. The MFEM’S instructor shall incorporate training aids as appropriate to assist in
the instruction. As a minimum, the training aids shall include text and figure
handouts. Texts shall be bound within three-ring binders. Other appropriate
training aids are:
a. Audio-visual aids (e.g., films, slides, videotapes, overhead transparencies,
posters, blueprints, diagrams, catalog sheets).
b. Equipment cutaways and samples (e.g., spare parts and damaged
equipment).
c. Tools (e.g., repair tools, customized tools, measuring and calibrating
instruments).
2. The MFEM’sinstructor shall utilize descriptive class handouts during the
instruction. Photocopied class handouts shall be good quality reproductions.
Class handouts should accompany the instruction with frequent reference made to
them. Customized handouts developed especiallyfor the instruction are required.
Handouts planned for the instruction shall be attached with the manufacturer’s
proposed lesson plan.
C. “Hands -On Demonstration”
1. The MFEM’s instructor shall present “hands-on” demonstrations of operations
and maintenance of the equipment. The proposed “hands-on” demonstrations
should be described in the MFEM’s proposed lesson plan. Roughly half of each
01731.TRAMMG OFOPERATIONS AND MAINTENANCE PERSONNEL.DOCO173 1-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
training session shall be classroom training and half field training with installed
equipment.
PART 2 - PRODUCTS (NOT USED)
PART 3 - EXECUTION
3.01 OPERATOR TRAINING
A. Equipment Operation:
1. Describe equipment's operating (process) function.
2. Describe'equipment's fundamental operating principals and dynamics.
3. Identify equipment's mechanical, electrical, and electronic components and
features.
4. Identify all support equipment associated with the operation of subject equipment
(e.g., compressed air intake filters, valve actuators, motors).
5. Recommend standard operating procedures to address start-up, routine
monitoring, and shut-down of the equipment.
B. Detailed Component Description:
1. Identify and describe in detail each component's function.
2. Group related components into subsystems, where applicable. Describe
subsystem functions and their interaction with other subsystems.
3. Identify and describe in detail equipment safeties and control interlocks.
4. Control system training shall cover the specific PLC and graphic interface
configuration provided for this project. The PLC program code and graphic
screens shall be discussed to explain the purpose of the code or graphic interface
object and maintenancehture programming options.
C. Equipment Preventive Maintenance (PM):
1. Describe PM inspection procedures required to:
a. Perform an inspection of the equipment in operation,
.b. Spot potential trouble symptoms and anticipate breakdowns.
c. Forecast maintenance requirements (predictive maintenance).
01731.TRAM~GOFOPERATlONSANDMAMTENANCEPERSONNEL.DOCO1731-4 APRIL 27,2001
City of Carlsbad
h4F EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
2.
3.
4.
5.
6.
7.
8.
9.
10.
Define the recommended PM intervals for each component.
Provide lubricant and replacement part recommendations and limitations.
Describe appropriate cleaning practices and recommend intervals.
Identify and describe the use of special tools required for maintenance of the
equipment.
Describe component removalhnstallation and disassembly/assembly procedures,
Perform at least two "hands-on" demonstrations of preventive maintenance
procedures.
Describe recommended measuring instruments and procedures, and provide
instruction on interpreting alignment measurements, as appropriate.
Define recommended torquing, mounting, calibration, and/or alignment
procedures and settings, as appropriate.
Describe recommended procedures to checkhest equipment following a corrective
repair.
D. Equipment Troubleshooting:
1. Define recommended systematic troubleshooting procedures.
2. Provide component specific troubleshooting checklists.
3. Describe applicable equipment testing and diagnostic procedures to facilitate
troubleshooting.
3.02 FOLLOW TRAINING
A. The h4FEM shall provide follow-up training (to be completed about two months after
completion of the system acceptance test) to present a review and summary of the
earlier sessions and to answer questions. At least two 4-hour sessions shall be
provided.
B. The follow-up training shall be scheduled to coincide with a cleaning of one of the MF
units.
+ + END OF SECTION + +
APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
TRAINING REQUEST FORM
CARLSBAD RECYCLING FACILITY
INSTRUCTION OF OPERATIONS AND MAINTENANCE PERSONNEL
Equipment Name:
Equipment Tag Number:
Equipment Description:
Specification Section:
Operations and Maintenance Data Submitted'Approved:
Start-up and Testing CompleteDate:
Lesson Plan SubmittedApproved:
Training Aids SubmittedApproved:
Hands-on Demonstration:
Training Schedule (Dates, Time, No. of Sessions):
APRJL. 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
SECTION 01740
MEMBRANE SYSTEM AND MODULE WARRANTY
PART 1 - GENERAL
A. Description of Work
1. This specification covers the membrane system performance and module
warranty.
B. Membrane System Warranty - Goods
1. The MFEM shall warrant all components of the MF system supplied against
defects in materials and workmanship for a period of twelve (12) months.
2. The warranty period shall commence following notice of substantial completion
or a period of no greater than six (6) months from the date of delivery.
3. If any component part of the system should fail due to defects in materials or
workmanship during the warranty period, it shall be restored to service at no
expense to the District.
C. Membrane System Warranty - Module Warranty
1. The MFEM shall warrant the performance of the membrane modules.
2. The module warranty period shall commence following notice of substantial
completion and continue until the end of the pro-rata warranty period specified by
the MFEM with his Bid.
3. During this period, off-spec membrane modules (as defined herein) shall be
replaced. Minor repairs to modules not determined to be off-spec as defined
herein will be conducted by the District’s operating personnel according to
instructions provided by the MFEM.
4. For warranty purposes, off-spec membrane modules are defined as those
exhibiting integrity failure defects. Membrane modules shall be determined to
have integrity failure defects and subject to the replacement provisions listed
above under the following conditions:
a. If for a single membrane module more than 0.05 percent of the fibers have
required repair (it. by pinning or gluing) in any single year.
01740.MEMBRANESYS7EMANDMODULEWARRANN.~ 01740-1 APRIL 27,2001
b. If over the life of a single membrane module, more than 0.15 percent of the
fibers have required repairs.
c. If a module fails the air pressure integrity test and cannot be repaired by
pinning or gluing.
d. If for an entire unit more than ten (10) percent of the membrane modules fail
the air pressure integrity test within a three month period, all modules
associated with the unit shall be replaced.
e. An individual membrane fiber shall be identified as requiring repair if it is
determined to leak during an air pressure integrity test according to the
manufacturer’s standard procedure.
5. Membrane Module Replacement Costs
a. The MFEM shall establish the initial membrane replacement price and
guarantee that the membrane replacement price shall not increase by more
than the prevailing Consumer Price Index (CPI) over the succeeding ten
(10) year period.
b. For a period of 12 months, commencing from the date of the notice of
substantial completion (refer to 01660), the MFEM shall provide
replacement modules for their ‘full replacement value’ (i.e., at no charge) to
the District.
c. The MFEM shall warrant the membrane modules for an additional period of
time on a ‘pro-rata’ basis beginning at the end of the full replacement value
period.
d. Module Replacement Price during the pro-rata warranty period shall be
calculated as follows:
Pro Rata Replacement Price = Replacement Price x Months of Beneficial Use
Module Warranty Period (Months) D. Warranty Affidavit
1. The MFEM shall submit with his bid an affidavit as required in Section 00100,
Instructions to Bidders signed by an authorized representative of the MFEM to
document compliance with the specified warranty provisions.
PART 2 - PRODUCTS - NOT USED
PART 3 - EXECUTION - NOT USED
++ END OFSECTION ++
OI~~.MEMBRANESYSTEM ANDMODULE WARRANTY.~ 01740-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCWNT
SECTION 01750
SPARE PARTS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. Spare parts and materials required to be supplied in the Procurement Documents
shall be furnished in unopened cartons, boxes, crates, or other protective covering
suitable for preventing corrosion or deterioration for the maximum length of
storage which may be normally anticipated. They shall be clearly marked and
identified as to the name of manufacturer or supplier, applicable equipment, part
number, description, and location in the system.
2. Spare parts and materials shall be delivered to the District at the Point of Delivery
or other location specified by the District prior to completion of acceptance
testing.
3. Provide a letter of transmittal and spare parts receiver form including the
following:
a. Date of letter and transfer of parts and material.
b. Contract title and number.
c. MFEMs name and address.
d. Applicable Sections of the Procurement Documents for each set of spare
parts supplied.
e. Acknowledgment signed by the MFEM, that all spare parts and maintenance
materials have been delivered.
4. The MFEM shall be fully responsible for loss or damage to parts and materials
until they are received by the District.
PART 2 - PRODUCTS (NOT USED)
PART 3 - EXECUTION (NOT USED)
+ + END OF SECTION + +
01150.SPAREPARTS.WC 01750-1 APRIL 27.2001
City of Carisbad Carlsbad Recycling Facility
h4F EQUIPMENT PROCUREMENT
SECTION 05503
ANCHOR BOLTS AND EXPANSION ANCHORS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work:
1. The MFBM shall provide all anchor bolts, nuts, and washers for components of
the MF system furnished by the MFEM.
2. This Section includes all required bolts and anchors not specified under other
Sections of the Procurement Documents.
3. The types of work using the bolts and anchors include, but are not limited to, the
following:
a. Membrane Filtration Equipment.
b. Pumps.
c. Blowers.
d. Compressors.
e. Tanks.
f. Control Panels.
1.02 QUALITY CONTROL / QUALITY ASSURANCE
A. Expansion anchors shall be UL or FM approved.
B. Reference Standards: Comply with the applicable provisions and recommendations of
the following, except as otherwise shown and specified.
1. ASTM A 307, Carbon Steel Externally and Internally Threaded Standard
Fasteners.
2. ASTM A 320, Alloy-Steel Bolting Materials for Low-Temperature Service.
1.03 SUBMITTALS
O5503.ANCHOR BOLTS AND EXPANSION ANCH0RS.m 05503-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Shop Drawings: Submit for approval in accordance with the requirements of Section
01340, Shop Drawing Procedures, the following:
1. Setting drawings and templates for location and installation of anchorage devices.
2. Copies of manufacturer’s specifications, load tables, dimension diagrams, and
installation instructions for the devices.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. Package all anchor bolts in a single shipping container.
B. Clearly identify in the shipment of anchor bolts the equipment that they are intended to
be used for. Plastic bags, tape or wire ties may be used to group anchor bolts together.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE - NOT USED
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. When the size, length, or load carrying capacity of an anchor bolt or expansion
anchor is not shown on the Drawings, the MFEM 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 Engineer.
b. Pipe hangers and supports - use one half the total weight of pipe, fittings,
valves, accessories, and water contained in pipe, between the hanger or
support in question and adjacent hangers and supports on both sides.
c. Vibration allowances - included in the safety factor specified above.
2. Unless otherwise shown or approved by the Engineer, expansion anchors shall
conform to the following:
a. Minimum embedment depth in concrete: 5 diameters.
b. Minimum anchor spacing on centers: 10 diameters.
OSSO3.ANCHOR BOLTS AND EXPANSION ANCHORS.DOC 05503-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
C. Minimum distance to edge of concrete: 5 diameters
3. The dimensions specified above shall be increased if necessary to accommodate
required anchor load capacity.
C. Fabrication and Material Requirements
1. Anchor Bolts: Provide stainless steel bolts complying with ASTM A 320, Type
316.
2.03 EQUIPMXNT AND COMPONENTS
A. Adhesive Anchors:
1. Unless otherwise shown or specified, the use of drilled concrete anchors in lieu of
cast-in-place anchors shall be subject to approval by the Engineer on a case-by-
case basis.
2. Unless otherwise shown or specified, all drilled concrete anchors shall be
adhesive anchors. No material substitutions will be considered unless
accompanied with ICBO Report verifying strength and arterial equivalency.
3. Epoxy adhesive anchors, where approved by the Engineer, are required for drilled
anchors exposed to weather andor subject to submerged, wet, splash, overhead,
or corrosive conditions, as well as for anchoring pumps and mechanical
equipment. Epoxy systems shall be SikaFl System with Sikadur Injection Gel
Epoxy or Masterbuilders Concresive Epoxy Cartridge Dispensing System and
Concresive Paste LPL, Raw1 or equal. Threaded rod shall be Type 316 stainless
steel.
4. Unless otherwise shown, glass capsule, polyester resin adhesive anchors may be
permitted only with approval by the Engineer and only in locations not specified
above. Anchors shall be Hilti HVA, Molly Parabond, or equal. Threaded rods
shall be 316 stainless steel.
5. All adhesive anchors shall be installed in strict accordance with manufacturer's
recommendations. Where special inspection is required by the manufacturer, the MFEM shall certify that the anchors were installed per the requirements of the
manufacturer, and the MFEM shall provide all special inspection at no additional
cost to the District.
B. Expansion Anchors:
1. Provide stainless steel anchors complying with ASTM A 320, Type 316. Provide
stud type (male thread) or flush type (female thread) as required.
05503.ANCHOR BOLTS ANDEXPANSlONANCHORS.DOC 05503-3 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Product and manufacturer: Provide anchors as manufactured by one of the
following:
a. Molly Division of USM Corporation.
b. Hilti, Inc.
c. Or equal.
C. Power actuated fasteners and other types of bolts and fasteners not specified herein
shall not be used unless approved by the Engineer
PART 3 - EXECUTION
3.01 INSTALLATION
A. Installation of MFEM-furnished anchors will be performed by the Installation
Contractor.
+ + END OF SECTION + +
OSSO3.ANCHOR BOLTS AND EXPANSION ANCHORS.WC 05503-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUPMENT PROCUREMENT
SECTION 09900
PAINTING
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work:
1. The MFEM shall provide all labor, materials, equipment, services, and incidentals
required to furnish and apply all painting for aluminum and ferrous metals,
fiberglass, galvanized metals, and other surfaces as specified herein or as
indicated on the Drawings.
2. All items andor surfaces specified in the Procurement Documents shall painted
and/or finished, as specified. Surface preparation, priming, and coats of paint
specified are in addition to shop priming and surface treatment specified under
other Sections of the Procurement Documents.
3. Paint all exposed surfaces whether or not colors are designated in any schedule,
except where the natural finish of the material is specifically noted as a surface
not to be painted.
4. Pre-applied coatings to all items delivered to the job site and not requiring field
sand blasting shall be done in accordance with the approved painting submittal
under this Section. All items delivered to the job site with pre-applied coatings
will be inspected by the Engineer and shall be repaired by the MFEM if, in the
judgement of the District, the coating is damaged. The MFEM shall then apply a
final coat of the approved protective coating to the equipment in the field.
B. Coordination:
1. Manufacturers and suppliers of the equipment and materials specified herein shall
be required to review and satisfy all relevant requirements of all of the
Procurement Documents.
2. Manufacturers and suppliers of the equipment and materials specified herein shall
provide preparations and coatings in accordance with this specification for
equipment with is manufactured or supplied as component equipment by the
MFEM.
3. Review installation procedures under .other Sections and coordinate the
installation of items that must be field painted in this Section.
(WWO.PAEVTING.DC€ 09900-1 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
4. Coordinate the painting of areas that are inaccessible once equipment has been
installed.
5. Ensure pre-applied prime coats not to be sand blasted are done in accordance with
the approved painting submittals under this Section. The MFEM shall be
responsible to ensure all coating systems are provided in accordance with the
approved painting and protective coating submittals under this Section.
6. The MFEM shall fumish materials, appurtenances, specialty items, and services
not provided by the MFEMs manufacturers, suppliers, fabricators, and/or
subcontractors but required for complete and operable systems as specified under
the Procurement Documents.
C. Special Considerations
1. Definitions:
a. The term "paint" as used herein is indicative of all coating systems
materials, including pretreatments, primers, emulsions, enamels, stain,
sealers and fillers, and other applied materials, whether used as prime,
intermediate, or finish coats.
2. Design or Performance Requirements
a. Painting Not Included The following items are not included as part of the
field-applied finish Work or are included in other Sections of these
Specifications.
1) Items furnished with factory finishes such as baked-on enamel,
porcelain, polyvinyl fluoride, or other similar finishes, where
specified, or noted on the Drawings.
2) Metal surfaces of anodized aluminum, stainless steel, chromium plate,
bronze, and copper will not require finish painting, unless shown or
specified otherwise.
b. Operating parts and labels:
1) Do not paint over any code-required labels, such as UL and Factory
Mutual, or any equipment identification, performance rating, name,
or nomenclature plates.
2) Remove all paint, coating, or splatter inadvertently placed on these
surfaces.
1.02 QUALITY ASSURANCE
W%W.PAINTING.WC 09900-2 APRIL 21,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Surface preparation and application of coatings shall be performed by the MFEM in
compliance with all applicable federal, state, and local occupational safety, health, and
air pollution control regulations. The MFEM shall obtain and comply with all safety
precautions recommended by the paint manufacturer in printed instructions or special
bulletins, and as required by applicable regulations. The MFEM shall provide forced
ventilation in all areas where inadequate ventilation exists.
1.03 SUBMITTALS
A. Shop Drawings
1. Submittals shall be provided as described in Section 01340, Shop Drawing
Procedures, and as specified below. The MFEM shall be required to submit his
proposed protective coating systems prior to any other equipment, piping, or
hardware submittals that require protective coatings. After the Engineer reviews
and approves of the MFEMs proposed protective coating system, the MFEM
shall be required to furnish only the approved protective coatings throughout the
project.
2. Submit for approval the following:
a. Copies of manufacturer's technical information, including paint label
analysis and application instructions for each material proposed for use.
b. Copies of the MFEMs proposed protection procedures for all coating
requirements.
c. Lists of all materials cross-referenced to the specific paint and finish system
and application. Identify by manufacturer's catalog number and general
classification.
d. Copies of manufacturers complete color charts for each coating system.
e. Maintenance Manual: Upon completion of the coating work, furnish copies of a detailed maintenance manual including the following information:
Product name and number.
Name, address, and telephone number of manufacturer and local
distributor.
Detailed procedures for routine maintenance and cleaning.
Detailed procedures for light repairs such as dents, scratches, and
staining.
09WO.PAINTING.DOC 09900-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
hw EQUIPMENT PROCUREMENT
3. Application Techniques: Application techniques shall be conducted in accordance
with Paragraph 3.04 of this Section.
B. Alternatives
1. No products shall be considered that decrease the film thickness, the surface
preparation or the generic type of coating specified. Approved substitute
manufacturers must furnish the same color selection as the manufacturers
specified, including accent colors and custom colors in all coating systems and
must document satisfactory performance of their coating system for at least two
(2) water treatment plants that have been in service at least three (3) years each.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE - NOT USED
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Provide manufacturer's best grade of the various types of coatings suitable for use
in projects as regularly manufactured by acceptable paint materials manufacturers. Materials not displaying the manufacturer's identification as a
standard, best-grade product will not be acceptable.
2. Provide primers produced by the same manufacturer as the finish coats. Use only
thinners recommended' by the paint manufacturer, and only to manufacturer's
recommended limits.
3. Provide paints and pipe markers of durable and washable quality. Use materials
that will withstand normal washing as required to remove grease, oil, chemicals,
etc., without showing discoloration, loss of gloss, staining, or other damage.
4. Colors and Finishes
a. Surface treatments and finishes, are shown under Paragraph 2.03,
Equipment and Components, below. All substrates referenced under
Paragraph 2.04 shall be painted whether or not shown or scheduled, unless
an item is specifically scheduled as not requiring the painting system
scheduled below.
b. After approval of submittals and prior to beginning the work specified under
this Section, the District will select color schedules for surfaces to be
painted.
099004 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
C.
d,
e.
f.
g.
h.
i.
Piping and Sign Color Coding: In general, and unless otherwise specified,
all color coding of piping, ducts, and equipment shall comply with
applicable standards of ANSI A13.1 and OSHA 1910.144.
Use representative colors when preparing samples for the District's review.
Color Pigments: Pigments shall be pure, non-fading, and applicable to suit
the substrates and service indicated.
Lead: Lead content shall not exceed the amount permitted by federal, state,
and local government laws and regulations.
Paints specified for application in contact with potable water shall be in
accordance with the requirements of the NSF. Submittals for paints to be
used in contact with potable water shall show evidence and shall contain a
written certification from the manufacturer that the paint meets all
applicable requirements of the NSF.
Submit proposed application techniques to the Engineer, along with proof of
the acceptability of the proposed techniques by the selected paint
manufacturer.
Special Requirements for Aluminum:
1) Aluminum surfaces bearing in or embedded in concrete and facing
surfaces of bolted aluminum joints, except anchor bolts, shall be
given two (2) coats of Glid Guard #5206 All Purpose Primer, or
equal. The primer shall be allowed to dry between coats and before
concrete is poured against it.
2) Where aluminum metals are placed in contact with or fastened to
ferrous or stainless steel metals, the contact surfaces of each shall
receive the protective coating specified for that metal and a gasket
shall be placed between the two contact surfaces. The gasket material
shall be non-conductive commercial grade neoprene, 60 durometer,
0.03-inch thickness unless otherwise specified. Bolts shall be
isolated using one piece non-conductive sleeves and washers as
manufactured by PSI Products, Inc., Burbank, California; Parker Seal
Col, Culver City, California; or equal.
3) Galvanizing: All galvanizing, where called for in the Procurement
Documents shall be hot dip process conforming to AS" A-123.
2.03 EQUIPMENT AND COMPONENTS
A. Manufacturer: Provide products as manufactured by one of the following:
099W.PAINTING.DCC 09900-5 APRIL 27.200 1
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PR0C”ENT
1. Tnemec Company, Inc.
2. Devoe,
3. Kop-Coat, Inc.
4. Or equal.
B. Painting Systems
1. Surfaces shall be painted according to the following schedule:
2. Ferrous Metals (including all structural steel, ferrous piping, and other
miscellaneous ferrous metals):
a. Surface Preparation: Blast cleaning as specified in Paragraphs 3.02.B
and/or 3.02.C.
b. Product and Manufacturer: Provide one of the following:
1) Tnemec:
a) Primer: 69 H.B. Epoxoline II - 1 coat, 1.5-2.5 dry mils per coat,
280-370 square feet per gallon.
b) Finish: 69 H.B. Epoxoline Ii - 2 coats, 4-5 dry mils per coat,
220-280 square feet per gallon per coat.
2) ICIIDevoe:
a) Primer: Devran 224 HS - 1 coat, 1.5-2.5 dry mils per coat, 280-
370 square feet per gallon.
b) Finish: Devran 224 HS - 2 coats, 4.0-5.0 dry mils per coat,
240-300 square feet per gallon.
3) Tenemec
a) Primer: 90-97 Tneme-Zinc 2.5-3.5 mils
b) Finish: 73 Endurashield 2 coats, 2 to 5 mils for a total of 9 mils.
4) Or equal.
3. Galvanized and Non-Ferrous Metals:
a. Surface Preparation: SSPC-SP 1 solvent cleaning, as specified in
Paragraphs 3.02.D and 3.02.E of this Section.
W9M.PAINTING.DOC 09900-6 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Product and Manufacturer: Provide one of the following:
1) Tnemec:
a) Primer: 69 H.B. Epoxoline II - 1 coat, 3-4 dry mils, 280-370
square feet per gallon.
b) Finish: 69 H.B. Epoxoline I1 - 1 coat, 4-5 dry mils, 220-280
square feet per gallon.
2) ICIIDevoe:
a) Primer: Devran 224 HS - 1 coat, 3-4 dry mils, 300-400 square
feet per gallon.
b) Finish: Devran 224 HS - 1 coat, 4-5 dry mils, 240-300 square
feet per gallon.
3) Or equal.
4. All Aluminum in Contact with Dissimilar Metals:
a. Surface Preparation: Remove all foreign matter.
b. Product and Manufacturer: Provide one of the following:
1) Tnemec:
a) 69 H.B. Epoxoline II - 2 coats, 2.0-3.0 dry mils per coat, 240-
360 square feet per gallon per coat.
2) ICUDevoe:
a) Devran 224 HS - 2 coats, 2.0-3.0 dry mils per coat, 400-600
square feet per gallon.
3) Or equal.
5. Fiberglass Structural Shapes:
a. Surface Preparation: Sand as specified in 3.2.F
b. Product and Manufacturer: Provide one of the following:
1) Tnemec
a) Finish: 69 H.B Epoxoline II - 2 coats, 2.0-3.0 dry mils per coat,
240-360 square feet per gallon per coat.
09900-7 APRIL 27.2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2) ICI/Devoe:
a) Finish: Devran 224 HS - 2 coats, 2.0-3.0 dry mills per coat,
400-600 square feet per gallon per coat.
3) Or equal.
PART 3 - EXECUTION
3.01 SURFACE PREPARATION
A. General:
1. Perform all preparation and cleaning procedures as specified herein in accordance
with the paint manufacturer's instructions for each particular substrate and
atmospheric condition.
2. Clean surfaces to be painted before applying paint or surface treatments. Remove
oil and grease with clean cloths and cleaning solvents prior to mechanical
cleaning. Conduct the cleaning and painting so that dust and other contaminants
from the cleaning process will not fall in wet, newly painted surfaces.
3. All surfaces to be painted, as determined by the Engineer, that were not shop
painted or improperly shop painted and all abraded or rusted shop painted
surfaces shall be prepared as specified below.
a. With the exception of motors, gears, and other equipment that might be
damaged by sandblasting, shop applied protective coatings shall be
completely removed at the jobsite by sandblasting, unless otherwise
specified.
b. The prime coat shall be applied as quickly as possible after blasting. In no
case shall bare metal surfaces be left overnight before applying the prime
coat. Each coat of the paint shall be applied at proper consistency and shall
be sprayed or brushed evenly and be free of brush marks, pin holes, sags,
and runs with no evidence of poor workmanship. All equipment
nameplates, valve stems, and other areas not to painted shall be masked
prior to painting.
c. Multiple coats shall be applied in conformance with the paint manufacturer's
recommendations for minimum drying time and maximum curing time
between coats. The surface preparation and each coat of a multiple-coat
system shall be of different colors (as selected by the Engineer) and
inspected by the Engineer before subsequent coasts are applied.
09900-8 APRIL 27,200 1
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREmh'T
d. If thinning is required for proper application of a coating, it shall be done
only in accordance with the recommendations of the paint manufacturer and
only to the manufacturer's recommended limits.
B. Ferrous Surfaces:
1. Ferrous metal surfaces to be painted, including above and below ground piping,
fittings, etc., supplied under Division 15 shall be prepared by field blast cleaning
as specified below, unless described otherwise elsewhere in the Procurement
Documents.
2. Prior to blast cleaning, the MFEM shall ensure that all rough welds are ground
smooth and sharp steel edges ground to approximately 118 inch radius. Weld
spatter shall be removed. Paint, mill scale, rust, flux, fume, and slag from weld
deposits shall be removed by blast cleaning. Any grease or oil shall be removed
by steam or solvent cleaning.
3. Surfaces to be blast cleaned other than ferrous piping and submerged ferrous
metals shall be dry blast cleaned to a near white blast-cleaned surface finish
conforming to Section 310.-2.5 "Blast Cleaning" of the SSPWC and SSPC-SP7.
Surface profile for surfaces not subject to submergence shall be 1.5 to 1.9 mils.
Surface profile for surfaces subject to submergence shall be 3.0 to 4.0 mils.
4. Surfaces of ferrous piping and submerged ferrous metals shall be dry blast
cleaned to a surface finish conforming to SSPC-10, "Near White Blast Cleaning."
This specification is equivalent to DIPRA #lo.
5. All dust shall be removed by brushing, vacuuming, or air blasting. The prime
coat shall be applied as soon as possible after blasting. In no case shall bare metal
surfaces be left overnight before applying the prime coat.
6. Sandblasting and painting shall not be performed concurrently in the same area.
No sandblasting will be allowed in areas adjacent to equipment that might be
damaged by sandblasting.
7. Heavy deposits of grease or oil shall be removed from all surfaces to be coated
using the paint manufacturer's specified cleaner prior to any other surface
preparation. Any chemical contamination shall be neutralized and/or flushed-off
prior to any other surface preparation.
8. In addition to the limitations imposed in Section 310-1 of the SSPWC, no surface
preparation or coating shall be performed during periods of excessive wind
which, in the opinion of the Engineer, would affect the quality of the work or
produce nuisance conditions in adjacent areas. All coatings shall be applied in
strict conformance with the manufacturer's printed recommendations regarding
minimum and maximum allowable air and surface temperatures. No coatings
shall be applied when the relative humidity is higher than 80 percent or when the
ffl9W.PAINTING.DOC 09900-9 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility m EQUIPMENT PROCUREMEN?
temperature is less than or equal to 5 degrees F above dewpoint. No coatings
shall be applied if any moisture is detectable on the surface to be coated.
C. Equipment that Cannot be Sandblasted:
1. Equipment that would be damaged by sandblasting, typically including motors,
gear reducers, switchboards, and similar equipment, shall receive the shop
coatings and finish coatings. The MFEM shall be solely responsible for ensuring
that all shop coating is done in conformance with the specifications and the
approved paint submittal, as determined by the Engineer. All components shall
have a finish color to match the plant color scheme. Color samples shall be
submitted for review and selection by the District.
2. Shop-applied coatings shall be inspected and evaluated at the jobsite and shall be
evenly applied and free of brush marks, sags, nicks, scratches, runs, holidays, or
other evidence of poor workmanship or damage. Shop coatings that are of good
quality shall be solvent cleaned, lightly sanded as directed by the Engineer, and
finish coated as specified. All bearings and openings shall be masked to prevent
damage during sanding and painting. Color shall be as specified above. Prior to
application, the MFEM shall perform spot testing to determine if the shop-applied
paint is of the same manufacturer as the specified finish coats. If, in the opinion
of the Engineer, the paints are not as specified, the MFEM shall apply a suitable
paint to act as a barrier or "tie coat" between the shop-applied and field-applied
finishes. Materials and application procedures for the "tie-coat'' shall be subject
to review and approval by the Engineer. "Tie coats" shall be applied at no
increase in contract price. It shall be the MFEMs sole responsibility to determine
if shop applied primers and finishes are as specified ,and the MFEM shall assume
complete responsibility for the entire coating system warranty.
3. Shop-applied coatings that show evidence of poor materials or workmanship, or
have been damaged, shall be repaired or replaced in the field as directed by the
Engineer. Nicks and scratches or other small imperfections in the finish shall be
repaired by wire brushing to a bright metal, primed with a universal primer and
finish coated as specified. Universal primer shall be Amercoat 185, Engard 123,
Koppers Pug Primer, or approved equal, to a minimum dry film thickness of 2
mils. An epoxy primer may be used as a universal primer if a test patch is applied
to check adhesion, and the Engineer approves. After repair, the equipment shall
be solvent cleaned, lightly sanded, and painted as specified above for equipment
with a good quality shop finish. If, in the opinion of the Engineer, the shop
coating is of such poor quality that repair is not warranted, it may elect to either:
(1) require the MFEM to return the equipment to the factory for refinishing, or (2)
require the MFEM to completely remove the existing coating, prepare the surface
for repainting and repaint the equipment using the applicable paint system as
specified herein. All work shall be done in a manner that will prevent damage to
the equipment. Costs incurred for repair or replacement of shop-applied coatings
shall be the sole responsibility of the MFEM.
099W.PAINTING.DOC 09900-10 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
h4F EQUPMENT PROCUREMENT
D. Galvanized Surfaces: Where coatings for galvanized surfaces are called for by the
Contract Documents, the MFEM shall prepare the galvanized surfaces as follows:
1.
2.
3.
4.
All surfaces shall be inspected jointly by the MFEM and the Engineer to
determine the condition of existing surfaces. The Engineer shall then designate
the surface condition and cleaning shall be performed as noted below. Any areas
overlooked during the joint inspection shall not relieve the MFEM from
completely preparing surfaces.
All oily or greasy surface contaminants shall be removed by wiping the
contaminated area with a clean rag wetted with degreasing solution in accordance
with Steel Structures Painting Council Specification SSPC-SPl (Solvent
Cleaning).
Surface contaminants not easily removed shall be additionally cleaned in
conformance with Steel Structures Painting Council Specification SSPC-SP7
(Brush-off Blast Cleaning).
All rusting, scaling, or damaged areas shall be blast cleaned in conformance with
Steel Structures Painting Council Specification SSPC-SP10 (Near-White Blast
Cleaning). Remaining galvanized surface shall be firmly bonded to the substrate
with sandblast edges feathered. Extreme care shall be exercised to insure
remaining galvanized surfaces are not damaged by cleaning operations.
E. Non-Ferrous Metal Surfaces: Non-ferrous metal surfaces shall be cleaned in
accordance with the coating system manufacturer's instructions for the type of service,
metal substrate, and application required.
F. Fiberglass Surfaces: Lightly sand and clean all surfaces to be painted.
3.02 MATERIALS PREPARATION
A. General:
1. Mix and prepare painting materials in strict accordance with the manufacturer's
directions.
2. Do not mix coating materials produced by different manufacturers, unless
otherwise permitted by the manufacturer's instructions.
3. Store materials not in actual use in tightly sealed containers. Maintain containers
used in storage, mixing, and application of paint in a clean condition, free of
foreign materials and residue.
4. Stir all materials before application to produce a mixture of uniform density Stir
as required during the application of the materials. Do not stir any film which
099LW.PAINTEVG.DOC 09900-1 1 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
may form on the surface into the material. Remove the film and, if necessary,
strain the material before using.
5. Mixing:
a. Mix only in containers placed in suitably sized non-ferrous or oxide resistant
metal pans to protect concrete floor from splashes or spills that could stain
exposed concrete or react with subsequent finish floor material.
b. Mix and apply paint only in containers bearing accurate product name of
material being mixed, or applied.
3.03 APPLICATION
A. General:
1. Apply paint by brush, roller, air spray, or airless spray in accordance with the
manufacturer's directions and the recommendations of Paint Application
Specification No. 1 in SSPC Vol. 2, where applicable. Use brushes best suited for
the type of material being applied. Use rollers of carpet, velvet back, or high pile
sheeps wool as recommended by the paint manufacturer for material and texture
required. Use air spray and airless spray equipment recommended by the paint
manufacturer for specific coating system specified. Submit a list of application
methods proposed, listing paint systems and location, as required under Paragraph
1.03 of this Section.
2. The paint film thickness required shall be the same regardless of the application
method. Do not apply succeeding coats until the previous coat has completely
dned.
3. Apply additional coats when undercoats, stains, or other conditions show through
the final coat of paint, until the paint film is of uniform finish, color, and
appearance. This is of particular importance regarding intense primary accent
colors. Ensure that all surfaces, including edges, comers, crevices, welds, and
exposed fasteners receive a film thickness equivalent to that of flat surfaces.
4. Multiple coats shall be applied in conformance with the paint manufacturer's
recommendations for minimum drying time and maximum curing time between
coats. The surface preparation and each coat of a multiple-coat system shall be of
different colors (as selected by the Engineer) and inspected by the Engineer
before subsequent coats are applied. The MFEM shall provide forced ventilation
in areas where inadequate ventilation exists.
5. If thinning is required for proper application of a coating, it shall be done only in
accordance with the recommendations of the paint manufacturer and with the
written approval of the Engineer.
099W.PAINTING.WC 09900-12 APRIL 21,2001
City of Carlsbad
h4F EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
6. Paint aluminum parts in contact with dissimilar materials as specified with
appropriate primer and isolation gasket material.
7. Omit field primer on metal surfaces which have been shop primed. Shop primed
coats shall be touched up only when approved by the Engineer.
8. Paint the backs of access panels and removable or hinged covers to match the
exposed surfaces.
B. Minimum Coating Thickness:
1. Apply each material at the manufacturer's recommended spreading rate, and
provide total dry film thickness as specified.
2. Apply extra coat if required to obtain specified total dry film thickness.
C. Scheduling Painting:
1. Apply the first-coat material to surfaces that have been cleaned, pretreated, or
otherwise prepared for painting as soon as practicable after surface preparation
and before subsequent deterioration.
2. Allow sufficient time between successive coatings to permit proper drying. Do
not recoat until paint has dried to where it feels firm, does not deform or feel
sticky under moderate thumb pressure. The application of another coat of paint
shall not cause lifting or loss of adhesion of the undercoat.
D. Prime Coats: Recoat primed and sealed walls and ceilings where there is evidence of
suction spots or unsealed areas in first coat in order to ensure a finish coat with no
bum-through or other defects caused by insufficient sealing,
E. Pigmented (Opaque) Finishes: Completely cover surfaces to provide an opaque,
smooth surface of uniform finish, color, appearance, and coverage.
F. Transparent (Clear) Finishes:
1. On exposed to view portions, use multiple coats to produce glass-smooth surface
film continuity of even matt luster. Provide a finish free of laps, cloudiness, color
irregularity, runs, brush marks, orange peel, nail holes, or other surface
imperfections.
2. Provide satin finish for final coats, unless otherwise indicated.
G. Brush Application:
09900-13 APRIL 27,200 1
City of Carlsbad
Carlsbad Recycling Facility
MF EQUrPMENT PRWUREMEm
1. Brush-out and work all brush coats onto the surfaces in an even film. Cloudiness,
spotting, holidays, laps, brush marks, runs, sags, ropiness, or other surface
imperfections will not be acceptable. Neatly draw all glass and color break lines.
2. Brush-apply all primer or first coats, unless othenvise permitted to use mechanical
applicators.
H. Mechanical Applicators:
1. Use mechanical methods for paint application only when permitted by governing
ordinances and paint manufacturer and only if approved by the Engineer. If
approved, limit the use of mechanical methods to only those surfaces
impracticable for brush applications.
2. Confine spray application to metal framework, siding, decking, wire mesh, and
similar surfaces where hand brush work would be inferior and to other surfaces
specifically recommended by paint manufacturer.
3. Wherever spray application is used, apply each coat to provide the equivalent
hiding of brush-applied coats. Do not double-back with spray equipment for the
purpose of building up film thickness of 2 coats in one pass.
I. Air Receivers:
1. The MFEM shall furnish all air receivers in fully painted condition,
2. After the air receivers have been installed, the MFEM will touch-up the paint if it
is determined to be necessary by the Engineer.
J. Completed Work: Match approved samples for color, texture, and coverage. Remove,
refinish, or repaint work not in compliance with specified requirements and approved
by Engineer.
3.04 PROTECTION
A. The MFEM shall take appropriate steps to ensure that all painting conducted under this
Section is done carefully and the no paint or coating of any kind is accidentally spilled,
spattered, and/or applied to equipment and other surfaces not addressed under this
Section. The MFEM shall correct all damages by cleaning, repairing or replacing, and repainting, as acceptable to the Engineer.
B. Provide "Wet Paint" signs as required to protect newly painted finishes, Remove all
temporary protective wrappings provided for protection upon completion of painting
work.
C. All equipment and/or materials to be painted at the jobsite shall be placed on raised
supports at least two (2) feet above the ground. Care shall be exercised to prevent paint
09WO.PAINTlNG.DOC 09900-14 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
from being spattered on surfaces that are not to be painted and if paint is dropped or
spattered on surfaces not to be painted, the paint shall be removed as directed by the
Engineer. All equipment nameplates, valve stems, and areas not to be painted Shall be
masked prior to painting.
D. The MFEM shall be responsible for containing all over-spray. Any over-spray on any
item of equipment, piping, structures, paving, or others including vehicles shall be
removed by the MFEM. If removal is not possible, the MFEM shall be responsible at
MFEMS cost for repainting the entire damaged item, to the satisfaction of the
Engineer.
3.05 CLEAN-UP
A. During the progress of the Work, remove from the site all discarded paint materials,
rubbish, cans, and rags at the end of each work day.
B. Upon completion of painting Work, clean all paint-spattered surfaces. Remove
spattered paint by proper methods of washing and scraping, using care not to scratch or
otherwise damage finished surfaces.
C. At the completion of work of other trades, touch-up and restore all damaged or defaced
painted surfaces as determined by Engineer.
+ + END OF SECTION + +
09900- 15 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 1121 1
HORIZONTAL END SUCTION PUMPS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work Scope: MFEM shall furnish Horizontal End Suction centrifugal
pumping equipment complete with base plates, motors, controls, anchors, drives
appurtenances, and specialty items, and as specified herein, required for complete and
operable system as shown and specified in the Procurement Documents.
B. Coordination: To ensure that all the equipment is properly coordinated and will
function in accordance with the requirements of the Procurement Documents, the
MFEM shall obtain all the pump and motor equipment specified herein from a single
pump supplier. However, the MFEM shall retain ultimate responsibility under this
Contract for equipment coordination, operation, and guarantee, and the MFEM shall
furnish all equipment, materials, appurtenances, specialty items, and services not
provided by the suppliers but required for a complete and operable system.
C. Special Considerations
1. The manufacturer of the equipment specified herein shall be required to review
and satisfy all relevant requirements of other Sections of the Procurement
Documents. The MFEM, manufacturer, supplier, fabricator, and/or
subcontractors furnishing equipment, services and specialties associated with this
Section shall fully coordinate their efforts to avoid potential disputes that are
based on failure to review all relevant Procurement Documents, including the
Drawings.
2. The MFEM shall have sole and total responsibility for the satisfactory operation
of each entire system including driven equipment, motors, VFDs, and controls as
specified by the Procurement Documents. If a VFD is used, the MFEM shall
submit an acceptance letter from both the driven equipment and motor
manufacturers stating that the VFD will fully meet all starting and operating
requirements of each driven equipment/motor combination. The MFEM shall
submit a letter from the VFD manufacturer stating that they have reviewed the
driven equipment requirements and that the VFD will successfully meet all
operating requirements in each instance. The MFEM shall be responsible for
coordinating all VFD units with the driven equipment to obtain successful
operation throughout the pump or mechanism speed range and all other operating
characteristics described in the Procurement Documents.
1121I.HORIZONTALPIDSUCnONPUMPS.DOC 1121 1-1 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
3. The equipment covered by this specification shall be standard equipment of
proven ability as manufactured by reputable concerns having extensive
experience in the production of such equipment. The equipment furnished shall
be manufactured in accordance with the best practice and methods, and shall
operate satisfactorily when installed as shown and specified in the Procurement
Documents.
1.02 QUALITY CONTROL I QUALITY ASSURANCE (QNQC)
A. Manufacturer's Qualifications: Manufacturer of the Horizontal End Suction centrifugal
pumping equipment shall have experience in providing similar type equipment and
shall show evidence with his submittal of at least five (5) installations where equipment
of the same material, same design and same application of the type specified herein
have been in satisfactory operation for at least five (5) years.
B. Reference Standards
1. Standards of the Hydraulic Institute.
2. Standards of the American Water Works Association.
3. National Electric Code.
4. Standards of National Electrical Manufacturers Association.
5. Institute of Electrical and Electronic Engineers.
6. American Gear Manufacturers Association.
7. American National Standards Institute.
8. National Sanitation Foundation
C. Manufacturers Field Services
1. The MFEM shall retain factory trained representatives of the horizontal end
suction pump manufacturer to perform the services listed below:
a. Inspect the completed installation and prepare an inspection report.
b. Test, calibrate, and adjust all components for optimum performance.
c. Assist in initial start-up and field testing.
d. Instruct District's personnel in the operation and user maintenance of all
components. Conduct a training seminar at the site per Section 01731,
Training of Operations and Maintenance Personnel.
IIZII.HORIZONTALENDSUCTlONPUMPS.DOC 11211-2 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEN
e. Supervise the correction of any defective or faulty work before and after
acceptance by District.
1.03 SUBMITTALS
A. Shop Drawings: Submit for approval the following:
1.
2.
3.
4.
5.
6.
Performance data curves showing the following parameters as defined in the
Hydraulic Institute Standards over the full operating range of the pump:
a. Total developed head in engineering units of feet.
b. Capacity in engineering units of gallons per minute.
c. Horsepower demand.
d. Pump efficiency.
e. Net positive suction head required in engineering units of feet.
Indicate on the performance curve(s) the point of operation of the pump at the
guarantee point(s) listed in the specifications. Also mark on the curve the
minimum and maximum recommended operating points on the curve.
Electrical wiring diagrams and other data as required for complete pump
installation.
Provide manufacturers data and drawings describing the equipment in sufficient
detail, including parts lists and materials of construction, to indicate full
conformance with the detailed specifications.
Detailed drawings showing the dimensions and weight of the pumping unit and
the motor.
Submit detailed information on the pump motors:
a. Manufacturer model and frame designation.
b. Horsepower and service factor.
c. Full load speed.
d. Insulation class.
e. Design ambient temperature.
f. Efficiency and power factor at 1/2,3/4, full load.
IIZII.HORUONTAL~SUC~ONPUMPS.DOC 1121 1-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
g. NO load, full load, and locked rotor currents.
h. Design starting code.
7. Operation and maintenance data including installation instructions.
8. Provide anchor bolt information, calculations, sizing and embedment depth
requirements.
9. Four (4) copies of certified pump tests, and a certified performance data curve.
10. Four (4) copies of certified motor tests and test data.
B. Factory Tests Reports:
1. Each Pump shall be Factory Tested. All tests shall be witness tested by a
Registered Professional Engineer, who is an employee of the manufacturer.
Helshe shall sign and seal all copies of curves and shall certify that hydrostatic
tests were performed.
2. All pump discharge heads shall be hydrostatically tested to twice the first design
point pump head or one and one half times the shutoff head, whichever is greater.
3. Each motor shall be given a complete, initial certified shop test, with the test data
submitted to the Engineer for approval.
C. Installation Instructions:
1. Package Installation Instruction with the Pump.
D. Operation and Maintenance Manuals: Operation and Maintenance Manuals
1. 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 01730, Operation and Maintenance Data and
Section 01731, Instruction of Operations and Maintenance Personnel.
E. Record Drawings -Not Used
F. Certificates, Warranties and Guarantees
1. Submit warranty certification.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Refer.to Section 01611, Protection of Goods and Section 01610 Transportation and
Handling of Goods.
IlZIl.HORUONTALDiDSUC~ONPUM~.WC 1121 1-4 APRIL 27.2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Horizontal end suction pumps shall be used where noted or shown. See Section
11300 and related system specifications for requirements.
B. Process Design Requirements
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. All parts of mechanisms shall be amply proportioned for stresses that may occur
during fabrication, shipping, erection, and intermittent or continuous operation.
All units shall be constructed such that dismantling and repairing can be
accomplished without difficulty.
2. The pumping units shall operate without surging, cavitation, vibration or
excessive noise.
3. Each motor shall be rated for continuous duty and sized such that it shall not be
required to provide more than rated nameplate horsepower, at unity service factor,
under any operating condition.
B. Equipment Design Requirements
1. The centrifugal pumping equipment shall be of the horizontal end suction design
in accordance with applicable ANSI standards. Suction and discharge
connections shall be flanged, with flanges conforming to ANSI B16.1, Class 150.
2. Casing: Top centerline discharge, self-venting. Fully confined gasket. Foot
support under casing for maximum resistance to misalignment and distortion from
pipe loads.
3. Impeller: open, partial shrouds for maximum vane support. Impeller threaded on
shaft, threads sealed by Teflon O-ring. Smoothly contoured passages and
statically balanced. Performance maintained by external impeller adjustment.
4. Stuffing Box Cover: Shall enclose the back of casing and contain the stuffing box
chamber. Stuffing box shall be completely machined for mechanical seal
installation, either originally or as a field conversion. Inside or outside, tandem,
IIZII.HORIZONTALENDSUCTlONPUMPS.DOC 11211-5 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCWmh'T
double or single, balanced or unbalanced seals, with any required gland,
restricting bushing and flushing lines shall be furnished to meet individual sealing
requirements. Gland shall completely confine the stationary seat gasket.
5. Frame Adapter: Machined rabbet fit to stuffing box cover. Contains stuffing box
drip basin, non-sparking rotating deflectors, and inboard bearing oil seal.
6. Bearing Frame: Heavy cast iron construction. Shall contain a large oil reservoir,
with water jacket. Oil level shall be maintained by constant level oiler with
visible oil supply. Oil seals on each end and breather shall protect oil from
contamination. Dowel pins shall be installed between the frame and adapter to
provide precision alignment.
7. Shaft: Designed for 0.002 inches (0.05 mm) maximum deflection at stuffing box
face. All bearing and packing surfaces shall be ground to less than 32 micro-
inches.
8. Shaft Sleeve: Renewable shaft sleeve shall be positively driven, hook type, with
one end free to expand with temperature variations. Teflon O-ring shall prevent
leakage under sleeve. Sleeve shall permit application of inside balanced
mechanical seals.
9. Bearings: Inboard bearing shall be pressed on shaft and free to float axially in
frame. Outboard bearing shall be shouldered and locked on shaft with locknut
and washer, and locked in bearing housing to carry radial and any unbalanced
axial thrust load. All bearing fits shall be precision (bored or ground) machined.
Inboard bearing shall be single row, deep groove. Outboard bearing shall be
double row, deep groove angular contact. Bearings shall be sized for two year
minimum life.
10. Acceptable Manufacturer:
a. Capacity Under 2,500 gpm:
1) Goulds Model 3196
2) Ingersoll Dresser Model HOC2
3) Sterling ANSI Pump
b. Capacity Greater than 2,500 gpm:
1) Goulds Models 3175 I3180
2) Ingersol Dresser FBRH
C. Fabrication and Material Requirements
1IZII.HORIU)NTALENDSUC~ONPUMPS.DOC 11211-6 APRIL. 27,200 1
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.03 EQUIPMENT AND COMPONENTS
A. Motors
1.
2.
3.
4.
5.
6.
7.
8.
Each pump shall be driven by a solid shaft TEFC, 3-phase, 60 Hz, 460 volt motor.
The motor shall have a 1.15 service factor and shall be NEMA Design B, with
Class F insulation to operate at full load with a Class B temperature rise per latest
EEMAC standards.
All motors rated from 1-200 HP shall meet the Minimum Motor Efficiency
Standard for Premium Efficiency Motors.
All motors intended for utilization with variable frequency dnves shall meet
NEMA MGI, Part 31 inverter duty requirements.
All grease lubricated bearings shall be provided with standard Alemite fittings.
The motors shall have stainless steel nameplates on which shall be stamped all
pertinent electrical and bearing information and the seal of the UL.
Eyebolts or lifting lugs shall be provided on the motors and they shall be of
adequate strength for lifting the motor. All metal parts shall be inherently
corrosion-resistant or shall be protected with corrosion-proof coatings.
Motors rated 20 HP and above shall be equipped with temperature sensing
thermostats installed adjacent to the stator windings. These shall have NC
(normally closed) automatic reset contacts rated for 120 VAC.
Approved Motor Suppliers
a. General Electric
b. USEM
c. Siemens
B. Drives
1. Where noted or shown, pumps shall be furnished with variable frequency drives
in accordance with Section 16484.
C. Nameplates
I121I.HORIZONTALENDSUCnONPUMPS.DOC 1121 1-7 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
D.
E.
F.
G.
1. Each pump and motor shall be furnished with a stainless steel nameplate securely
mounted to the body of the equipment.
2. As a minimum, the nameplate for the pumps shall include the equipment number,
manufacturer's name and model number, serial number, rated flow capacity, head,
speed, and all other pertinent data.
3. As a minimum, nameplates for motors shall include the motor number,
manufacturer's name, and model number, serial number, horsepower, speed, input
voltage, amps, number of cycles, and power and service factors.
Base Plates
1. Heavy fabricated steel base (with drip lip) to mount the pump and dnver shall be
furnished.
Couplings
1. Flexible shaft coupling shall be furnished to connect the driver to the pump.
2. Coupling shall be enclosed in OSHA coupling guard and have a minimum 1.5
service factor based on the drive rated horsepower.
Seals
1. Mechanical seal, type that does not require any external water connection.
2. John Crane Type 21 or equal.
Anchor Bolts
1. Anchor bolts and inserts shall be furnished under this Section and shall be sized in
accordance with the manufacturer's recommendations.
2. Refer to Section 05503.
3. All bolts, nuts, and cap screws shall have hexagonal heads.
2.04 INSTRUMENTATION AND CONTROLS
A. Controls shall be provided under Division 13.
2.05 SPARE PARTS
A. Each pump shall be furnished with the following:
1. One mechanical seal assembly.
IlZLI.HORIU)NTALWO SUCTION PuMpS.WC 11211-8 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
B. Spare parts shall be packed in sturdy containers with clear indelible identification
markings and shall be stored in a protected location until transferred to the District at
the conclusion of the project.
2.06 SHOP PAINTING
A. All interior and exterior non-stainless steel ferrous surfaces of the pump unit, including
motor, motor stand, frames, baseplates and appurtenances shall be shop primed and
painted in accordance with Section 09900. Shop painting shall include surface
preparation, prime, and finish coats.
B. NSF-61 Coating
1. Extent: All interior surfaces of the pumping unit which are not bronze or stainless
steel and the exterior surfaces of the pumping unit which may become submerged
shall be painted with a coating currently listed in NSF-61.
2. Materials: Epoxy, Tnemec Series 20, Ameron 395, or equal.
3. Machined and Polished Surfaces: Coat with a corrosion prevention compound
listed in NSF-61.
4. All Other Surfaces: As specified in Section 01600 for non-submerged exterior
ferrous metals.
2.07 SPECIAL TOOLS
A. The h4FEM shall furnish a complete set of special tools as required for operation,
maintenance, dismantling, and assembly of the pumps.
2.08 LUBRICANTS
A. Furnish NSF 61 Approved Lubricants.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. The MFEM and District I Engineer shall inspect all equipment upon delivery to site. If
damaged, notify Engineer and MFEM at once.
B. Installation Contractor will not install damaged equipment until repairs are made in
accordance with manufacturer's written instructions and approved by the Engineer.
Only minor repair work shall be permitted in the field. All other damaged items shall
be sent to factory for repair or replacement.
I121I.HORIZONTALENDSUC~ONPUMPS.DOC 11211-9 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
C. The Installation Contractor will complete the installation in accordance with pump
manufacturer's instructions and recommendations.
3.02 COMMISSIONING
A. MFEM shall inspect and verify that structures, pipes and equipment are compatible.
The MFEM shall make any adjustments required to place system in proper operating
condition.
3.03 OPERATOR TRAINING
A. Manufacturer of the Pump shall provide instruction to the Operations and Maintenance
in personnel in accordance with Section 01731.
B. The Manufacturer shall demonstrate the mechanical seal replacement procedures.
3.04 ACCEPTANCE TESTING
A. The Installation Contractor and MFEM shall test the installed pump to determine
conformance to the applicable design and performance criteria.
3.05 MANUFACTURERS FIELD SERVICES
A. Field Services: The MFTM shall provide the following services in addition to any
other services specified herein, and required by these Specifications.
1. A factory trained representative shall be provided for startup and field testing
services and Operation and Maintenance training services. The representative
shall set the mechanical seal and a millwright shall confirm that the rotating
assembly is properly aligned. The startup and field testing, and the Operation and
Maintenance services shall be coordinated with the Engineer. The field
representative may be a factory-trained employee of the MFEM.
+ + END OF SECTION + +
11211.HORIZONTALENLSUCTlONPUMPS.DOC 11211-10 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUFEIvENT
SECTION 11213
VERTICAL TURBINE PUMPS
PART 1 - GENERAL
1.01 DESCRIPTION
A.
B.
C.
Description of Work The MFEM shall provide all materials and equipment to provide
Vertical Turbine Pumps complete with base plates, motors, VFDs, controls, anchors,
appurtenances, and specialty items, and as specified herein, required for complete and
operable system as shown and specified in the Procurement Documents.
Coordination: To ensure that all the equipment is properly coordinated and will
function in accordance with the requirements of the Procurement Documents, the
MFEM shall obtain all the pump and motor equipment specified herein from a single
pump supplier. The MFEM shall retain ultimate responsibility under this Contract for
equipment coordination, operation, and warranty, and the MFEM shall furnish
equipment, materials, appurtenances, specialty items, and services not provided by the
suppliers but required for a complete and operable system.
Special Considerations:
1. The manufacturer of the equipment specified herein shall be required to review
and satisfy all relevant requirements of other Sections of the Procurement
Documents. The MFEM, manufacturer, supplier, fabricator, and/or
subcontractors furnishing equipment, services, and specialties associated with this
Section shall fully coordinate their efforts to avoid potential disputes that are
based on failure to review all relevant Procurement Documents, including the
Drawings.
2. The MFEM shall have sole and total responsibility for the operation of each entire
system including driven equipment, motors, VFDs, and controls as specified by
the Procurement Documents. If applicable, the MFEM shall submit an acceptance
letter from both the driven equipment and motor manufacturers stating that the
VFD will fully meet all starting and operating requirements of each driven
equipment/motor combination. The MFEM shall submit a letter from the VFD
manufacturer stating that they have reviewed the driven equipment requirements
and that the VFD will successfully meet all operating requirements in each
instance. The MFEM shall be responsible for coordinating all VFD units with the
dnven equipment to obtain successful operation throughout the pump or
mechanism speed range and all other operating characteristics described in the
Procurement Documents.
11213.VERTICALNRBlMPUMPS.DOC 11213-1 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
3. The equipment covered by this specification is intended to be standard equipment
as manufactured by reputable concerns having extensive experience in the
production of such equipment. The equipment furnished shall be manufactured in
accordance with the best practice and methods, and shall operate satisfactorily
when installed as shown and specified in the Procurement Documents.
1.02 QUALITY CONTROL I QUALITY ASSURANCE (QNQC)
A. Manufacturers’ Qualifications: Manufacturer of the vertical turbine pumping equipment
shall have experience in providing similar type equipment and shall show evidence
with his submittal of at least five (5) installations where equipment of the same
material, same design, and same application of the type specified herein have been in
satisfactory operation for at least five (5) years in the United States.
B. Reference Standards: Comply with applicable provisions and recommendations of the
following, except as otherwise shown or specified.
1. Standards of the Hydraulic Institute.
2. Standards of the American Water Works Association.
3. National Electric Code.
4. Standards of National Electrical Manufacturers Association.
5. Institute of Electrical and Electronic Engineers.
6. American Gear Manufacturers Association.
7. American National Standards Institute.
8. National Sanitation Foundation
C. Manufacturers Field Services
1. The MFEM shall retain factory trained representatives of the vertical turbine
pump manufacturer to perform the services listed below:
a. Inspect the completed installation and prepare an inspection report.
b. Test, calibrate, and adjust all components for optimum performance.
c. Assist in initial start-up and field testing.
d. Instruct District’s personnel in the operation and user maintenance of all
components. Conduct a training seminar at the site per Section 01731,
Training of Operations and Maintenance Personnel.
lI7.13.VU(TICALNRBMF:PUMPS.DOC 11213-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
e. Supervise the correction of any defective or faulty work before and after
acceptance by District.
1.03 SUBMIlTALs
A. Shop Drawings: Submit for approval the following:
1. Performance data curves showing the following parameters as defined in the
Hydraulic Institute Standards over the full operating range of the pump:
a. Total developed head in engineering units of feet.
b. Capacity in engineering units of gallons per minute.
c. Horsepower demand.
d. Pump efficiency.
e. Net positive suction head required in engineering units of feet.
2. Indicate on the performance curve(s) the point of operation of the pump at the
guarantee point(s) listed in the specifications. Also mark on the curve the
minimum and maximum recommended operating points on the curve.
3. Electrical wiring diagrams and other data as required for complete pump
installation.
4. Provide manufacturers data and drawings describing the equipment in sufficient
detail, including parts lists and materials of construction, to indicate full
conformance with the detailed specifications.
5. Detailed drawings showing the dimensions and weight of the pumping unit and
the motor.
6. Submit detailed information on the pump motors:
a. Manufacturer model and frame designation.
b. Horsepower and service factor.
c. Full load speed.
d. Insulation class.
e. Design ambient temperature.
f. Efficiency and power factor at 1/2,3/4, full load.
11213.VERTICAL~BINEPUMPS.WC 11213-3 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
g. No load, full load, and locked rotor currents.
h. Design starting code.
7. Operation and maintenance data including installation instructions.
8. Provide anchor bolt information, calculations, sizing and embedment depth
requirements.
9. Four (4) copies of certified pump tests, and a certified performance data curve.
10. Four (4) copies of certified motor tests and test data.
B. Factory Tests Reports:
1. Each Pump shall be Factory Tested. All tests shall be witness tested by a
Registered Professional Engineer, who is an employee of the manufacturer.
He/she shall sign and seal all copies of curves and shall certify that hydrostatic
tests were performed.
2. All pump discharge heads and columns shall be hydrostatically tested to twice the
first design point pump head or one and one half times the shutoff head,
whichever is greater.
3. Each motor shall be given a complete, initial certified shop test, with the test data
submitted to the Engineer for approval.
C. Installation Instructions:
1. Package Installation Instruction with the Pump.
D. Operation and Maintenance Manuals:
1. 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 01730, Operation and Maintenance Data and
Section 01731, Instruction of Operations and Maintenance Personnel.,
E. Certificates, Warranties and Guarantees
1. Submit warranty certification.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Refer to Section 01611, Protection of Goods and Section 01610 Transportation and
Handling of Goods.
IL213.VERSICALNRBMEPUMPS.DOC 11213-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Vertical turbine pumps with VFDs shall be used where noted or shown. See
Section 11300 and related system specifications for requirements.
B. Process Design Requirements
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Pump Type: Vertical turbine centrifugal type, self lubricated conforming to
ANSIAWWA E-101-88.
2. Running Clearances: Performance of each pump shall be stable and free from
damaging cavitation, vibration, and noise in the operating head range. The
performance of each pump shall be based on a radial running clearance between
the bowl wearing ring and impeller as follows:
Diameter of Rotating Member Minimum Diametrical
at Clearance Clearance
[inches]
0.012 2.500 - 2.999
0.01 1 2.000 - 2.499
0.010 <2.000
[inches]
0.014 3.000 - 3.499
3.500 - 3.999 0.016
4.000 - 4.499
4.500 - 4.999
0.016
0.017 5.000 - 5.999
0.016
The above requirements shall not apply to bowl, stuffing box or column bearings.
3. Balance
a. All rotating parts shall be accurately machined and shall be in as nearly
perfect rotational balance as practicable. 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 vibration displacement (peak-to-peak) as
1I213.VERTlCALTURB(NEPUMPS.WC 11213-5 APRIL 27,200 1
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
measured at any point on the assembly shall not exceed 0.13 IPS at the
highest point on the motor.
b. At any operating speed, the ratio of rotative speed to the critical speed of a
unit or components thereof shall be less than 0.8.
4. Acceptable Manufacturers
a. Afton Pumps Type GSV.
b. Ingersoll Dresser Type VTP
c. Goulds Type VIT
B. Equipment Design Requirements
1. Discharge Head
a. Fabricated Heads shall be a one-piece fabricated design from seamless
0,375-inch minimum wall pipe to support the drive unit and entire pump
assembly. The head shall be designed in accordance with ASME Section
VIII Division 1. The head shall be stress relieved.
b. Suitable openings shall be provided for access to the mechanical seal and
other accessories.
c. The motor mounting flange shall have registered fits to insure accurate
alignment of the drive motor to the pump shaft.
d. The head shall be designed to accept a mechanical seal. The gland plate
shall be O-ring sealed to the stuffing box and the stationary seat is O-ring
sealed to the gland. A suitable mechanical seal leakage collector with a 112-
inch tapped drain opening shall be provided. Each pocket shall have a drain
connection.
e. The pump discharge connection shall be flanged ANSI Class 150, integral
with the discharge head. The safe working pressure of the discharge section
of the head shall exceed the pump differential pressure at shut-off plus
maximum suction pressure.
f. A 112-inch NPT tapped and plugged pressure gauge connection shall be
provided on the horizontal centerline of the pump discharge outlet. The
connection size and configuration shall conform to Figures 30 and 40 of the
Hydraulic Institute Standards.
2. Mounting Flange / Soleplate
11213.VERTICALTURBINEPUMPS.DOC 11213-6 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEm
a. A rigid mounting flange shall be provided to support each pump.
b. The mounting flange shall have rounded comers; abutting surfaces between
components shall be machined to provide uniform bearing.
c. Provide a center opening large enough to permit withdrawal of the entire
pump assembly.
3. Column
a. Column shall be of flanged and bolted construction in lengths not exceeding
5-feet with a minimum diameter such that head loss does not exceed 5 feet
per 100 feet at the maximum rated capacity of the pump.
b. Minimum wall thickness of column piping shall be 0.375-in.
4. Impellers and Bowls
a. Impellers shall be enclosed type.
b. Impellers shall be accurately machined, dynamically balanced and securely
locked on the pump shaft by means of double longitudinal shaft keys and
circular thrust washers for each impeller.
c. Bowls shall be of flanged design. Bowls shall be equipped with wearing
rings. Wearing rings shall be securely locked in place so that they will not
move or loosen during any condition of operation or handling, including
reverse rotation of the pump.
5. Shafting
a. The shaft shall be a one-piece design with no reduction in diameter through
the stuffing box.
b. Shafting shall be precision ground and polished pump quality.
c. Shaft diameter shall not be less than the minimum permitted for the
applicable driver nameplate horsepower rating.
6. Coupling
a. A rigid four piece adjustable spacer type coupling shall be furnished.
b. The spacer length shall be long enough to permit removal of the mechanical
seal assembly without removing the drive motor.
11213-7 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROC'JREMENT
C. The coupling shall be nickel plated to prevent atmospheric corrosion.
Coupling bolting shall be G8.
d. Coupling alignment shall provide for a maximum pump shaft run out of
0,002-inch TIR directly above the mechanical seal.
C. Fabrication and Material Requirements
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.03 EQUrPMENT AND COMPONENTS
A. Motors
1.
2.
3.
4.
5.
6.
7.
8.
Each pump shall be driven by a solid shaft TEFC, 3-phase, 60 Hz, 460 volt motor.
The motor shall have a 1.15 service factor and shall be NEMA Design B, with
Class F insulation to operate at full load with a Class B temperature rise per latest
EEMAC standards.
All motors rated from 1-200 HP shall meet the Minimum Motor Efficiency
Standard for Premium Efficiency Motors.
All motors intended for utilization with variable frequency adjustable speed drives
shall meet NEMA MGI, Part 31 inverter duty requirements.
All grease lubricated bearings shall be provided with standard Alemite fittings.
The motors shall have stainless steel nameplates on which shall be stamped all
pertinent electrical and bearing information and the seal of the UL.
Eyebolts or lifting lugs shall be provided on the motors and they shall be of
adequate strength for lifting the motor. All metal parts shall be inherently
corrosion-resistant or shall be protected with corrosion-proof coatings.
Motors rated 20 HP and above shall be equipped with temperature sensing
thermostats installed adjacent to the stator windings. These shall have NC
(normally closed) automatic reset contacts rated for 120 VAC.
Approved Motor Suppliers
a. General Electric
b. USEM
c. Siemens
11213-8 AF'RE 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PRoCUREMEh'T
B.
C.
D.
E.
F.
Drives
1. Where noted or shown, pumps shall be furnished with variable frequency drives
in accordance with Section 16484.
Nameplates
1. Each pump and motor shall be furnished with a stainless steel nameplate securely
mounted to the body of the equipment.
2. As a minimum, the nameplate for the pumps shall include the equipment number,
manufacturer's name and model number, serial number, rated flow capacity, head,
speed, and all other pertinent data.
3. As a minimum, nameplates for motors shall include the motor number,
manufacturer's name, and model number, serial number, horsepower, speed, input
voltage, amps, number of cycles, and power and service factors.
Seals: Mechanical seal, John Crane Type 1, Type 4200 or equal.
Seal Flush Tubing: Seal flush tubing and fittings shall provide for recirculation from
the seal chamber back to the pump suction.
Anchor Bolts
1. Anchor bolts and inserts shall be furnished under this Section and shall be sized in
accordance with the manufacturer's recommendations.
2. Refer to Section 05503.
3. All bolts, nuts, and cap screws shall have hexagonal heads.
2.04 INSTRUMENTATION AND CONTROLS -NOT USED
2.05 SPARE PARTS
A. One set of bearings.
B. One complete mechanical seal.
C. One complete set of auxiliary seals.
2.06 SHOP PAINTING
A. All interior and exterior non-stainless steel ferrous surfaces of the pump unit, including
motor, motor stand, frames, baseplates and appurtenances shall be shop primed and
11213-9 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
painted in accordance with Section 09900. Shop painting shall include surface
preparation, prime, and finish coats.
B. NSF-61 Coating
1. Extent: All interior surfaces of the pumping unit which are not bronze or stainless
steel and the exterior surfaces of the pumping unit which may become submerged
shall be painted with a coating currently listed in NSF-61.
2. Materials: Epoxy, Tnemec Series 20, Ameron 395, or equal.
3. Machined and Polished Surfaces: Coat with a corrosion prevention compound
listed in NSF-61.
4. All Other Surfaces: As specified in Section 09900 for non-submerged exterior
ferrous metals.
2.07 SPECIAL TOOLS
A. The MFEM shall furnish a complete set of special tools as required for operation,
maintenance, dismantling, and assembly of the pumps.
2.08 LUBRICANTS
A. Furnish NSF 61 Approved Lubricants.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. The MFEM and District / Engineer shall inspect all equipment upon delivery to site. If
damaged, notify Engineer and MFEM at once.
B. Installation Contractor will not install damaged equipment until repairs are made in
accordance with manufacturer's written instructions and approved by the Engineer.
Only minor repair work shall be permitted in the field. All other damaged items shall
be sent to factory for repair or replacement.
C. The Installation Contractor will complete the installation in accordance with pump
manufacturer's instructions and recommendations.
3.02 COMMISSIONING
A. MFEM shall inspect and verify that structures, pipes and equipment are compatible.
The MFEM shall make any adjustments required to place system in proper operating
condition.
11213-10 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
3.03 OPERATOR TRAINING
A. Manufacturer of the Pump shall provide instruction to the Operations and Maintenance
in personnel in accordance with Section 01731.
B. The Manufacturer shall demonstrate the mechanical seal replacement procedures.
3.04 ACCEPTANCE TESTING
A. The Installation Contractor and MFEM shall test the installed pump to determine
conformance to the specified design and performance criteria.
3.05 MANUFACTURERS FIELD SERVICES
A. Field Services: The MFEM shall provide the following services in addition to any other
services specified herein, and required by these Specifications.
1. A factory trained field representative shall be provided for startup and field testing
services and Operation and Maintenance training services. The representative
shall set the mechanical seal and a millwright shall confirm that the rotating
assembly is properly aligned. The startup and field testing, and the Operation and
Maintenance services shall be coordinated with the Engineer. The field
representative may be a factory-trained employee of the MFEM.
++ END OFSECTION ++
11213-11 APRIL 21,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 11214
VERTICAL IN-LINE PUMPS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work The MFEM shall provide all materials and equipment to provide
Vertical In-Line Pumps complete with base plates, motors, VFDs, controls, anchors,
appurtenances, and specialty items, and as specified herein, required for complete and
operable system as shown and specified in the Procurement Documents.
B. Coordination: To ensure that all the equipment is properly coordinated and will
function in accordance with the requirements of the Procurement Documents, the
MFEM shall obtain all the pump and motor equipment specified herein from a single
pump supplier. The MFEM shall retain ultimate responsibility under this Contract for
equipment coordination, operation, and warranty, and the MFEM shall furnish
equipment, materials, appurtenances, specialty items, and services not provided by the
suppliers but required for a complete and operable system.
C. Special Considerations:
1. The manufacturer of the equipment specified herein shall be required to review
and satisfy all relevant requirements of other Sections of the Procurement
Documents. The MFEM, manufacturer, supplier, fabricator, and/or
subcontractors furnishing equipment, services, and specialties associated with this
Section shall fully coordinate their efforts to avoid potential disputes that are
based on failure to review all relevant Procurement Documents, including the
Drawings.
2. The MFEM shall have sole and total responsibility for the operation of each entire
system including driven equipment, motors, VFDs, and controls as specified by
the Procurement Documents. If applicable, the MFEM shall submit an acceptance
letter from both the dnven equipment and motor manufacturers stating that the
VFD will fully meet all starting and operating requirements of each driven
equipment/motor combination. The MFEM shall submit a letter from the VFD
manufacturer stating that they have reviewed the driven equipment requirements
and that the VFD will successfully meet all operating requirements in each
instance. The MFEM shall be responsible for coordinating all VFD units with the
driven equipment to obtain successful operation throughout the pump or
mechanism speed range and all other operating characteristics described in the
Procurement Documents.
11214.VERTICALIN-LMEFWMPS.DOC 11214-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
3. The equipment covered by this specification is intended to be standard equipment
as manufactured by reputable concerns having extensive experience in the
production of such equipment. The equipment furnished shall be manufactured in
accordance with the best practice and methods, and shall operate satisfactorily
when installed as shown and specified in the Procurement Documents.
1.02 QUALITY CONTROL I QUALITY ASSURANCE (QNQC)
A. Manufacturers’ Qualifications: Manufacturer of the vertical in-line pumping equipment
shall have experience in providing similar type equipment and shall show evidence
with his submittal of at least five (5) installations where equipment of the same
material, same design, and same application of the type specified herein have been in
satisfactory operation for at least five (5) years in the United States unless otherwise
allowed by the Engineer.
B. Reference Standards: Comply with applicable provisions and recommendations of the
following, except as otherwise shown or specified.
1. Standards of the Hydraulic Institute.
2. Standards of the American Water Works Association.
3. National Electric Code.
4. Standards of National Electrical Manufacturers Association.
5. Institute of Electrical and Electronic Engineers.
6. American Gear Manufacturers Association,
7. American National Standards Institute.
8. National Sanitation Foundation
C. Manufacturers Field Services
1. The MFEM shall retain factory trained representatives of the vertical in-line pump
manufacturer to perform the services listed below:
a. Inspect the completed installation and prepare an inspection report.
b. Test, calibrate, and adjust all components for optimum performance.
c. Assist in initial start-up and field testing.
11214-2 APRIL 27,200 1
City of Carlsbad Carlsbad Recycling Facility
MF EQUIF’MENT PRoCUREMEm
d. Instruct District’s personnel in the operation and user maintenance of all
components. Conduct a training seminar at the site per Section 01731,
Training of Operations and Maintenance Personnel.
e. Supervise the correction of any defective or faulty work before and after
acceptance by District.
1.03 SUBMITTALS
A. Shop Drawings: Submit for approval the following:
1.
2.
3.
4.
5.
6.
Performance data curves showing the following parameters as defined in the
Hydraulic Institute Standards over the full operating range of the pump:
a. Total developed head in engineering units of feet.
b. Capacity in engineering units of gallons per minute.
c. Horsepower demand.
d. Pump efficiency.
e. Net positive suction head required in engineering units of feet.
Indicate on the performance curve(s) the point of operation of the pump at the
guarantee point(s) listed in the specifications. Also mark on the curve the
minimum and maximum recommended operating points on the curve.
Electrical wiring diagrams and other data as required for complete pump
installation.
Provide manufacturers data and drawings describing the equipment in sufficient
detail, including parts lists and materials of construction, to indicate full
conformance with the detailed specifications.
Detailed drawings showing the dimensions and weight of the pumping unit and
the motor.
Submit detailed information on the pump motors:
a. Manufacturer model and frame designation.
b. Horsepower and service factor.
c. Full load speed.
d. Insulation class,
I IZII.VUITICAL IN-LINE FWMPS.WC 11214-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
e. Design ambient temperature.
f. Efficiency and power factor at 1/2, 3/4, full load.
g. No load, full load, and locked rotor currents,
h. Design starting code.
7. Operation and maintenance data including installation instructions.
8. Provide anchor bolt information, calculations, sizing and embedment depth
requirements.
9. Four (4) copies of certified pump tests, and a certified performance data curve.
10. Four (4) copies of certified motor tests and test data.
B. Factory Tests Reports:
1. Each Pump shall be Factory Tested. All tests shall be witness tested by a
Registered Professional Engineer, who is an employee of the manufacturer.
He/she shall sign and seal all copies of curves and shall certify that hydrostatic
tests were performed.
2. All pump discharge heads and columns shall be hydrostatically tested to twice the
first design point pump head or one and one half times the shutoff head,
whichever is greater.
3. Each motor shall be given a complete, initial certified shop test, with the test data
submitted to the Engineer for approval.
C. Installation Instructions:
1. Package Installation Instruction with the Pump.
D. Operation and Maintenance Manuals:
1. 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 01730, Operation and Maintenance Data and
Section 01731, Instruction of Operations and Maintenance Personnel.
E. Certificates, Warranties and Guarantees
1. Submit warranty certification.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
IIZI4.VERllCALIN-LINEFWMPS.DOC 11214-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Refer to Section 01611, Protection of Goods and Section 01610 Transportation and
Handling of Goods.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Vertical in-line pumps with VFDs shall be used where noted or shown. See
Section 11300 and related system specifications for requirements.
B. Process Design Requirements
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Pump Type: Vertical in-line centrifugal type, self lubricated, close coupled
design.
2. Balance
a. 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 vibration displacement (peak-to-peak) as
measured at any point on the assembly shall not exceed 0.13 IPS at the
highest point on the motor.
b. At any operating speed, the ratio of rotative speed to the critical speed of a
unit or components thereof shall be less than 0.8.
3. Acceptable Manufacturers
a. Gilbert, Gilkes & Gordon, Model CV150
b. Goulds, Model 3996
c. Flowserve/Ingersoll Dresser Pumps, Model D-800
B. Equipment Design Requirements
lI214.V€RTICAL~-LINEPUMPSDOC 11214-5 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Discharge Head
a. Fabricated Heads shall be a one-piece fabricated design from seamless to
support the drive unit and entire pump assembly.
b. Suitable openings shall be provided for access to the mechanical seal and
other accessories.
c. The motor mounting flange shall have registered fits to insure accurate
alignment of the drive motor to the pump shaft.
d. The head shall be designed to accept a mechanical seal. The gland plate
shall be O-ring sealed to the stuffing box and the stationary seat is O-ring
sealed to the gland. A suitable mechanical seal leakage collector with a 112-
inch tapped drain opening shall be provided. Each pocket shall have a drain
connection.
e. The pump suction and discharge connections shall be flanged ANSI Class
150, integral with the discharge head. The safe working pressure of the
discharge section of the head shall exceed the pump differential pressure at
shut-off plus maximum suction pressure.
f. A 1/2-inch NF'T tapped and plugged pressure gauge connection shall be
provided on the horizontal centerline of the pump suction and discharge
outlets. The connection size and configuration shall conform to Figures 30
and 40 of the Hydraulic Institute Standards.
2. Impellers
a. Impellers shall be open type.
b. Impellers shall be accurately machined, dynamically balanced and securely
locked on the pump shaft by means of double longitudinal shaft keys and
circular thrust washers.
3. Shafting
a. The shaft shall be a one-piece design with no reduction in diameter through
the stuffing box.
b. Shafting shall be precision ground and polished pump quality.
c. Shaft diameter shall not be less than the minimum permitted for the
applicable driver nameplate horsepower rating.
C. Fabrication and Material Requirements
1IZICVERTICALIN-LINEPUMPS.DOC 11214-6 APRIL 21,200 1
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEW
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.03 EQUIPMENT AND COMPONENTS
A. Motors
1.
2.
3.
4.
5.
6.
7.
8.
Each pump shall be driven by a solid shaft TEFC, 3-phase, 60 Hz, 460 volt motor.
The motor shall have a 1.15 service factor and shall be NEMA Design B, with
Class F insulation to operate at full load with a Class B temperature rise per latest
EEMAC standards.
All motors rated from 1-200 HP shall meet the Minimum Motor Efficiency
Standard for Premium Efficiency Motors.
All motors intended for utilization with variable frequency adjustable speed drives
shall meet NEMA MG1, Part 31 inverter duty requirements.
All grease lubricated bearings shall be provided with standard Alemite fittings.
The motors shall have stainless steel nameplates on which shall be stamped all
pertinent electrical and bearing information and the seal of the UL.
Eyebolts or lifting lugs shall be provided on the motors and they shall be of
adequate strength for lifting the motor. All metal parts shall be inherently
corrosion-resistant or shall be protected with corrosion-proof coatings.
Motors rated 20 HP and above shall be equipped with temperature sensing
thermostats installed adjacent to the stator windings. These shall have NC
(normally closed) automatic reset contacts rated for 120 VAC.
Approved Motor Suppliers
a. General Electric
b. USEM
c. Siemens
B. Drives
1. Where noted or shown, pumps shall be furnished with variable frequency drives
in accordance with Section 16484.
C. Nameplates
11214-7 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
1. Each pump and motor shall be furnished with a stainless steel nameplate securely
mounted to the body of the equipment.
2. As a minimum, the nameplate for the pumps shall include the equipment number,
manufacturer's name and model number, serial number, rated flow capacity, head,
speed, and all other pertinent data.
3. As a minimum, nameplates for motors shall include the motor number,
manufacturer's name, and model number, serial number, horsepower, speed, input
voltage, amps, number of cycles, and power and service factors.
D. Seals: Mechanical seal, John Crane Type 1, Type 4200 or equal.
E. Seal Flush Tubing: Seal flush tubing and fittings shall provide for recirculation from
the seal chamber back to the pump suction.
F. Anchor Bolts
1. Anchor bolts and inserts shall be furnished under this Section and shall be sized in
accordance with the manufacturer's recommendations.
2. Refer to Section 05503.
3. All bolts, nuts, and cap screws shall have hexagonal heads.
2.04 INSTRUMENTATION AND CONTROLS - NOT USED
2.05 SPARE PARTS
A. One set of bearings.
B. One complete mechanical seal.
C. One complete set of auxiliary seals.
2.06 SHOP PAINTING
A. All interior and exterior non-stainless steel ferrous surfaces of the pump unit, including
motor, motor stand, frames, baseplates and appurtenances shall be shop primed and
painted in accordance with Section 09900. Shop painting shall include surface
preparation, prime, and finish coats.
B. NSF-61 Coating
1. Extent: All interior surfaces of the pumping unit which are not bronze or stainless
steel and the exterior surfaces of the pumping unit which may become submerged
shall be painted with a coating currently listed in NSF-61.
II214.VERTKAL IN-LINE PUMPS.DC€ 11214-8 APRIL 27.2001
City of Carlsbad Carlsbad Recycling Facility
hfF EQUIPMENT PROCUREMENT
2. Materials: Epoxy, Tnemec Series 20, Ameron 395, or equal.
3. Machined and Polished Surfaces: Coat with a corrosion prevention compound
listed in NSF-61.
4. All Other Surfaces: As specified in Section 09900 for non-submerged exterior
ferrous metals.
2.07 SPECIAL TOOLS
A. The MFEM shall furnish a complete set of special tools as required for operation,
maintenance, dismantling, and assembly of the pumps.
2.08 LUBRICANTS
A. Furnish NSF 61 Approved Lubricants.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. The MFEM and District / Engineer shall inspect all equipment upon delivery to site. If
damaged, notify Engineer and MFEM at once.
B. Installation Contractor will not install damaged equipment until repairs are made in
accordance with manufacturer's written instructions and approved by the Engineer.
Only minor repair work shall be permitted in the field. All other damaged items shall
be sent to factory for repair or replacement.
C. The Installation Contractor will complete the insiallation in accordance with pump
manufacturer's instructions and recommendations.
3.02 COMMISSIONING
A. MFEM shall inspect and verify that structures, pipes and equipment are compatible.
The MFEM shall make any adjustments required to place system in proper operating
condition.
3.03 OPERATOR TRAINING
A. Manufacturer of the Pump shall provide instruction to the Operations and Maintenance
in personnel in accordance with Section 01731.
B. The Manufacturer shall demonstrate the mechanical seal replacement procedures.
3.04 ACCEPTANCE TESTING 7 F,
11214-9 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. The Installation Contractor and MFEM shall test the installed pump to determine
conformance to the specified design and performance criteria.
3.05 MANUFACTURERS FIELD SERVICES
A. Field Services: The MFEM shall provide the following services in addition to any other
services specified herein, and required by these Specifications.
1. A factory trained field representative shall be provided for startup and field testing
services and Operation and Maintenance training services. The representative
shall set the mechanical seal and a millwright shall confirm that the rotating
assembly is properly aligned. The startup and field testing, and the Operation and
Maintenance services shall be coordinated with the Engineer. The field
representative may be a factory-trained employee of the MFEM.
+ + END OF SECTION + +
11214-10 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 11215
LIQUID RING VACUUM PUMPS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work: The MFEM shall provide all materials and equipment to provide
Liquid Ring Vacuum Pumps complete with base plates, motors, controls, anchors,
appurtenances, and specialty items, and as specified herein, required for complete and
operable system as shown and specified in the Procurement Documents.
B. Coordination: To ensure that all the equipment is properly coordinated and will
function in accordance with the requirements of the Procurement Documents, the
MFEM shall obtain all the pump and motor equipment specified herein from a single
pump supplier. The MFEM shall retain ultimate responsibility under this Contract for
equipment coordination, operation, and warranty, and the MFEM shall furnish
equipment, materials, appurtenances, specialty items, and services not provided by the
suppliers but required for a complete and operable system.
C. Special Considerations:
1. The manufacturer of the equipment specified herein shall be required to review
and satisfy all relevant requirements of other Sections of the Procurement
Documents. The MFEM, manufacturer, supplier, fabricator, andor
subcontractors furnishing equipment, services, and specialties associated with this
Section shall fully coordinate their efforts to avoid potential disputes that are
based on failure to review all relevant Procurement Documents, including the
Drawings.
2. The MFEM shall have sole and total responsibility for the operation of each entire
system including driven equipment, motors, and controls as specified by the
Procurement Documents.
3. The equipment covered by this specification is intended to be standard equipment
as manufactured by reputable concerns having extensive experience in the
production of such equipment. The equipment furnished shall be manufactured in
accordance with the best practice and methods, and shall operate satisfactorily
when installed as shown and specified in the Procurement Documents.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
11215-1 APW 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Manufacturers' Qualifications: Manufacturer of the vertical in-line pumping equipment
shall have experience in providing similar type equipment and shall show evidence
with his submittal of at least five (5) installations where equipment of the same
material, same design, and same application of the type specified herein have been in
satisfactory operation for at least five (5) years in the United States.
B. Reference Standards: Comply with applicable provisions and recommendations of the
following, except as otherwise shown or specified.
1.
2.
3.
4.
5.
6.
7.
8.
Standards of the Hydraulic Institute.
Standards of the American Water Works Association.
National Electric Code.
Standards of National Electrical Manufacturers Association.
Institute of Electrical and Electronic Engineers.
American Gear Manufacturers Association.
American National Standards Institute.
National Sanitation Foundation
C. Manufacturers Field Services
1. The MFEM shall retain factory trained representatives of the liquid ring vacuum
pump manufacturer to perform the services listed below:
a. Inspect the completed installation and prepare an inspection report
b. Test, calibrate, and adjust all components for optimum performance.
c. Assist in initial start-up and field testing.
d. Instruct District's personnel in the operation and user maintenance of all
components. Conduct a training seminar at the site per Section 01731,
Training of Operations and Maintenance Personnel.
e. Supervise the correction of any defective or faulty work before and after
acceptance by District.
1.03 SUBMITTALS
A. Shop Drawings: Submit for approval the following:
I1215.UQWD RING VACUUM PuMPS.Doc 11215-2 AF'FUL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Performance data curves showing the following parameters as defined in the
Hydraulic Institute Standards over the full operating range of the pump:
a. Total developed vacuum in engineering units of in Hg.
b. Capacity in engineering units of cubic feet per minute.
c. Horsepower demand.
d. Rated speed.
2. Indicate on the performance curve(s) the point of operation of the pump at the
guarantee point(s) listed in the specifications. Also mark on the curve the
minimum and maximum recommended operating points on the curve.
3. Electrical wiring diagrams and other data as required for complete pump
installation.
4. Provide manufacturers data and drawings describing the equipment in sufficient
detail, including parts lists and materials of construction, to indicate full
conformance with the detailed specifications.
5. Detailed drawings showing the dimensions and weight of the pumping unit and
the motor.
6. Submit detailed information on the pump motors:
a.
b.
C.
d.
e.
f.
g.
h.
Manufacturer model and frame designation.
Horsepower and service factor.
Full load speed.
Insulation class.
Design ambient temperature.
Efficiency and power factor at 1/2, 3/4, full load.
No load, full load, and locked rotor currents.
Design starting code.
7. Operation and maintenance data including installation instructions.
8. Provide anchor bolt information, calculations, sizing and embedment depth
requirements.
11215.UQUIDIUNG VACUUM PUMPS.WC 11215-3 APRIL 27,2001
City of Carisbad
MF EQUIF'MENT PROCUEMEN?
Carlsbad Recycling Facility
9. Four (4) copies of certified pump tests, and a certified performance data curve.
10. Four (4) copies of certified motor tests and test data.
B. Factory Tests Reports:
1. Each Pump shall be Factory Tested. All tests shall be witness tested by a
Registered Professional Engineer, who is an employee of the manufacturer.
He/she shall sign and seal all copies of curves and shall certify that hydrostatic
tests were performed.
2. Each motor shall be given a complete, initial certified shop test, with the test data
submitted to the Engineer for approval.
C. Installation Instructions:
1. Package Installation Instruction with the Pump.
D. Operation and Maintenance Manuals:
1. 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 01730, Operation and Maintenance Data and
Section 01731, Instruction of Operations and Maintenance Personnel.
E. Certificates, Warranties and Guarantees
1. Submit warranty certification.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Refer to Section 01611, Protection of Goods and Section 01610 Transportation and
Handling of Goods.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Liquid ring vacuum pumps shall be used where noted or shown. See Section
11300 and related system specifications for requirements.
B. Process Design Requirements
112IS.UQLilDRMG VACLRlM PLMPS.DOC 11215-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Pump Type: Close coupled, multi-service, liquid ring vacuum type.
2. Balance
a. 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 vibration displacement (peak-to-peak) as
measured at any point on the assembly shall not exceed 0.13 IPS at the
highest point on the motor.
b. At any operating speed, the ratio of rotative speed to the critical speed of a
unit or components thereof shall be less than 0.8.
3. Acceptable Manufacturers
a. Sterling SMI, Model LEM
b. Atlantic Fluidics, Fluid-Vac
c. Or equal.
B. Equipment Design Requirements
1. Discharge Head
a. Fabricated Heads shall be a one-piece fabricated design.
b. The pump suction and discharge connections shall be threaded. ’
2. Rotors
a. Free rotating type without metal-to-metal contact with the casing,
b. Rotors shall be accurately machined, dynamically balanced and securely
locked on the pump shaft.
C. Fabrication and Material Requirements
IIZIS.UQUIDRMGVACUUMPUMPS.DOC 11215-5 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUPMENT PROCUREMENT
1. Requirements for pumps are included by system. See the individual system
specification sections following Section 11300 for requirements.
2.03 EQUIPMENT AND COMPONENTS
A. Motors
1. Each pump shall be driven by a solid shaft TEFC, 3-phase, 60 Hz, 460 volt motor.
The motor shall have a 1.15 service factor and shall be NEMA Design B, with
Class F insulation to operate at full load with a Class B temperature rise per latest
EEMAC standards.
2. All motors rated from 1-200 HP shall meet the Minimum Motor Efficiency
Standard for Premium Efficiency Motors.
3. All grease lubricated bearings shall be provided with standard Alemite fittings.
4. The motors shall have stainless steel nameplates on which shall be stamped all
pertinent electrical and bearing information and the seal of the UL.
5. Eyebolts or lifting lugs shall be provided on the motors and they shall be of
adequate strength for lifting the motor. All metal parts shall be inherently
corrosion-resistant or shall be protected with corrosion-proof coatings.
6. Approved Motor Suppliers
a. General Electric
b. USEM
c. Siemens
B. Nameplates
1. Each pump and motor shall be furnished with a stainless steel nameplate securely
mounted to the body of the equipment.
2. As a minimum, the nameplate for the pumps shall include the equipment number,
manufacturer's name and model number, serial number, rated flow capacity, head,
speed, and all other pertinent data.
3. AS a minimum, nameplates for motors shall include the motor number,
manufacturer's name, and model number, serial number, horsepower, speed, input
voltage, amps, number of cycles, and power and service factors.
C. Anchor Bolts
I12IS.LIQUIDRMGVACUUMPLlMPS.DOC 11215-6 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Anchor bolts and inserts shall be furnished under this Section and shall be sized in
accordance with the manufacturer's recommendations.
2. Refer to Section 05503.
3. All bolts, nuts, and cap screws shall have hexagonal heads,
2.04 INSTRUMENTATION AND CONTROLS -NOT USED
2.05 SPARE PARTS
A. One set of bearings.
B. One complete set of auxiliary seals.
2.06 SHOP PAINTING
A. All interior and exterior non-stainless steel ferrous surfaces of the pump unit, including
motor, motor stand, frames, baseplates and appurtenances shall be shop primed and
painted in accordance with Section 09900. Shop painting shall include surface
preparation, prime, and finish coats.
B. NSF-61 Coating
1. Extent: All interior surfaces of the pumping unit which are not bronze or stainless
steel and the exterior surfaces of the pumping unit which may become submerged
shall be painted with a coating currently listed in NSF-61.
2. Materials: Epoxy, Tnemec Series 20, Ameron 395, or equal.
3. Machined and Polished Surfaces: Coat with a corrosion prevention compound
listed in NSF-61.
4. All Other Surfaces: As specified in Section 09900 for non-submerged exterior
ferrous metals.
2.07 SPECIAL TOOLS
A. The h4FEM shall furnish a complete set of special tools as required for operation,
maintenance, dismantling, and assembly of the pumps.
2.08 LUBRICANTS
A. Furnish NSF 61 Approved Lubricants.
PART 3 - EXECUTION
ll2lS.LlQWD RMG VACW PUMPS.DC€ 11215-7 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMEN?
Carlsbad Recycling Facility
3.01 DELIVERY AND INSTALLATION
A.
B.
C.
The MFEM and District / Engineer shall inspect all equipment upon delivery to site. If
damaged, notify Engineer and MFEM at once.
Installation Contractor will not install damaged equipment until repairs are made in
accordance with manufacturer's written instructions and approved by the Engineer.
Only minor repair work shall be permitted in the field. All other damaged items shall
be sent to factory for repair or replacement.
The Installation Contractor will complete the installation in accordance with pump
manufacturer's instructions and recommendations.
3.02 COMMISSIONING
A. MFEM shall inspect and verify that structures, pipes and equipment are compatible.
The MFEM shall make any adjustments required to place system in proper operating
condition.
3.03 OPERATOR TRAINING
A. Manufacturer of the Pump shall provide instruction to the Operations and Maintenance
in personnel in accordance with Section 01 73 1.
3.04 ACCEPTANCE TESTING
A. The Installation Contractor and MFEM shall test each installed pump to determine
conformance to the specified design and performance criteria.
3.05 MANUFACTURERS FIELD SERVICES
A. Field Services: The MFEM shall provide the following services in addition to any other
services specified herein, and required by these Specifications.
1. A factory trained field representative shall be provided for startup and field testing
services and Operation and Maintenance training services. The startup and field
testing, and the Operation and Maintenance services shall be coordinated with the
Engineer. The field representative may be a factory-trained employee of the
MFEM.
+ + END OF SECTION + +
I1215.LIQUID RING VACUUM PUMPS.WC 11215-8 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEW
SECTION 11240
CHEMICAL FEED SYSTEMS, GENERAL
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. This section covers the chemical feed systems to be installed at the Carlsbad WRF
for the MF system, including sodium hydroxide, sodium hypochlorite, Memclean
C, and citric acid.
B. Coordination
1. Requirements for individual chemical feed subsystems are specified in the
following sections:
Section
11244
11245
11246
11248
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
Subsystem
Sodium Hypochlorite
Citric Acid
Memclean
Sodium Hydroxide
A. Manufacturers' Qualifications
1. All equipment furnished under this specification shall be new and shall be the
standard product of a manufacturer who is fully experienced, reputable, qualified
and regularly engaged for at least 5 years in the manufacture of the equipment to
be furnished.
2. The MFEM shall assume responsibility for the satisfactory installation and
operation of the chemical feed systems specified. Upon completion of system
installation, the MFEM shall inspect and shall submit a certificate of proper
installation.
B. Reference Standards
1. NFPA 70, National Electrical Code
2. NEMA MG1 - Motors and Generators
1124C.CHEMICAL FEED SYSTFMS. GENERAL.LXX 11240-1 APRIL 21,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
3. NEMA ICs 6 - Industrial Control and Systems Enclosures
C. Manufacturers Field Services
a. Inspect the completed installation and prepare an inspection report.
b. Test, calibrate, and adjust all components for optimum performance.
c. Assist in initial start-up and field testing.
d. Instruct District’s personnel in the operation and user maintenance of all
components. Conduct a training seminar at the site per Section 01731,
Training of Operations and Maintenance Personnel.
e. Supervise the correction of any defective or faulty work before and after
acceptance by District.
1.03 SUBMI’ITALS
A. Shop Drawings
1. Provide manufacturers’ catalog sheets with the selected model numbers and
accessories clearly indicated. Include a data sheet listing guaranteed operating
points as well as performance curves over the required operating range showing
compliance with specified head, capacity, NPSHR, and brake horsepower.
Curves shall be submitted on individual 8-112-in by 11-in sheets.
2. Certified fabrication drawings of the equipment including a complete bill of
materials.
3. Manufacturer’s recommended spare parts list, including current list prices for all
components. List bearings and seals by the respective manufacturer’s part
number only.
4. Panel fabrication and wiring diagrams.
5. Complete motor data.
6. Operating and installation instructions.
B. Factory Test Reports
1. Chemical Metering Pumps
a. Conduct tests on actual equipment to be furnished to the job site, including
pump head and motor.
I1M.CHEMICALFEEDSYSTEMS. GENERALWC 11240-2 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
b. Notify the Engineer two weeks prior to equipment factory tests.
c. Furnish certified test reports which include test data sheets, performance test
logs, and equipment performance curves over the specified operating'range.
Indicate separately equipment guaranteed operating points.
2. Pump Control Panels
a. Conduct a factory test on each metering pump control panel to demonstrate
proper operation of all discrete control circuits, indicating lights, and local
control stations.
b. Submit a test demonstration plan to the Engineer for review and approval a
minimum 2 weeks prior to scheduling the panel factory tests. Incorporate
comments and resubmit the corrected plan at least 48-hours prior to the test.
C. Operation and Maintenance Manuals
1. The MFEM shall provide operations and maintenance manuals for components of
the chemical feed systems meeting the requirements of Section 01730.
D. Certificates Warranties and Guarantees
1. Submit warranty certification.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. Refer to Section 01611, Protection of Goods and Section 01610 Transportation and
Handling of Goods.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Individual metering systems and equipment shall be installed where noted or
shown. See Section 11300 and related system specification sections for
requirements.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Metering Pumps
1. General: All chemical metering pumps shall be of the simplex mechanically
balanced diaphragm type, wherein a piston reciprocates within a gear box and
directly deflects a flat diaphragm. Tubular diaphragms will not be permitted.
Il2.UICHEMICALFEEDSYS"i?h%S. GENERAL.DOC 1 1240-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Mechanical Drive Assembly:
a. The internal drive assembly shall consist of a worm gear that drives a cam,
which in turn actuates the reciprocating piston.
b. Manual capacity adjustment shall be accomplished by changing piston
stroke length from 0 to 100%. Device actuation shall be active with the
pump idle or running, through a frame mounted control knob (handwheel).
The handwheel shall incorporate an integral auto-locking mechanism to
prevent drift and detent positioning with a resolution of M.5 percent.
3. Metering Head:
a. The metered liquid shall enter the reagent head at the bottom and exit at the
top through gravity seating three component ball-type valves.
b. Process connections shall be FNPT.
4. Motor Mount:
a. Arranged for vertical mounting of a C-face motor.
b. The mounting arrangement shall eliminate exposure to rotating couplings.
The coupling enclosure shall be totally enclosed and part of the motor
mounting assembly.
5. Motors:
a. Type: 120 VAC constant speed motor.
b. Size: 314 hp, minimum.
c. Speed: 1800 rpm.
d. Enclosure: TEFC.
e. Power Supply: 115 VAC, 1 phase, 60 Hz.
6. Performance Requirements:
a. Pumps shall be selected such that the maximum operating capacity point is
achieved at a point between 40 and 60 percent of the available stroke
adjustment.
b. The pump shall be capable of operating with a net positive suction pressure
available as low as 3 psi.
1IZIUI.CHEMICAL FED SYSTEMS. GENERAL.WC 1 1240-4 APRIL 27,2001
City of Carlsbad
Ca&bad Recycling Facility
MF EQUIPMENT PROCUREMENT
C. Flow adjustment shall be from 0 to 100 percent with a guaranteed accuracy
of 20.5% steady state on setpoint over a 10: 1 flow turndown range.
7. Manufacturer: Pumps shall be as manufactured by the Liquid Metronics division
&MI) of Milton Roy, or equal.
2.03 EQUIPMENT AND COMPONENTS
A. Air Diaphragm Chemical Transfer Pumps
1. General: Chemical transfer pumps where noted or shown shall be shall be of
the duplex mechanically balanced air diaphragm type, wherein a piston
reciprocates within a chamber and directs pressurized air to deflect the pump
diaphragms.
2. Drive Assembly:
a. The internal drive assembly shall consist of a ported air valve body which
houses a reciprocating piston. Piston motion shall directly charge alternate
air chambers to deflect the pump diaphragms.
b. The system shall operate through variations in differential pressure only,
without the use of mechanical trip rods, bearings, or springs.
3. Metering Head:
a. The metered liquid shall enter the reagent head at the bottom and exit at the
top through gravity seating three component ball-type valves installed on
each chamber.
b. Process connections shall be FNF'T
4. Air Loading Valve:
a. Type: 24 VAC solenoid operated.
b. Electrical Rating: NEMA 4.
5. Performance Requirements:
a. The pump shall be self priming type, capable of developing a suction lift up
to 10 feet.
b. Pump shall be capable of running dry without damage.
c. Pump shall have dead head capability without the use of a bypass valve.
II24L.CHEMICALFEEDSYSIEMS. GF.NERAL.WC 1 1240-5 APRIL 21,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
6. Manufacturer: Pumps shall be as manufactured by Wilden, or equal.
B. Calibration Columns
1. Size: Selected by the metering pump manufacturer to provide 2 minutes of
testing at the maximum capacity of the pump (100 percent stroke, 100 percent
speed), or 170 mL, whichever is greater.
2. Style: Clear cylinder with graduations marked in liters and gallons. A
minimum of five intermediate graduations shall be provided.
3. Process Connections: FNPT, 1/2-inch minimum, located in the top and bottom
end caps.
4. Materials of Construction: As specified in the individual system specifications
which follow.
C. Pulsation Dampeners:
1. Size: Selected by the metering pump manufacturer to match the capacity of
the pump.
2. Style: The pulsation dampener shall consist of two separate chambers
separated by an elastomeric diaphragm. The lower section shall be wetted by the
process fluid, while the upper section shall be isolated from the fluid and filled
with compressed air.
3. Process Connection: FNPT, 112-inch minimum.
4. Materials of Construction: As specified in the individual system specifications
which follow.
D. External Pressure Relief Valves:
1. Designation: Type PRV4.
2. Size: Selected by the metering pump manufacturer to provide external
pressure relief on the chemical injection line, as shown, for field installation on
the pump discharge line.
3. Style: Internal spring actuated diaphragm type, 3 port design. Valve
shall be capable of closing without an external source of pressure. Relief pressure
setting shall be externally adjustable between 0 and 150 psig via a top mounted
adjustment screw.
11240.CHEMICAL FEED SYSTEMS. GENERALDOC 11240-6 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPhENT PROCUREMENT
4. Operation: The valve shall remain closed with injection line pressures below the
setpoint. When the setpoint relief pressure is exceed, the valve shall open and
relieve pressure to the metering pump suction line.
5. Process Connections: FNPT, 112-inch minimum.
6. Materials of Construction: As specified in the individual system specifications
which follow.
E. Back Pressure Regulating Valves:
1. Designation: Type BPR3.
2. Size: ' Selected by the metering pump manufacturer to provide backpressure
on the chemical injection line, as shown, for field installation at the injection
point.
3. Style: Internal spring actuated diaphragm type. Valve shall be capable of
closing without an external source of pressure. Pressure setting shall be
externally adjustable between 0 and 150 psig via a top mounted adjustment screw.
4. Operation: The valve shall maintain a constant upstream pressure higher than the
downstream injection pressure. When the pressure on the upstream side of valve
reduces below the set pressure, the valve shall close, eliminating siphoning into
the process line and/or back-mixing in the injection line.
5. Process Connections: FNPT, 1R-inch minimum.
6. Materials of Construction: As specified in the individual system specifications
which follow.
F. Relief Line Flow Indicators:
1. Description: Pumps shall be supplied with a visual flow indicator installed in
the relief valve exhaust line.
2. Style: The indicator shall be of double wall construction with a,Pyrex inner
cylinder, plexiglass outer cylinder, and stainless steel fasteners. Flow indication
shall be accomplished visually without the use of internal streamers or other
moving parts.
3. Process Connections: 112-inch FNPT.
4. Port Materials: Materials for wetted connections shall be per the individual
system specifications which follow.
G. Chemical Injectors (Quills):
II2dL.CHF.MICALFEEE SYSTEMS. GEN73AL.m 11240-7 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
1. Size: Selected by the chemical pump manufacturer to provide the required
injection capacity at maximum pump operating conditions and provide adequate
mixing.
2. Style: Metallic quill with integral spring loaded injection check valve to
prevent back-mixing as manufactured by Neptune or equal.
3. Process Connections:
a. The injection line shall interface with the quill via a FNPT inlet, 1/2-inch
minimum. A union fitting shall be incorporated at the interface to permit
disassembly.
b. The quill shall interface with the process line via a MNPT fitting, 1/2-inch
minimum.
4. Materials of Construction: As specified in the individual system specifications
which follow.
2.04 INSTRUMENTATION AND CONTROLS
A. Control Panels
1. Where shown, provide a NEMA 4X control enclosure of Type 316 stainless steel
construction housing the pump starters and related accessories.
2. Power supply to the panels will be single phase, 120 VAC.
3. Door mounted components shall include the following as a minimum unless
otherwise shown:
a. Pump controller LOCAL-OFF-REMOTE selector switch.
b. Power ON-OFF switch.
c. A pump ON indicator light.
4. Internal components shall include the following as a minimum:
a. Pump motor controller and related accessory components.
b. Terminal blocks for interfacing all field wiring.
c. Interposing control relays.
5. Panel construction, components, and wiring shall comply with the requirements of
Sections 13320 and 13325.
I IZI(O.CHEMICAL FEED SYSTEMS, GENU(ALWC 11240-8 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
h4F EQUIPMENT PROCUREMENT
6. Signal Interface:
a. In REMOTE mode, the drive shall start and stop based on a control signal
from PLC-MF, with speed regulation based manual stroke length
adjustment.
b. Provide the following drive status outputs unless otherwise shown:
1) Drive controller in REMOTE mode, SPST dry contact rated 5A at
120 VAC.
2) Drive controller in LOCAL mode, SPST dry contact rated 5A at 120
VAC.
3) Drive controller ON, SPST dry contact rated 5A at 120 VAC.
c. Control signals: Discrete input signals from the PLC shown on the Drawings
will be 120 VAC. Provide any interposing relays required to interface with
the specified panel control circuits.
SPARE PARTS
Furnish the following:
1. O-ring Gaskets: Provide six spare O-ring gaskets of each type.
2. Panel Lamps: Provide four spare bulbs for panel indicating lamps.
3. Panel Fuses: Provide four spare fuses of each type incorporated in panel
circuitry.
4. Panel Relays: Provide two spare relays of each type incorporated in panel
circuitry.
SHOP PAINTING
Painting of components shall be in accordance with the requirements of Section 09900.
SPECIAL TOOLS
The MFEM shall furnish a complete set of special tools as required for operation,
maintenance, dismantling, and assembly of the pumps.
LUBRICANTS
The MFEM shall furnish all lubricants required for equipment startup and initial
operations.
2.05
A.
2.06
A.
2.07
A.
2.08
A.
11240-9 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. The MFEM and District I Engineer will inspect all equipment upon delivery to site. If
damaged, notify Engineer and MFEM at once.
B. Installation Contractor will not install damaged equipment until repairs are made in
accordance with manufacturer's written instructions and approved by the Engineer.
Only minor repair work shall be permitted in the field. All other damaged items shall
be sent to factory for repair or replacement.
C. The Installation Contractor will complete the installation in accordance with pump
manufacturer's instructions and recommendations.
3.02 COMMISSIONING
A. MFEM shall inspect and verify that structures, pipes and equipment are compatible.
The MFEM shall make any adjustments required to place system in proper operating
condition.
3.03 OPERATOR TRAINING
A. Manufacturer of the associated systems shall provide instruction to the Operations and
Maintenance in personnel in accordance with Section 01731.
B. The Manufacturer shall demonstrate the mechanical seal replacement procedures.
3.04 ACCEPTANCE TESTING
A. The Installation Contractor and MFEM shall test the installed systems to determine
conformance to the applicable design and performance criteria.
3.05 MANUFACTURERS FIELD SERVICES
A. Field Services: The MFEM shall provide the following services in addition to any other
services specified herein, and required by these Specifications.
1. A factory trained field representative shall be provided for startup and field testing
services and Operation and Maintenance training services. The startup and field
testing, and the Operation and Maintenance services shall be coordinated with the
Engineer. The field representative may be a factory-trained employee of the
MFEM.
I IZW.CHEMICAL FEED SYSTEMS. GWERALWC
+ + END OF SECTION + +
11240-10 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
SECTION 11244
SODIUM HYPOCHLORITE FEED SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. MFEM shall furnish equipment and incidentals for a sodium hypochlorite feed
system. The equipment shall include, but not be limited to, mixing tank, mixer,
metering pumps, calibration columns, and all associated accessories as shown or
as specified herein.
2. All equipment shall be designed and built for continuous service over the
specified flow range without excessive strain and requiring only that degree of
maintenance generally accepted for the specific type of equipment supplied.
3. Equipment shall be supplied and placed in proper operating condition by the
MFEM in full conformity with the drawings, specifications, and instruction of the
equipment manufacturers.
B. Reference Specifications:
1. See Section 11240 for general component requirements.
2. See Section 11300 and related system specification sections for requirements
applicable to the MFEM's system.
1.02 QUALITY ASSURANCE
A. Refer to Section 11240.
1.03 SUBIvfI'lTALS
A. Shop Drawings: To be submitted in accordance with Section 01340, Shop Drawing
Procedures and specific requirements under Section 11240.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Solution Concentration, %by weight: 12.5.
IIZ44.SODNM HYPOCHLORIIEFEED SYSTEMDOC 1 1244- 1 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Specific Gravity @ 70 "F: 1.21.
2.02 EQUIPMENT DESIGN AND FABRICAnON
A. General
1. Sodium hypochlorite dosing and metering pumps with accessories shall be
furnished as shown on the Drawings and as specified in Section 11240.
B. Equipment Design Requirements
1. Equipment Numbers: See the individual system sections following Section 11300
for requirements.
2. Flow Range: See the individual system sections following Section 11300 for
requirements.
3. Discharge Pressure:
a. Operating: See the individual system sections following Section 11300 for
requirements.
b. Rated: 150 psig.
4. Suction Lift: Flooded.
C. Fabrication and Material Requirements
1. Metering Head: PVC or PVDF.
2. Diaphragm:PTFE.
3. Ball Check Valves: Ceramic.
2.03 EQUIPMENT AND COMPONENTS
A. Sodium Hypochlorite Bulk Storage Tank
1. The bulk storage tank will be furnished by the Installation Contractor.
B. Calibration Columns
1. General: Install where noted or shown,
2. Materials:
a. Column: Clear PVC.
1 IW.SODR1M HYPOCHLORITE FEED SYSTEM.Doc 11244-2 APRIL 27,2001
b. End Caps: PVC.
C. Pulsation Dampeners
1. General: Install where noted or shown.
2. Materials:
a. Wetted Compartments: PVC.
b. Non-Wetted Compartments: PVC.
c. Diaphragm: Viton.
d. Fittings: Type 316 stainless steel.
D. Chemical Injectors
1. General: Install where noted or shown.
2. Materials:
a. Stinger: Hastelloy C276.
b. Ball-Check and Spring: Hastelloy C276.
c. Fittings: Hastelloy C276.
E. Valves
1. Relief Valves:
a. Body: PVC.
b. Seals: Viton.
c. Fasteners: Type 316 stainless steel.
2. Backpressure Valves:
a. Body: PVC.
b. Seals: Viton.
c. Fasteners: Type 316 stainless steel.
F. Relief Line Flow Indicators
1 IW.SODNh4 HYFOCHLORITE WED SYSTEM.wC 11244-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUR!3MZNT
1. General: Install where noted or shown
2. Materials:
a. Tube: Clear PVC.
b. Fittings: PVC.
c. Seals: Viton.
G. Hardware and Supports
1. A11 pipe and valve mounting hardware and fasteners used in the chemical feed
system shall be fabricated from Type 316 Stainless Steel.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Installation of all tanks and equipment shall be in accordance with manufacturer’s
instructions and recommendations and approved Shop Drawings.
3.02 COMMISSIONING
A. h4FEM shall make adjustments required to place feed system in proper operating
condition. MFEM shall field test and calibrate the equipment to assure that the system
operates in accordance with these Specifications and to the satisfaction of the Engineer.
3.03 OPERATOR TRAINING
A. Refer to Section 01731, Training of Operation and Maintenance Personnel.
3.04 ACCEPTANCE TESTING
A. Refer to Section 01670, Acceptance Testing of Membrane Equipment.
3.05 MANUFACTURERS ASSISTANCE
A. See Section 11240,
+ + END OF SECTION + +
11244.SODRIM HYPOCHLORlTE FEED SYSTEM.DOC 1 1244-4 APRIL 27,2001
City Of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 1 1245
CITRIC ACID FEED SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work:
1. MFEM shall furnish equipment and incidentals for a citric acid feed system. The
equipment shall include, but not be limited to, mixing tank, mixer, metering
pumps, calibration columns, and all associated accessories as shown or as
specified herein.
2. All equipment shall be designed and built for continuous service over the
specified flow range without excessive strain and requiring only that degree of
maintenance generally accepted for the specific type of equipment supplied.
3. Equipment shall be supplied and placed in proper operating condition by the
MFEM in full conformity with the drawings, specifications, and instruction of the
equipment manufacturers.
B. Reference Specifications:
1. See Section 11240 for general component requirements.
2. See Section 11300 and related system specification sections for requirements
applicable to the MFEMs system.
1.02 QUALITY ASSURANCE
A. Refer to Section 11240.
1.03 SUBh4JTTALS
A. Shop Drawings: To be submitted in accordance with Section 01340, Shop Drawing
Procedures and specific requirements under Section 11240.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Solution Concentration, % by weight: 34.
I1245.CITRICACIDFEEDSYSTEM.WC 11245-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
2. Specific Gravity @ 70 "F: 1.5.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Citric acid dosing and metering pumps with accessories shall be furnished as
shown on the Drawings and as specified in Section 11240.
B. Equipment Design Requirements
1. Equipment Numbers: See the individual system sections following Section 11300
for requirements.
2. Flow Range: 10.6 to 106.0 gallonshour.
3. Discharge Pressure:
a. Operating: 10 psig.
b. Rated: 150 psig.
4. Suction Lift: Flooded.
C. Fabrication and Material Requirements
1. Metering Head: PVC or PVDF.
2. Diaphragm:PTFE.
3. Ball Check Valves: Ceramic.
2.03 EQUIPMENT AND COMPONENTS
A. Citric Acid Mix Tank
1. General: Refer to Section 11250 for requirements.
2. Tank Construction Details:
a. Type: Vertical, cylindrical, flat bottom, flat top.
b. Minimum Capacity: 280 gallons.
c. Nominal Diameter: 4 feet.
d. Nominal Straight Shell Height: 3 feet.
11245.CnRlC ACID FEED SYSTZM.Doc 11245-2 APRIL 27.2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUlPMENT PROCUREMENT
e. Top Connections:
1) Coordinate with mixer and bag loader manufacturers.
2) Provide a hinged access port for dilution water addition.
f. Side Connections:
1) One 2-inch flanged drain connection.
2) One 2-inch flanged outlet connection.
g. Platform: Required. Height and configuration shall be sufficient to provide
access to the bag loader for loading of dry citric acid bags.
h. Bag Loader: Required, see section 11250 for requirements.
i. Mixer Supports: Required.
B. Citric Acid Tank Mixer
1. General: The mixer will be used to batch approximately 200 gallons of citric acid
solution in an FRF' solution tank. The citric acid will be in crystal form and will
be mixed with water.
2. Requirements:
a. Type: Direct drive, furnished complete with motor, gear, impeller,
shaft, bearings, and mounting accessories.
b. Shaft: Single piece, sized by manufacturer to accomplish the required
mixing.
c. Impeller: Sized by the manufacturer, configured for extraction through
the tank top entryway.
d. Construction Materials:
1) Impellers: A-100 stainless steel.
2) Shaft: Type 316 stainless steel.
e. Motor:
1) Rating: 120 VAC, 1 phase, 60 Hz.
2) Enclosure: TEFC.
I1245.CnRIC ACrn FEED SYSTEM.DOc 11245-3 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
C.
D.
E.
F.
3) Size: 114 hp, minimum.
4) Service Factor: 1.15.
f. Controls: The mixer shall be provided with a minimum 15-ft power cord
and a local operating hand switch in a NEMA 4X, Type 316 stainless steel
enclosure.
Calibration Columns
1. General: Install where noted or shown.
2. Materials:
a. Column: Clear PVC.
b. End Caps: PVC.
Chemical Injectors
1. General: Install where noted or shown.
2. Materials:
a. Stinger: Type 316 stainless steel.
b. Ball-Check and Spring: Type 316 stainless steel.
c. Fittings: Type 316 stainless steel.
Valves
1. Relief Valves:
a. Body: PVC.
b. Seals: EPDM.
c. Fasteners: Type 316 stainless steel.
Hardware and Supports
1. All pipe and valve mounting hardware and fasteners used in the chemical feed
system shall be fabricated from Type 316 Stainless Steel.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
I124S.CITRIC ACID FEED SYSTEM.WC 11245-4 APRIL 27.2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Installation of all tanks and equipment shall be in accordance with manufacturer's
instructions and recommendations and approved Shop Drawings.
3.02 COMMISSIONING
A. h4FEM shall make adjustments required to place feed system in proper operating
condition. MFEM shall field test and calibrate the equipment to assure that the system
operates in accordance with these Specifications and to the satisfaction of the Engineer.
3.03 OPERATOR TRAINING
A. Refer to Section 01731, Training of Operation and Maintenance Personnel.
3.04 ACCEPTANCE TESTING
A. Refer to Section 01670, Acceptance Testing of Membrane Equipment.
3.05 MANUFACTURERS ASSISTANCE
A. See Section 11240.
+ + END OF SECTION + +
IIZ~S.C~RIC Acm FEED SYSTEM.DOC 11245-5 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 11246
MEMCLEAN FEED SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope:
1. This specification applies to the Memcor CMF and CMF-S systems. The
chemical feed equipment under this section will supply a proprietary cleaning
agent to the membrane CIP system.
2. MFEM shall furnish all materials, equipment and incidentals to supply, install,
test, and place into satisfactory operation a Memclean feed system. The
equipment shall include, but not limited to, chemical delivery tote, air diaphragm
transfer pump, and associated ancillary equipment as shown and as specified
herein.
3. All equipment shall be designed and built for continuous service over the
specified flow range without excessive strain and requiring only that degree of
maintenance generally accepted for the specific type of equipment supplied.
4. Equipment shall be supplied and placed in proper operating condition by the
MFEM in full conformity with the drawings, specifications, and instruction of the
equipment manufacturers.
B. Reference Specifications:
1. See Section 11240 for general component requirements.
2. See Section 11300 and related system specification sections for requirements
applicable to the MFEM's system.
1.02 QUALITY ASSURANCE
A. Refer to Section 11240.
1.03 SUBMITTALS
A. Shop Drawings: To be submitted in accordance with Section 01340, Shop Drawing
Procedures and specific requirements under Section 11240.
PART 2 - PRODUCTS
11246.MF.MCLEAN~DSYSTEM.WC 11246-1 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Fluid Memclean C
2. Fluid Temperature: 50-1 10 degrees F
3. Specific Gravity: 1.10- 1.15
4. Solution Strength: 100 percent (undiluted)
2.02 EQUIPh4ENT DESIGN AND FABRICATION
A. General
1. Memclean air diaphragm transfer pumps with accessories shall be furnished as
shown on the Drawings and as specified in Section 11240.
B. Equipment Design Requirements
1. Equipment Numbers: See the individual system sections following Section 11300
for requirements.
2. Flow Range: 0 - 5 gallonshinute.
3. Discharge Pressure:
a. Operating: 10 feet.
b. Rated: 40 feet.
4. Suction Lift: 3 feet.
C. Fabrication and Material Requirements
1. Wetted Housing: Polypropylene.
2. Diaphragm:PTFE.
3. Air Valve: PTFE coated brass.
2.03 EQUIPMENT AND COMPONENTS
A. Memclean Delivery and Storage Tote
1. Tank Construction Details:
11246-2 lIZ46.MEMCLEAN FEEDSYSTEM.DOC APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Type: 55 gallon drum.
b. Top Connections: Coordinate with transfer pump requirements.
B. Calibration Columns
1. General: Install where noted or shown.
2. Materials:
a. Column: Clear PVC.
b. End Caps: PVC.
C. Hardware and Supports
1. All pipe and valve mounting hardware and fasteners used in the chemical feed
system shall be fabricated from Type 316 Stainless Steel.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Installation of all tanks and equipment shall be in accordance with manufacturer's
instructions and recommendations and approved Shop Drawings.
3.02 COMMISSIONING
A. MFEM shall make adjustments required to place feed system in proper operating
condition. MFEM shall field test and calibrate the equipment to assure that the system
operates in accordance with these Specifications and to the satisfaction of the Engineer.
3.03 OPERATOR TRAJNING
A. Refer to Section 01731, Training of Operation and Maintenance Personnel.
3.04 ACCEPTANCE TESTING
A. Refer to Section 01670, Acceptance Testing of Membrane Equipment.
3.05 MANUFACTURERS ASSISTANCE
A. See Section 11240.
+ + END OF SECTION + +
II246MEMCLEAN FEED SYSTEM.DOC 11246-3 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 11248
SODIUM HYDROXIDE FEED SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall fumish all, equipment and incidentals required to supply, test,
and place into operation a sodium hydroxide feed system for the CIP system. The
equipment shall include, but not be limited to, metering pumps, calibration
columns, piping, valves, fittings, and controls to provide a complete system.
2. All equipment shall be designed and built for continuous service over the
specified flow range without excessive strain and requiring only that degree of
maintenance generally accepted as peculiar to the specific type of equipment
supplied.
3. Equipment shall be supplied and placed in proper operating condition by the
MFEM in full conformity with the drawings, specifications, and instruction of the
equipment manufacturers.
B. Reference Specifications:
1. See Section 11240 for general component requirements.
2. See Section 11300 and related system specification sections for requirements
applicable to the MFEM's system.
1.02 QUALITY ASSURANCE
A. Refer to Section 11240.
1.03 SUBMITTALS
A. Shop Drawings: To be submitted in accordance with Section 01340, Shop Drawing
Procedures and specific requirements under Section 11240.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
11248.SODRIM HYDROXIDEFEED SYSTEM.Doc 11248-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCWMENT
1. Solution Concentration, %by weight: 25.
2. Specific Gravity @ 70 "F 1.27.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Sodium hydroxide dosing pump with accessories shall be furnished as shown on
the Drawings and as specified in Section 11240.
B. Equipment Design Requirements
1. Equipment Numbers: See the individual system sections following Section 11300
for requirements.
2. Flow Range: 10.6 to 106.0 gallonshour.
3. Discharge Pressure:
a. Operating: 10 psig.
b. Rated: 150 psig.
4. Suction Lift: Flooded.
C. Fabrication and Material Requirements
1. Metering Head: PVC or PVDF.
2. Diaphragm:F'"FE.
3. Ball Check Valves: Ceramic.
2.03 EQUIPMENT AND COMPONENTS
A. Bulk Storage Tote
1. General: Refer to Section 11255 for requirements.
2. Tank Construction Details:
a. Type: Vertical, cubic, sloped bottom, flat top, permanently installed in system.
b. Minimum Capacity: 350 gallons.
c. Nominal Cross-Section: 48-inches by 42-inches
11248.SODNM HYDROXIDE FEED SYSTEM.DoC 11248-2 APRIL 27,200 1
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
d. Nominal Straight Shell Height: 5 feet 3 inches.
e. Top Connections: One 7-inch screw cap closure assembly with 2-inch
threaded bung.
f. Side Connections: One 2-inch threaded end plate flange.
B. Shipping Tote
1. General: Refer to Section 11255 for requirements.
2. Tank Construction Details:
a. Type: Vertical, cubic, sloped bottom, flat top, used for shipping chemical
from the manufacturer.
b. Minimum Capacity: 250 gallons.
c. Nominal Cross-section: 48-inches by 42-inches
d. Nominal Straight Shell Height: 4 feet 2 inches.
e. Top Connections: One 7-inch screw cap closure assembly with 2-inch
threaded bung.
f. Side Connections: One 2-inch threaded end plate flange.
C. Calibration Columns
1. General: Install where noted or shown.
2. Materials:
a. Column: Clear PVC.
b. End Caps: PVC.
D. Valves
1. Relief Valves:
a. Body: PVC.
b. Seals: EPDM,
c. Fasteners: Type 316 stainless steel.
E. Hardware and Supports
IIWSODTUM HyDRoxrnE= SYSTEMDOC 11248-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. All pipe and valve mounting hardware and fasteners used in the chemical feed
system shall be fabricated from Type 316 Stainless Steel.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Installation of all tanks and equipment shall be in accordance with manufacturer's
instructions and recommendations and approved Shop Drawings.
3.02 COMMISSIONING
A. MFEM shall make adjustments required to place feed system in proper operating
condition. MFEM shall field test and calibrate the equipment to assure that the system
operates in accordance with these Specifications and to the satisfaction of the Engineer.
3.03 OPERATOR TRAINING
A. Refer to Section 01731, Training of Operation and Maintenance Personnel.
3.04 ACCEPTANCE TESTING
A. Refer to Section 01670, Acceptance Testing of Membrane Equipment.
3.05 MANUFACTURERS ASSISTANCE
A. See Section 11240.
+ + END OF SECTION + +
11248.SODRIM HYOROXDEND SYSTEM.Doc
~
1 1248-4 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEW
SECTION 11250
FIBERGLASS REINFORCED PLASTIC TANKS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall furnish materials, equipment, appurtenances, specialty items,
and services required to provide fiberglass reinforced plastic (FRP) tanks as
shown on the Drawings and specified in the Procurement Documents.
1.02 QUALITY ASSURANCE / QUALITY CONTROL
A. Manufacturer's Qualifications: Manufacturer of the FRP tanks shall have experience in
providing similar type equipment and shall show evidence with his submittal of at least
five (5) installations where equipment of the same material and design and similar
application as specified herein have been in satisfactory operation for at least five (5)
years.
B. Reference Standards: The material employed in items fabricated of fiberglass
reinforced plastic shall be capable of withstanding maximum calculated stresses that
may occur during fabrication, installation, and continuous operation, with allowance for
an adequate safety factor. The MFEM shall provide a certification from the
manufacturer that materials employed in items of fabrication of fiberglass reinforced
plastic shall meet the materials testing requirements defined in the latest revisions of
the following ASTM standards as applicable for each FRP tank to be furnished under
this Section.
1. ASTM C 581, Determining Chemical Resistance of Thermosetting Resins Used
in Glass Fiber Reinforced Structures Intended for Liquid Service.
2. ASTM C 582, Contact-Molded Reinforced Thermosetting Plastic Laminates for
Corrosion Resistant Equipment.
3. ASTM D 638, Test for Tensile Properties of Plastics.
4. ASTM D 695, Test for Compressive Properties of Rigid Plastics.
5. ASTM D 746, Test Method for Brittleness Temperature of Plastics and
Elastomers by Impact.
6. ASTM D 790, Test for Flexural Properties of Plastic.
IIZSO.LIBERGW\SSRUNK)R~EDPW\STICTANKS.DOC 11250-1 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
ASTM D 883, Standard Nomenclature Relating to Plastics.
ASTM D 1505, Test Method for Density of Plastics by the Density Gradient
Technique.
ASTM D 1693, Test Method for Environmental Stress Craclang of Ethylene
Plastics.
ASTM D 2310, Machine Made Reinforced Thermosetting Resin Pipe.
ASTM D 2563, Classifying Visual Defects in Glass Reinforced Laminate Parts.
ASTM D 2583, Test for Indentation Hardness of Plastics by Means of a Barcol
Jmpresser.
ASTM D 2996, Filament Wound, Reinforced Thermosetting Resin Pipe.
ASTM D 3299, Filament Wound Glass Reinforced Thermoset Resin Chemical
Resistant Tanks.
ASTM D 4097, Contact Molded Fiber Reinforced Thermoset Chemical Resistant
Tanks.
NBS Voluntary Product Standard PS15-69 Custom Contact Molded Reinforced-
Polyester Chemical-Resistant Process Equipment.
1.03 SUBMIlTALS
A. Shop Drawings:
1. Fabrication, assembly, foundation, and installation drawings, and operation,
maintenance, and storage instructions, together with detailed specifications and
data covering materials used, parts, devices, and other accessories forming a part
of the equipment furnished, shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340, Shop Drawing
Procedures. Data and specifications for the equipment shall include, but shall not
be limited to, the following:
a. Sufficient literature, detailed specifications, and drawings to show
dimensions, materials used, design features, internal construction, weights,
and any other information required by the Engineer for review of FRP tanks
and accessories.
b. Resin and materials of construction including thickness of each layer,
c. Service conditions for chemical environment and temperature,
IIZ5O.FlBERGLASS REINFORCED PLASTIC TANKSDOC 11250-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
d.
e.
f.
g.
h.
1.
1.
k.
1.
A Statement from the manufacturer that fabrication shall be in accordance
with these Specifications.
A statement from the manufacturer that the materials and resin used for each
tank are designed to meet all requirements for the intended service as
specified herein and as shown on the Procurement Drawings.
Tabulation in checklist form to indicate compliance with applicable ASTM
standards for each tank and service condition.
Sizing and details of anchoring and tie-down systems for each tank for the
service and load conditions specified herein.
Layouts and assembly schedules for each tank identifying the location and
elevation from the bottom of the tank for all inlet, outlet, and other
integrally molded connections and appurtenances specified herein and
shown on the approved Shop Drawings.
Details of access ladders, and top access platforms and handrails for all
tanks requiring top access with design calculations.
A certificate from resin manufacturer listing nomenclature, composition,
and characteristics of the resin.
Structural calculations signed by a structural engineer registered in the State
of California for anchorage of tank and supportlattachment of external
components.
Color chart for selection of tank color.
B. Factory Test Reports:
1. Each tank shall be given a hydrostatic test by the manufacturer before shipment.
2. Each tank shall be inspected for defects in accordance with the requirements of
ASTM D2563.
3. Each tank shall be completely shop-fabricated and shall be shipped to the Point of
Delivery as a single unit.
C. Installation Instructions
1. Submit with the delivery of the FRP tank detailed installation instructions.
D. Operation and Maintenance Manuals
11250.FlBEiGLASS REINFORCED PLASTIC TANKSDOC 1 1250-3 APRIL 27.2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Maintenance and troubleshooting guides shall be submitted for review in
accordance with the procedures and requirements set forth in Section 01730,
Operation and Maintenance Data, and Section 01731, Training of Operations and
Maintenance Personnel.
E. Certificates Warranties and Guarantees
1. Certification of Design: The MFEM shall provide with the submittals, written
certification from the manufacturer verifying that:
a. The FRP storage tanks to be furnished under this Section meet the
applicable ASTM and Uniform Building Code (UBC) standards, and
requirements specified herein for the conditions of service for each tank.
The Certification of Design shall be signed by a Licensed Professional
Engineer.
b. The design of the tanks and supports to be furnished under this Section meet
the loading conditions, lateral restraint, and UBC Seismic Zone 4
requirements specified herein.
2. Warranty
a. The FRP tank shall be provided with a manufacturers warranty for defects in
workmanship and materials for of period of 7 years from the date of
delivery to the project site. This warranty shall specifically state that if any
leaks occur in the tank, the manufacturer shall repair the leaks at their own
cost. If 3 leaks occur in the tank during the warranty period, the tank
manufacturer shall remove the defective tank, and install a new tank at no
cost to the District.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Provide FRP tanks and related accessories as shown on the Drawings and as
specified in other sections of the specifications.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Configuration: Completely self-draining, either sloped bottom, vertical
cylindrical, vented tank with dished tops.
1IZW.FIBERCLASSRUNFORaDPLASTlCTANKS.DOC 11250-4 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
2. Tank volume shall include only that volume in the straight shell below the
ovefflow pipe invert elevation. Nominal capacity or the inclusion of volumes
above the overflow pipe invert as additional capacity shall not be acceptable.
3. All storage tanks shall be designed for a concentrated top load of 250 pounds
distributed over a 4 x 4 square inch area at the top of the tank
B. Equipment Design Requirements
1. Details of Construction:
a. Filament wound main structure shall meet the requirements of ASTM
D3299.
b. All tanks shall meet or exceed Visual Acceptance Level XI in accordance
with ASTh4 D2563.
c. The laminate comprising the structural tank (bottom, cylindrical shell, top
head) shall consist of a corrosion resistant barrier comprised of an inner
surface, interior layer, and structural layer.
Inner Surface: The inner surface exposed to the chemical
environment shall be a resin rich layer 15 to 30 mils thick, reinforced
with 2 ply of synthetic fiber surface mat.
InteriorLayer: The inner surface layer exposed to the corrosive
environment shall be followed with a layer composed of resin,
reinforced only with non-continuous glass fiber strands applied to a
minimum thickness of 100 mils. The combined thickness of the inner
surface and interior layer shall be 115 to 130 mils and in no case less
than 110 mils.
Glass content of the inner liner and the interior layer combined shall
be 27 percent ?5 percent by weight.
The degree of cure, after post cure shall be such as to exhibit a Em01
hardness on the inner surface of at least 90 percent of the resin
manufacturer's minimum specified hardness for the cured laminate
with a synthetic surface mat.
Structural Layer: Subsequent reinforcement shall be continuous
strand roving that, in combination with the inner surface and interior
layers, is needed to satisfy the design requirements. Glass content of
this filament wound structural layer shall be 50 to 80 percent by
weight. Only those constructions evaluated for design properties
shall be used.
IIZSO.FIBW~GLASS REINFORCEDPLASTICTANKSDOC 11250-5 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPh4ENT PROCUREIvENl
d.
2. Flar
a.
b.
C.
d.
e.
Post Cure: The complete tank shall be post-cured with dry heat in
accordance with the resin manufacturer’s recommendations. Any internal
repairs or rework shall be completed prior to post curing. If any repairs are
made following post cure, an additional post cure cycle is required.
Head: The head knuckle radius shall be 1.5-inches, minimum.
Bottom: The bottom knuckle radius shall be 2-inches, minimum.
Reinforcement of the knuckle radius area shall extend up the vertical tank
shell a minimum of 12-inches.
lged Nozzles:
All nozzles shall be of hand lay-up construction with the pipe stub molded
integrally with the pipe flange, constructed in conformance with
requirements of the referenced standard.
Flanged Nozzles: FRP gussetted, flat face, conforming to ANSI 150-pound
drilling. Flanges shall be contact molded to the tank wall with inside and
outside layups as required and shall be located and oriented as shown on the
approved shop drawing submittal. The MFEM shall be responsible for the
coordination of flanged nozzle to ensure that the flange positions and
orientations shall be per specific tank locations, and that all tank connections
shall match the installation requirements according to specific site locations
and positions. All nozzles must protrude sufficiently to allow clear distance
between the back of the tank flange and the outer surface of the tank (5-
inches minimum) to allow access to flange bolts. Threaded (NPT) coupling
tank penetrations are not permitted.
Pump suction nozzles on tanks shall be flanged and shall be of the sizes and
locations shown on the approved shop drawings and of the siphon drain type
to minimize submergence requirements.
Tank drain nozzles shall be flanged and shall be of the sizes and locations
shown on the approved shop drawings and of the full drain type with
centerline of the nozzle positioned at the elevation of the tank bottom. If a
flat bottom tank is provided, the tank concrete pad shall be notched as
required to accommodate the tank drain nozzles.
Top of overflow pipes shall be located 3 inches below the top seam line
separating the dished top from the vertical side walls. Overflow connections
shall be flanged and shall be positioned as shown on the approved shop
drawings. Pipe supports shall be FRP as required and shall be laminated or
resin bonded to the tank’s exterior wall.
IIZSO.L~BERGLASS REINFORCED PLASTICTANKS.DOC 1 1250-6 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
f. Where noted or shown, each storage tank shall be furnished with a top
gooseneck Schedule 80 CPVC vent connected to the roof mounted, flanged
nozzle with 6-inch minimum flange protrusion. The vent shall be of the size
and location as shown on the approved shop drawings. End of vent pipe
shall be equipped with a 24 mesh polypropylene insect screen. A 12-inch
minimum clearance shall be provided between the insect screen and the top
of the tank.
g. Where noted or shown, each storage tank shall be furnished with a top
located flanged fill connections of the sizes and orientation shown on the
approved shop drawings. Fill connections shall be installed with fill tubes
that extend to within 12 inches of the tank bottom and shall be supported by
FRP supports as required, laminated or resin bonded to the tank’s interior
walls. Provide 112-inch diameter openings in the side of the fill tube inside
the tank and 4-inches below the top of the tank at approximately 180
degrees apart. Orient openings away from the overflow connection.
h. Where noted or shown, each tank shall be furnished with a 3-inch side
mounted flanged connection for a level transducer positioned 4 inches above
the bottom of the tank.
i. Where noted or shown, each tank shall be furnished with two 2-inch side
mounted flanged connections for connection of an external level sight gauge assembly.
j. Where noted or shown, each tank shall be furnished with additional 3-inch side mounted flanged connections for installation of discrete level switches.
k. Where noted or shown, each tank shall be furnished with a side mounted flange connection for installation of an electric immersion heater.
3. Manways:
a. All manways shall be minimum 24-inches in diameter and furnished with
covers constructed of the same material as the tank. Manways shall be
installed with all Type 316L stainless steel hardware, including nuts,
washers, bolts, and with 118-inch thick 40-60 durometer gasket material
chemically resistant to contained fluid. Flange protrusion shall be 6-inch
minimum with inside and outside layups as required. All manways shall be
flanged, flat faced, conforming to ANSUAWWA C207, Class B, or equal,
drilling.
b. Sidewall manways shall be used for tanks that do not contain or store CIP
solution for tanks with straight shell heights in excess of 6 feet. The manway
centerline shall be positioned 3 feet above the bottom of the tank.
11250.FIBERGLASS RUNFORCEDPUSTICTANKS.DOC 11250-7 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUrPMENT PROCUREMENT
C. Top manways shall be used for tanks that store acid or caustic (Le., CIP)
solutions and for tanks less than 6 feet tall. Top manways shall be dished
type, with a post and bar type hinge, a dnp lip and raised collar laminated
into the tank top.
4. Lifting Lugs: Lifting lugs shall be capable of withstanding weight of empty tank
with safety factor of 5 to 1. Provide a minimum of four (4) lifting lugs on all
storage tanks. Lifting lugs shall be Type 316L stainless steel and attached to tank
wall with hand-layed up laminate equal to or greater than the tank wall thickness.
5. Tie-down RinglMounting Lugs:
a. Vessel housing shall be designed for full bottom support and shall be
provided with a minimum of four (4) Type 316L stainless steel hold down
lugs.
b. Furnish all necessary Type 316 stainless steel cast-in-place anchor bolts,
nuts and washers, as required to meet the design requirements specified.
c. Tank housing and base shall be designed with ample supports so that the
whole assembly shall be self supporting in any operation condition and in
accordance with all external loading specified herein.
d. Mounting ring shall be factory assembled as part of the tank construction.
e. Each outside tank shall receive several layers (as required by the
manufacturer) of 30-pound roofing felt equal in diameter to the outside
diameter of the tank plus 2 inches for mounting onto the tank to resist
uneven loading on the tank and anchor system.
6. Identification Labels: Permanently attach either Type 316 stainless steel or
fiberglass label to each tank at an elevation 6 feet above the tank support pad with
the following minimum information:
a. Chemical to be stored including:
1) Concentration.
2) Specific gravity.
3) Maximum temperature.
b. Type of liner reinforcement.
c. Corrosion-resistant surface veil.
d. Resin.
11250.FlBERGLASS REINFORCEDPLAS'TlCTANKS.DOC 11250-8 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
e. Tank capacity.
f. Date of manufacture.
C. Fabrication and Material Requirements (Materials of Construction)
1. Fiberglass reinforced polyester or vinylester complying with ASTM D 3299 and
NBS Voluntary Product Standard PS 15.
a. Resin:
1) The resin used shall be a commercial grade, premium, corrosion
resistant vinyl-ester that has been evaluated in a laminate by test in
accordance with ASTM C-581 for the intended service and
recommended for this service by the resin manufacturer. The tank
manufacturer shall strictly adhere to the resin manufacturer’s
recommendations for surface veil materials, resin cure systems, and
post cure requirements.
..
2) The resin shall contain no pigments, dyes, colorants, or filler, except
as follows:
a) A thixotropic agent that does not interfere with visual
inspection of laminate quality may only be added for viscosity
control in resins that are not to be used in the inner corrosion
barrier, interior layers, interior secondary layers, and interior top
coats.
b) Resin pastes used to fill crevices may contain thixotropic agents
provided that all such areas are subsequently covered with a full
corrosion-resistant barrier laminate.
c) A pigmented exterior gel coat shall be provided on the tank to
reduce ultraviolet decomposition of the sodium hypochlorite,
where applicable.
d) Ultraviolet absorbers shall be added to the exterior surface for
improved weather resistance.
e) The same premium grade resin shall be used throughout wall
section of the tank for each specific tank.
3) Acceptable commercially available resins shall be:
a) Bisphenol “A“, such as Atlac 382.
b) Vinylester, such as Derakane 41 1, Derakane 470 or Atlac 580.
llYO.LlBERGLASSREWFORCEDPLASTlCTANKS.DOC 11250-9 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c) Chlorinated polyester, such as Hetron 197.
b. Surface Veils:
1) Surface veils shall be used on all interior tank wall surfaces.
2) Where "C" glass surface veil is not suitable, it shall be replaced with
compatible synthetic materials such as Nexus 10-12 as manufactured
by Burlington Industries, or equal.
c. Cure System:
A BPO-DMA cure system shall be applied throughout the tanks to
increase service life. In addition, interior of tanks shall be post-cured
as required.
Post-cure shall consist of a cure temperature of at least 180 degrees F
for a minimum of 4 hours. Barcol readings taken after the post-cure
shall not be greater than 4 points less than the resin manufacturer's
published Barcol readings and in no case less than 35.
Where steam is used in the post-cure, no steam shall impinge on the
interior surface of the vessel or the inside of any nozzle.
A steam sparge pipe projecting at least 12 inches beyond the interior
surface of any nozzle and away from any wall shall be used.
During steam post-curing, the tank shall be maintained at atmospheric
pressure.
Cobalt compounds shall not be used in curing in any way.
d. Reinforcement:
1) Chopped Strand Mat: Chopped strand mat shall be constructed from
chopped commercial grade E-type glass strands bonded together
using a binder. The strands shall be treated with a sizing that is
chemically compatible with the resin system used.
2) Continuous Roving: Continuous roving shall be a commercial
grade of E-type glass fiber with a sizing that is chemically compatible
with the resin system used.
3) Woven Roving: Woven roving shall be in accordance with ASTM
specification D2150.
11250.nBERGVISSREINFORCEDPLASTlCTANKS.DOC 11250-10 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
4) Surface Mat: The reinforcement used for the inner surface shall be
either a commercial grade chemical resistant glass surface mat or an
organic fiber surface mat as recommended by the resin manufacturer
for the intended service.
D. Tank Manufacturer
1. Provide FRP storage tanks as manufactured by one of the following:
a. DEI Systems, Inc.
b. Paramount Fabricators Inc.
c. Pacific Tank Co.
2.03 EQUIPMENT AND COMPONENTS
A. Access Ladder
1. Where noted or shown, tank shall be furnished with a ladder for access to the top
of the tank.
2. The access ladder shall be constructed of fiberglass and shall include a safety
cage.
3. Ladder rungs shall have non-slip surfaces.
4. Ladder supports shall be constructed integral with the tower of FRP or Type 316
stainless steel structural shapes.
5. All fasteners shall be Type 316 stainless steel.
6. The complete installation shall comply with applicable OSHA standards.
B. Access Platform and Handrail
1. Where noted or shown, the tank shall be furnished with a loading platform,
railing, and access ladder.
2. The platform shall be Constructed of fiberglass structural members and grating.
3. Grating shall be designed for a maximum deflection of 0.25 inch at a minimum
uniform load rating of 312 pounds per square foot and concentrated load rating of
786 pounds per foot of width.
4. All fasteners shall be Type 316 stainless steel.
Il~.FlBERGLASS REINFORCEDPLASTICTANKXDOC 11250-1 1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
5. The platform shall be 4-feet long with a minimum width of 4-feet and located
against the tank wall at a height which allows ready access to accessories located
on top of the tank.
6. Grating and ladder treads shall have non-skid surfaces.
7. Platform supports may be attached to the tank or to the concrete support pad-
coordinate requirements with the Engineer.
C. Bag Loader
1. Where noted or shown, the tank shall be furnished with a dry chemical bag
loading hopper installed in the top.
2. The bag loader shall be of all Type 316 stainless steel construction, Wallace and
Tiernan Part No. U23751 or equal.
D. Immersion Heaters
1. Where noted or shown, provide a tank mounted immersion heater with
accessories.
2. The heater shall be a flanged immersion type of the size indicated in the detailed
system specifications.
3. Power supply to the heater shall be 480 volts, 3 phase, 60 Hz.
4. The heater shall be furnished with an integral moisture tight terminal enclosure.
5. Heater elements shall be constructed of Incoloy.
6. The mounting flange shall be constructed of Type 316 stainless steel.
7. Protective wells shall be provided for temperature control and overtemperature
protection.
8. A control panel shall be furnished to house the heating contactors, auxiliary
controls, and other CIP system accessories as required by the MFEM for his
system.
a. Panel construction and wiring shall conform to requirements of Section
13325.
b. The panel enclosure shall be rated NEMA 4X of Type 316L stainless steel
construction. Panel mounted controls shall be rated NEMA 4 as a
minimum.
II~~D.L~BERGWSS~FORCEDPWSTICTANKS.DOC 11250-12 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c. A door mounted disconnect shall be provided, interlocked with panel ingress
to prevent access when the disconnect is in the ON position.
d. Provide necessary interposing relays in the panel to turn the heaters ON and
OFF on signal from the PLC. Control signals from the PLC will be 120
VAC, single phase.
e. Provide dry contacts rated 5 A at 120 VAC for all remote status indication
indicated on the Drawings.
E. Mist Arresters
1. Maximum Velocity, ft/s: 25
2. Design Requirements:
a. Mist arrester shall consist of a vertical FRP tank outlet sized to meet the
maximum velocity requirement.
b. The mist eliminator shall be selected and sized by the manufacturer such
that no visible mist escapes from the tank and shall remove mist as follows;
100% removal of 40 micron mist, 95% removal of 10 micron mist.
c. The outlet shall be fitted with a 316 stainless steel screen to prevent the
ingress of insects or debris
d. The mist eliminator shall be of rigid design to withstand the shock of the
cyclic MF backwash sequence.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. FRP tanks will be installed by the Installation Contractor as shown on the approved
shop drawings and as recommended by the manufacturer's representative.
3.02 MANUFACTURERS ASSISTANCE
A. Manufacturer's Field Services: The MFEM shall provide the following services in
addition to any other services specified herein, and required by these Specifications.
1. A factory trained field representative, shall be provided for a minimum of one (1)
trip and a minimum of one (1) eight-hour day to provide installation assistance
and field testing services. The field representative may be an employee of the
MFEM. The installation services and field testing services shall be coordinated
with the Installation Contractor.
1125O.FIBERGLASS~~HIRCU)PUSTlCTANKS.DOC 11250-13 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. After installation assistance and field testing services by the manufacturer, the
MFEM shall submit to the Engineer, a certification letter on the manufacturer's
letterhead and signed by the manufacturer certifying that the equipment was
installed per the manufacturer's recommendations and requirements and shall
furnish all field test data.
+ + END OF SECTION + +
I12SO.FIBERGLASSRUNFORCEDPLASTlCTANKS.DOC 11250-14 APRIL 27,2001
City of Carlsbad
MF equipment procurement
Carlsbad Recycling Facility
SECTION 11255
POLYETHYLENE STORAGE TANKS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work:
1. The MFEM shall furnish materials, equipment, appurtenances, specialty items,
and services required to provide cylindrical above grade polyethylene storage
tanks and related accessories as shown on the Drawings and specified in the
Procurement Documents.
2. This specification covers polyethylene tanks denoted Type I and Type 11. The
MFEM shall select the type of tank suited to the application and submit a letter
from the tank manufacturer certifying compatibility in the intended service.
1.02 QUALITY ASSURANCE / QUALITY CONTROL
A. Manufacturer's Qualifications:
1. Manufacturer of the polyethylene tanks shall have experience in providing similar
type equipment and shall show evidence with his submittal of at least five (5)
installations where equipment of the same material and design and similar
application as specified herein have been in satisfactory operation for at least five
(5) years.
B. Reference Standards
1. ASTM (American Society for Testing and Materials) Standards:
a.
b.
C.
d.
e.
f.
D618 - Conditioning Plastics and Electrical Insulating Materials for Testing
D638 - Tensile Properties of Plastics
D790 - Flexural Properties of Unreinforced and Reinforced Plastics and
Electrical Insulation Materials
D883 - Definitions of Terms Relating to Plastics
Dl505 - Density of Plastics by the Density-Gradient Technique
Dl525 - Test Method for Vicat Softening Temperature of Plastics
I t25S.Polyclhylem Slomgc Ts&s.doe 11255-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF equipment procurement
g. Dl693 - Test Method for Environmental Stress-Cracking of Ethylene
Plastics
h. Dl998 - Standard Specification for Polyethylene Upright Storage Tanks
i. D2765 - Degree of Crosslinking in Crosslinked Ethylene Plastics as
Determined by Solvent Extraction
j. D2837 - Method for obtaining Hydrostatic Design Basis for Thermoplastic
Pipe Materials
k. D3892 - Practice for Packaginflacking of Plastics
1. F412 - Definitions of Terms Relating to Plastic Piping Systems
2. ARM (Association of Rotational Molders) Standards:
a. Low Temperature Impact Resistance (Falling Dart Test Procedure)
3. ANSI Standards:
a. B-16.5 Pipe Flanges and Flanged Fittings
4. OSHA Standards:
a. 29 CFR 1910.106 Occupational Safety and Health Administration,
Flammable and Combustible Liquids
5. Uniform Building Code 1997 Edition
1.03 SUBMITTALS
A. Shop Drawings:
1. Provide complete shop drawing including the tanks, and all accessories included
on the tanks as specified herein.
2. Provide manufacturers data and drawings describing the equipment in sufficient
detail, including parts lists and materials of construction, to indicate full
conformance with the detailed specifications.
3. Provide calculations for anchorage of tank and suppodattachment of external
components.
B. Factory Test Reports
1 IZS5.Polyslhylsnc Storage Ta.n*s.doc 11255-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF equipment procurement
1. Submit results of water-test and chemical compatibility on actual tank and fittings
to be furnished to the job site.
2. Leakage Testing: Hydrostatic test each polyethylene tank at the factory for 24-
hours following assembly. Submit certified test report.
C. Installation Instructions
1. Submit detailed installation instructions with the delivery of the polyethylene
tanks.
D. Operation and Maintenance Manuals
1. Maintenance and troubleshooting guides shall be submitted for review in
accordance with the procedures and requirements set forth in Section 01730,
Operation and Maintenance Data, and Section 01731, Training of Operations and
Maintenance Personnel.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. Refer to Section 01610 - Transportation and Handling of Goods and Section 01611 -
Protection of Goods.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Provide cylindrical above gade polyethylene storage tanks and related
accessories as shown on the Drawings and as specified in other sections of the
specifications.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Design Requirements
1. The minimum required wall thickness of the cylindrical shell at any fluid level
shall be determined by the following equation, but shall not be less than 0.187 in.
thick.
T = P x O.D./2 SD = 0.433 x S.G. x H x O.D./2 SD
T =wall thickness
SD =hydrostatic design stress, PSI
P =pressure (.433 x S.G. x H), PSI
H = fluid head, ft.
112SS.Polpthylmc Slorage Tsnlu.doe 11255-3 APRIL 27,2001
City of Carlsbad
MF equipment procurement
Carlsbad Recycling Facility
2.
3.
4.
5.
6.
7.
B. Fabl
1.
S.G. = specific gravity, glcm"3
O.D. = outside diameter, in.
a. The hydrostatic design stress shall be determined by multiplying the
hydrostatic design basis, determined by ASTM D2837 using rotationally
molded samples, with a service factor selected for the application. The
hydrostatic design stress is 600 PSI at 73 degrees Fahrenheit. In accordance
with the formula in 6.1, the tank shall have a stratiform (tapered wall
thickness) wall.
b. The hydrostatic design stress shall be derated for service above 100 degrees
Fahrenheit and for mechanical loading of the tank.
c. The standard design specific gravity shall be 1.5 or 1.9.
The minimum required wall thickness for the cylinder straight shell shall be
sufficient to support its own weight in an upright position without any external
support. Flat areas shall be provided to allow locating large fittings on the
cylinder straight shell.
The top head shall be integrally molded with the cylinder shell. The minimum
thickness of the top head shall be equal to the top of the straight wall. The top
head of tanks with 2000 or more gallons of capacity shall be designed to provide
a minimum of 1300 square inches of flat area for fitting locations.
Tanks with 2000 or more gallons of capacity shall have a minimum of 3 lifting
lugs integrally molded into the top head. The lifting lugs shall be designed to
allow erection of an empty tank.
The tank shall be designed to provide a minimum of 4 tie-down lugs integrally
molded into the top head. The tie-down lugs shall be designed to allow tank
retention in wind and seismic loading situations without tank damage. Refer to
section 2.03.B.2 for tank tie-down accessories.
The finished tank wall shall be free, as commercially practicable, of visual defects
such as foreign inclusions, air bubbles, pinholes, pimples, crazing, cracking and
delaminations that will impair the serviceability of the vessel.
All cut edges where openings are cut into the tanks shall be trimmed smooth.
rication and Material Requirements (Materials of Construction)
The material used shall be virgin polyethylene resin as compounded and certified
by the manufacturer. Type I tanks shall be made from crosslinkable polyethylene
resin as manufactured by Phillips 66, or resin of equal physical and chemical
112S5.Polycthyknc Slorngc TsnLr.dac 11255-4 APRIL 27,2001
City of Carlsbad
MF equipment procurement
Carlsbad Recycling Facility
properties. Type I1 tanks shall be made from linear polyethylene resin as
manufactured by Exxon Chemical, or resin of equal physical and chemical
properties.
2. All polyethylene resin material shall contain a minimum of a U.V. 8 stabilizer as
compounded by the resin manufacturer. Pigments may be added at the supplier's
request, but shall not exceed 0.25% (dry blended) of the total weight.
3. Mechanical Properties of Type I tank material:
PROPERTY
Density (Resin)
Tensile (yield Stress 2"lmin)
Elongation at Break (2"/min)
ESCR (100% Igepal, Cond. A, F50)
ESCR (1 0% Igepal, Cond. A, F50)
Vicat Softening Degrees F. Temperature
Flexural Modulus
ASTM
Dl505
D638
D638
Dl693
Dl525
Dl525
D790
4. Mechanical Properties of Type I1 tank material:
PROPERTY
Density (Resin)
Tensile (Yield Stress 2"/min)
Elongation at Break (2"Imin)
ESCR (100% lgepal, Cond A, F50)
ESCR (10% lgepal, Cond. A, F50)
Vicat Softening Degrees F. Temperature
Flexural Modulus
ASTM
Dl505
D638
D638
Dl693
D 1693
Dl525
D790
C. Tank Manufacturer
1. KEFCO Inc.;
2. Or equal.
2.03 EQUIPMENT AND COMPONENTS
A. Tank Fittings (Nozzles)
1. Threaded Bulkhead
VALUE
2600 PSI
400%
>lo00 hours
>lo00 hours
248
100,000 PSI
0.938-0.944 ~/CC
VALUE
2700 PSI
350%
400-1 000 hours
235
0.940-0.947 ~/CC
200-500 hours
97,000 - 103,000 PSI
a. Threaded bulkhead fittings are allowed for below liquid installation
depending on the tank diameter and the placement of the fitting in the tank.
11255.Polysthylcnc SIOR%C Tsnlu.doc 11255-5 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF equipment procwment
Fittings shall be placed away from tank knuckle radius' and flange lines.
The maximum allowable size for bulkhead fittings placed on a curved
sidewall section of tanks 48 in. to 142 in. in diameter is 2-inch size. Tank
wall thickness shall be considered for bulkhead fitting placement. The
maximum wall thickness for each fitting size is shown below.
Fitting Size Maximum Wall Thickness
!4 in.
1.125 in. (Flat Surface Only) 3 in.
1 in. 2 in.
0.875 in. 1-112 in.
0.875 in. 1-114 in.
0.875 in. 1 in.
0.875 in. 314 in.
0.750 in.
b. The bulkhead fittings shall be constructed of PVC, PP, or other specified
material. Gaskets shall be a minimum of 1/4" thickness and constructed of
40-50 durometer EPDM, 60-70 durometer Viton, or other specified material.
2. Bolted Double 150 lb. Flange Fittings
a. Bolted double flange fittings are required for below liquid level installation
for sizes above 2 in. depending on the tank diameter and the placement of
the fitting in the tank. Fittings shall be placed away from tank knuckle
radius' and flange lines. Allowable fittings sizes based on tank diameter for
curved surfaces are shown below.
Tank Diameter Maximum Bolted Fitting
Size Allowable
48 in. - 86 in. 3 in.
90 in. - 102 in.
120 in. - 142 in.
6 in.
8 in.
b. The bolted double flange fittings shall allow tank wall thickness up to 2 %
inches.
c. The bolted double flange fitting shall be constructed with 2 ea. 150 lb.
flanges, 2 ea. 150 lb. flange gaskets, and the correct number and size of all-
thread bolts for the flange specified by the flange manufacturer.
1) The flanges shall be constructed of PVC Type I, Grade I or other
specified material. Gaskets shall be a minimum of 1/4" thickness and
I1255.Polyethylmc Smmge Tanfo.doe 11255-6 APRIL 27,2001
City of Carlsbad
MF equipment procurement
Carlsbad Recycling Facility
constructed of 40-50 durometer EPDM, 60-70 durometer Viton or
other specified material.
2) There shall be a minimum of 4 ea. full thread bolts. The bolts shall
have bolt heads encapsulated n Type I1 polyethylene material. The
encapsulated bolt shall be designed to prevent metal exposure to the
liquid in the tank and prevent bolt rotation during installation. The
polyethylene encapsulation shall fully cover the bolt head and a
minimum of 1"' of the threads closest to the bolt head. The
polyethylene shall be color coded to distinguish bolt material (white -
316 S.S., yellow - Hastelloy C276, ed - Monel, green - Titanium).
Each encapsulated bolts shall have a gasket to provide a sealing
surface against the inner flange.
d. Standard orientation of bolted double flange fittings shall have bolt holes
straddling the principal centerline of the tank in accordance with
ANWASME B-16.5 unless otherwise specified.
3. Bolted Stainless Steel Fittings
a. Bolted stainless steel fittings may be used for below liquid level installation
depending on the service, tank diameter, and the placement of the fitting in
the tank. Fittings must be placed away from tank knuckle radius and flange
lines. Allowable fittings sizes based on tank diameter for curved surfaces
are shown below.
Tank Diameter Maximum Bolted Fitting
Size Allowable
48 in. 3 in.
64 in. - 142 in. 4 in.
b. The bolted stainless steel fittings shall allow tank wall thickness up to 2 ?4
inches.
c. The bolted stainless steel fittings shall be constructed with a minimum of 4
fully threaded 3/8 in. studs.
1) Each fitting shall have two gaskets and two flanges.
2) One gasket shall be compressed between the inside of the tank wall
surface and the inside flange of the fitting.
3) The other gasket shall be compressed between the outside tank wall
surface and the outside flange of the fitting.
11255-7 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF equipment procurement
4) The stainless steel fittings shall be furnished with female pipe threads
on both the inner and outer flanges.
5) The fittings shall be constructed of Type 316 stainless steel. Gaskets
shall be a minimum of 1/4" thickness and constructed of 40-50
durometer EPDM, 60-70 durometer Viton or other specified material.
4. Siphon Tube Fittings
a. Siphon tubes may be added to the fittings specified in sections 2.03.A.1, 2,
and 3. Siphon tubes will allow these fittings, when used as drainage fittings
to provide better tank drainage.
5. Snyder Unitized Molded Outlet (SUMO)
a. The SUMO fittings shall be an integral part of the tank and provide
complete drainage of liquid through the sidewall of a flat bottom container
without the use of a special support structure or concrete pad. The standard
outlet provided shall be a PVC socket which allows solvent weld PVC pipe
attachments at the tank pad level.
b. The tank attachment shall be constructed from a PVC schedule 80 male
adapter. This shall provide a Schedule 80 pipe socket attachment in sizes up
through 4-inches. O-rings shall be constructed of 70 +/- 5 durometer Viton
or other specified material.
6. All tank fitting attachments shall be equipped with flexible couplers or other
movement provisions provided by the tank customer.
a. The tank will deflect based upon tank loading, chemical temperature,and
storage time duration.
b. Tank piping flexible couplers shall be designed to allow 4% design
movement.
c. Movement shall be considered to occur both outward in tank radius and
downward fitting elevation from the neutral tank fitting placement.
B. Tank Attachments
1. Manway and Fill Cap (Non-sealed)
a. Fill caps shall be 10 in. vented-threaded style on various tank sizes with a
minimum opening diameter of 7.125 in. Cap attachment shall be provided
with all standard 10 in. cap placements with a polyurethane cap tie.
11255-8 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF equipment procurement
b. Manways shall be 24-inches vented threaded style (minimum opening
diameter of 22 in.).
c. All caps and manways shall be constructed of polyethylene material.
2. Bolted Sealed Top Manway
a. Sealed manways shall be 24 -inches size.
b. The sealed manway shall be constructed of polyethylene material. The bolts
shall be Isoplast or stainless steel material. The gaskets shall be closed cell
crosslinked polyethylene foam and Viton materials.
3. Down Pipes and Fill Pipes
a. Down pipes and fill pipes shall be prepared per the customer approved
drawings and specifications. All down pipes and fill pipes shall be
supported at 5 ft. maximum intervals with support structures. Standard
support structure design shall utilize bulkhead fitting tank attachments.
Other optional designs are available. All down pipes and fill pipes shall be
constructed of PVC.
4. U-Vents
a. Each tank must be properly vented for the type of material and flow rates
expected. Vents must comply with OSHA 1910.106 (F) (iii) (2) (IV) (9)
normal venting for atmospheric tanks or other accepted standard, or shall be
as large as the filling or withdrawal connections, whichever is larger but in
no case less than 1 in. nominal inside diameter.
b. All U-vents shall be constructed of PVC.
5. Flange Adapters
a. Flange adapters may be furnished as optional equipment to adapt threaded
or socket fitting outlets to 150 Ib. flange connections for connection to
piping system components. Flange adapters shall be in PVC, CPVC or
other specified materials. Flange adapter construction shall utilize Schedule
80 components in sizes ranging from 3/4" to 8" depending on material
required.
C. Tank Accessories
1. Ladders
a. Ladders shall be constructed of painted mild steel, stainless steel, or FRF'.
112SS.Polyelhylcne Storage 1aanks.dOc 11255-9 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF equipment procurement
b. Safety cages shall be provided with ladders where required by OSHA
standards.
c. All ladders shall be designed to meet applicable OSHA standards.
Reference: OSHA 2206; 1910.27; fixed ladders.
d. Ladders shall be mounted to the tank to allow for tank expansion and
contraction due to temperature and loading changes. All top ladder mounts
shall be connected to integrally molded in attachment lugs that allow for
tank movement.
e. Mild steel parts shall be deburred and painted with a chemical resistant
enamel paint.
2. Tie Down Systems
a. The tie down system shall be designed to withstand 110 MPH wind loads.
Tie down systems must meet seismic Zone 4 requirements per UBC 1997
code.
b. The tie down system shall be constructed of all Type 316 stainless steel
materials, including brackets, cables and fasteners.
3. Cone Bottom Tank Stands
a. Cone Bottom Tank Stands shall be offered in 30 and 45 degree cone styles
with rated gross weight capacities for all cone bottom tanks. The stands
shall be designed for a minimum of 2.4 safety factor accounting for wind
and seismic loads. Ratings shall be based on stands anchored to an
appropriate concrete support structure and the tank adequately secured.
b. Cone bottom tanks stands shall be offered in painted mild steel. Mild steel
parts shall be deburred and painted with a chemical resistant enamel paint in
accordance with Section 09900.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Tanks will be installed by the Installation Contractor as shown on the approved shop
drawings and as recommended by the manufacturer's representative.
B. Marking, Packing and Packaging
1. The tanks shall be marked to identify the product, date (month and year) of
manufacture, capacity, and serial number. The tank shall be shipped with a 3 by 9
I1255.Polyclhylcnc Slomge Tanksdcx 11255-10 APRIL 27,2001
City of Carlsbad
MF equipment procurement
Carlsbad Recycling Facility
HFU bar code label containing tank description, manufacturing order number, part
number, serial number, manufacturer, and date.
2. The proper caution or warning signs as prescribed by OSHA standard 29 CFR
1910.106 shall be supplied.
3. All packing, packaging, and marking provisions of ASTM Practice D3892 shall
apply to this standard.
4. All fittings shall be installed, removed and shipped separately.
3.02 MANUFACTURERS ASSISTANCE
A. Manufacturer's Field Services: The MFEM shall provide the following services in
addition to any other services specified herein, and required by these Specifications.
1. A factory trained field representative, shall be provided for a minimum of one (1)
trip and a minimum of one (1) eight-hour day to provide installation assistance
and field testing services. The field representative may be an employee of the
MFEM. The installation services and field testing services shall be coordinated
with the Installation Contractor.
2. After installation assistance and field testing services by the manufacturer, the
MFEM shall submit to the Engineer, a certification letter on the manufacturer's
letterhead and signed by the manufacturer certifying that the equipment was
installed per the manufacturer's recommendations and requirements and shall
furnish all field test data.
++ END OF SECTION ++
112SS.Polyethylene SrorngcTadu.doc 11255-1 1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility m EQUIPMENT PROCUREMENT
SECTION 1130b
MEMBRANE FILTRATION (MF) SYSTEM, GENERAL
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. This Section specifies the requirements for the design, fabrication, shipment,
installation, startup, performance testing and demonstration testing of a hollow
fiber membrane filtration system. It describes the work to be perfonned by both
the membrane filtration equipment manufacturer (MFEM) and the follow on
Installation Contractor.
2. The MF system will treat a secondary treated, undisinfected municipal wastewater
effluent that has received conventional primary and secondary treatment at the
Encina Water Pollution Control Facility.
3. The MF system shall consist of inlet pumping, pretreatment chemical addition,
particulate straining, a 0.85 mgd (filtrate capacity) membrane system complete
with skid mounted hollow fiber membrane units, the membrane cleaning system,
the membrane backwashheverse filtration system, compressed air system, excess
feed recirculation system (if required), interconnecting piping, valves, controls
and instrumentation.
4. Goods provided under this procurement contract shall include, but not be limited
to, the following equipment:
a. Hollow fiber membrane filtration units (Units).
b. Backwash equipment.
c. Membrane clean-in-place (CP) equipment.
d. Compressed air andor air blower equipment.
e. Pumps and motors.
f. Membrane integrity test system.
g. Valves.
I I3W.MEMBRANEFILTRATION (MF) SYSTEM, CENERAL.DOC 1 1300-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
h. Actuators.
i. Electrical process control equipment.
j. Programmable logic controllers (PLCs).
k. Instrumentation components.
1. Chemical feed equipment.
m. Variable frequency drives.
n. All required fasteners, anchor bolts, and miscellaneous appurtenances for
the equipment provided.
5. Special services shall be provided as part of the procurement contract for project
related activities including: equipment and drawing submittals, technical and
engineering services, bills of materials, O&M manuals, installation,
commissioning and acceptance testing field services and operator training
necessary for the installation of the System as described within these Procurement
Documents.
B. Reference Specifications: The MF system is further specified in the following
individual system specification sections and other sections as referenced herein:
Section Item@) 11305, Memcor CMF System
Core MF system equipment 11 306, Memcor CMFS System
Core MF system equipment
items
items
items
items
11307, Pall System
Core MF system equipment 11308, Zenon System
Core MF system equipment
C. Coordination:
1. The design of a proprietary membrane filtration system requires considerable
coordination between the District, Engineer and MFEM. The MFEM shall
provide assistance to the Engineer and District and provide the information
needed to coordinate the design of the membrane filtration system and the
ancillary equipment designed by the Engineer but not provided by the MFEM.
2. The MFEM shall provide all parts, equipment, materials, and components
including instrumen'tation and controls. Equipment will be installed and
113W.MEMBRANE FILTRATION(MF) SYSTEM. GENERAL.DOC 11300-2 APRIL. 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
interconnections made by an Installation Contractor under a separate installation
contract.
3. The Installation Contractor shall be responsible for installation of equipment
furnished under this contract and for provision of interconnecting piping and
electrical power supply and connections.
4. The MFEM shall coordinate the installation of the System by the Installation
Contractor and provide written and verbal instruction to ensure proper
installation. The MFEM shall review installation of equipment prior to
commissioning of equipment.
D. Special Considerations
1. Scope
a. The Drawings and Specifications identify major components of the System
and establish minimum performance and quality standards for these
components. It is the responsibility of the MFEM to provide all parts,
equipment, materials, and components required for a complete and
functional System.
b. Because of variations in design, operational and facility requirements for the
various proprietary membrane systems offered by the various prospective
MFEMs, the documents may establish or present design criteria or
philosophy that may not apply to all manufacturers. In the event that the
MFEM is unsure if a design concept applies, the MFEM shall submit to the
Engineer in writing a request for clarification. All requests for clarification
shall be submitted to the Engineer prior to the receipt of the bids.
c. The MFEM shall furnish all components identified on the process Drawings
and as specified herein. If an item is shown to be furnished by either the
Drawings or Specifications, it shall be furnished whether or not shown on
both.
2. Alternatives
a. This specification was developed for proprietary membrane systems offered
by US-Filter (Memcor CMF and CMFS) system, Pall, and Zenon
(ZeeWeed). Pursuant to Article 1.02-A herein, alternative MFEM’s will not
be considered.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
I13W.MEMBRANE FILTRATION IMF) SYSTEM, GENERAL.WC 1 1300-3 APRIL. 27,2001
city of Carlsbad
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MF EQUIPMENT PROCUREMENT
A. Manufacturers’ Qualifications: Major components of the MF system shall be furnished
by a single pre-qualified MFEM. The MFEM shall be responsible for the design,
procurement, fabrication, and proper operation of the MF system.
1. Qualified MFEM’s: Through testing and use in equivalent applications to the
proposed reclamation system, the following MFEM’s have demonstrated
competent performance in treating a reclaimed water supply and are accepted by
the District to submit bids on this project:
a. Memcor Division of U.S. Filter Corporation (Memcor)
b. Pall Corporation (pall)
c. Zenon Environmental Systems, Inc. (Zenon)
2. Selection: The successful MFEM will be selected as set forth in the bidding
documents according to a lowest total cost evaluation incorporating both capital
and operating cost factors. Bids from an MFEM not listed above will not be
considered.
B. Reference Standards: Where reference is made to one of the following standards, the
revision in effect at the time of bid opening shall apply.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Standards of American Water Works Association, AWWA.
Standards of the National Electrical Manufacturers Association, NEMA.
Standards of American Society for Testing and Materials, ASTM.
Standards of American National Standards Institute, ANSI.
Standards of the American Society of Mechanical Engineers, ASME.
Standards of the U.S. Department of Defense, MIL
Standards of the American Welding Society, AWS.
Standards of the Manufacturers Standardization Society of the Valve and Fittings
Industry, MSS.
National Sanitation Foundation, NSF.
C. Manufacturers Quality Assurance / Quality Control Program
II3W.MEMBRANE FILTRATION (MR SYSTEM, GENERALDOC 1 1300-4 APRIL 27,2001
City of Carlsbad
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MF EQUIPMENT PROCUREMENT
D.
1.03
A.
1. MFEM Project Engineer Qualifications: The MFEM shall assign a project
engineer for the requirements of the project. The project engineer shall be a
single source of contact between the MFEM and the Engineer.
2. The Engineer and District may elect to visit the MFEM’s facility to witness
fabrication, assembly, or testing of the equipment and systems specified herein.
If so elected, the visits will be at District or Engineer’s expense.
Manufacturers Field Services: Field services associated with the MF system and
associated equipment items shall be provided in accordance with applicable provisions
of Division 1 specifications, Sections 01620 through 01731 inclusive.
SUBMITTALS
Shop Drawings
1. Coordination Meetings
a. Within seven days after execution of the Procurement Agreement, the
MFEM shall meet with the Engineer at the Engineer’s location to address
any issues related to the project.
b. Refer to Section 13320 - Instrumentation and Control System, General.
2. Drawings and Samples
a. The MFEM shall coordinate production and submit the following submittal
packages for approval by the Engineer, including calculations for equipment
anchorage and supports as required herein. All drawings shall be produced
electronically in AutoCAD v.14 format. Hardcopy submittals shall be
plotted on white bond with l/S-inch (minimum) black lettering, D-size (22
inches by 34 inches) sheets unless otherwise noted or approved by the
District.
b. The MFEM shall submit for review and approval in accordance with the
Shop Drawing Procedures (Section 01340) the following ‘First Shop
Drawing Submittals’:
1) Plan and elevation arrangement drawings of the units giving physical
dimension and weights of the units.
2) A bill of material for all tagged devices and components supplied with
the Unit including component original part numbers identifying each
furnished component.
11300.MEMBRANEFILTRATlON (MF) SYSTEM.GENERAL.DC€ 11300-5 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
3) Setting drawings, templates, and directions for the installation of
anchor bolts and other anchorages for the units.
4) Electrical schematic diagrams including motor horsepower and other
electrical load information and identification of external wiring
connections.
5) P&ID’s of the System, including hydraulic and pneumatic schematics
detailing the equipment supplied by the MFEM and showing
equipment provided by others that will interface with the System.
6) Manufacturer’s literature, illustrations, specifications, weights, pump
curves, and engineering data for component equipment of standard
design including pumps, variable frequency drives, strainers,
compressed air equipment, air blower equipment, valves/actuators,
instrumentation, flow meters, analyzers, including dimensions,
materials, sizes, and performance data.
7) Compatible AutoCAD drawings of the Unit in electronic format.
c. The MFEM shall submit for review and approval in accordance with the
Shop Drawing Procedures (Section 01340) the following ‘Second Shop
Drawing Submittals’:
Manufacturer’s literature, illustrations, specifications, weights, pump
curves, and engineering data for project engineered equipment
including dimensions, materials, sizes, and performance data.
Panel construction drawings, panel wiring diagrams, and loop
diagrams as specified in Division 13.
Operator interface stations and supervisory control and data
acquisition (SCADA) system submittals as identified in Division 13.
A bill of material for all tagged devices and components supplied with
the System including component original part numbers identifying
each furnished component and corresponding to the number provided
on the arrangement drawings to facilitate work by the Installation
Contractor.
General arrangement drawings of the CIP equipment and
interconnecting pipe work, valves, supports, and appurtenances for
the membrane system. Detail drawings (sections and views) in the
most recent version of AutoCAD for System interconnecting piping
11300.MEMBRANE FILTRATION (MF) SYSTEM, GMERAL.DOC 1 1300-6 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
6) All other submittals and/or shop drawings as required under the
Procurement Documents.
7) Certificates of compliance with referenced standards as required.
B. Factory Test Reports
1. Submit prior to delivery of the membrane modules the following:
a. The MFEM shall identify each membrane module by a unique serial
number.
b. The MFEM shall provide a membrane specification sheet listing the
membrane module’s normalized specific flux (gpdpsi @ 20 degrees C),
nominal pore size, and the nominal inside and outside surface area of the
filter module.
c. Certification of wet testing for each membrane module conducted at the
MFEM’S facilities. The MFEM shall identify membrane module serial
number. The MFEM shall certify that each membrane module has passed
the quality assurancelquality control tests for membrane element integrity.
Acceptable quality assurance and quality control tests include bubble point
or pressure hold tests above the minimum value recommended by the
MFEM and approved by the Engineer.
C . Installation Instructions
1. Submit installation instructions in accordance with the requirements of Section
01620.
D. Operation and Maintenance Materials
1. Submit operation, and maintenance manuals supplied by manufacturers of
individual system components, including copies of all approved Shop Drawings,
test reports, maintenance data and schedules, description of operation, and spare
parts information.
2. Furnish Operation and Maintenance manuals for the membrane filtration system
in accordance with the requirements of Section 01730.
3. Provide Material Safety Data Sheets (MSDSs) for all applicable items (chemicals,
oils, lubricants, etc) hished by the MFEM.
4. Lubricant Specification: Furnish lubricants of the type and grade necessary to
meet the requirements of the equipment.
I I3W.MEMBRANE FILTRATION (MF) SYSTEM, GENERAL.DOC 1 1300-7 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
E. Record Drawings
1. Upon completion of system performance and demonstration testing, the MFEM
shall revise and submit to the District Operational and Maintenance Manuals
using As-Constructed information for the equipment provided by the MFEM.
F. Certificates, Warranties and Guarantees
1, Refer to Section 01740 Membrane System and Module Warranty.
G. Regulatory Agencies: The MFEM shall supply hydraulic calculations, certifications and
drawings for tbe System and any other system performance data required by regulatory
agencies.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Feed Water Quality Data: The water quality data, as feed water to the membrane
system for the project is summarized in the table below. In submitting a bid, the
MFEM certifies that its System is capable of treating the feed water as described
in the table so as to meet all design requirements, performance requirements, and
filtered water quality objectives as specified in these Procurement Documents.
Design Feed Water Quality
Value
~
Water Quality Parameters Minimum Marimum Average
Total Organic Carbon, mg/L
Chlorine Demand, mg/L
8 12 10
- " 0 Chloramine, m&
2 10 5 Turbidity, NTU
8 15 12
I Free Chlorine, mgL I0I"I"I
pH, units
220 250 238 Alkalinity, mg/L as CaC03
340 3 80 360 Hardness, mgiL as CaCO,
1.3 1.1 1.5
Temperature, "C 20 21 22 I
II3W.MEMBRANE FILTRATION (MF) SYSTEM, GENERAL.DOC 1 1300-8 APRIL. 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
Water Quality Parameters
Total Suspended Solids, mg/L
B. Process Design Requirements
1. Membrane Flux: Design flux for each system has been determined by the
Engineer and is set forth in the system configuration requirements specified in the
individual system specifications, Sections 11305, 11306, 11307, and 11308.
2. Design Elevations: Applicable design elevations for the System shall be as
follows:
Location Elevation (M.S.L)
Wetwell Water Elevation (working range)
Bottom of Wetwell
14.0 -19.0 feet
Top of Wetwell
3.0 feet
21.5 feet
Membrane Process Area Floor Level 64.0 feet
Filtrate Storage Tank Water Elevation (maximum) 82.0 feet
MF Waste Sump Water Elevation (maximum) 62.0 feet
3. Facility Capacity and Design Temperature:
a. The System facility design capacity (Le., net filtered water) shall be as
follows (at the specified reference temperature):
1) Design Capacity (Net Filtered Water) 0.85 mgd
2) Design Temperature 20 "C
b. Excess Capacity / Redundancy: None.
c. Expandability: System components shall be selected and arranged to permit
phased expansion of the system to a net filtered water capacity of 3.40 mgd
through interconnection to existing equipment and facilities and the addition
of new equipment and facilities.
I lJW.MEMBRANE FILTRATION (MF) SYSTEM. GENERAL.DC€ 1 1300-9 APRIL 27,2001
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MF EQUPMENT PROCUREMENT
d. Recovery: The design values for minimum and maximum recovery shall be
not less than 88 percent. The system shall operate above the MFEM’s
design recovery at all times during operation. Design recovery values shall
be calculated as follows:
[Net filtered water (mgd)/feed (mgd)] x 100 percent
Where the quantity: net filtered water (mgd) is equal to the total amount of
filtered water produced (mgd) less any amount used for backwashing,
chemical cleaning, chemical washing and rinsing of the membrane filters
(mgd).
e. Minimum Run Time between Chemical Cleaning: The design minimum
duration of continuous operation between manufacturer prescribed chemical
cleanings is 21 days at the specified operating flow and temperature.
4. Filtered Water Quality Requirements: Filtered water quality shall meet the
following water quality requirements:
Turbidity
Maximum filtered water turbidity (ntu) 0.15
Maximum filtered water turbidity 95% of time (ntu) 0.10
Silt Densitv Index (SDI)
Maximum filtered water SDI 2.00
Maximum filtered water SDI 95% of time 1.50
5. The MFEM shall submit the non-destructive integrity test parameters (bubble
point, diffisive flow, or pressure hold criteria) used for quality control of the
membrane modules.
2.02 EQUIPMENT AND COMPONENTS
A. MF System Components
1. Drawings PI-3[A-D] through PI-11[A-Dl are the piping and instrumentation
diagrams (P&IDs) for the main MF treatment system, while Drawing PI-12 shows
the associated sodium hypochlorite ancillary feed facilities. Drawings PI-1 and
PI-2 are legend sheets which describe the symbols and abbreviations used on the
P&IDs.
2. The P&IDs are arranged by system according to the following designations:
a. A - Memcor CMF System
II3W.MEMBRANEFILTRATlON (MF) SYSTEM, GENERAL.WC 11 300-1 0
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Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b.
C.
d.
3. Ova
a.
b.
C.
d.
e.
B -Pall System
C - Zenon System
D - Memcor CMFS System
rview:
Drawing PI-3[A-D] of the P&IDs shows the plant feedwater line from the
feed wetwell entering the membrane filtration system. The feedwater will
be delivered to the feed wetwell by gravity. Vertical turbine feed pumps
will be used to transfer feed to the MF units.
Sodium hypochlorite will be added to the secondary effluent feedwater as
shown on Drawing PI-4[A-D]. The sodium hypochlorite combines with a
large excess of ammonia in the secondary effluent feed to provide a
combined chlorine residual of 3 to 6 mg/L through the membrane filtration
system. The sodium hypochlorite addition rate shall be based on influent
flow with a small bias based on residual measured at the point of injection.
The chlorinated feed stream shall undergo inlet screening in two automatic
backwashing basket strainers (1 operating, 1 standby) rated at 500 microns.
Strainer backwash flow shall be collected and routed to waste, while
pretreated feed shall continue to the MF units.
Drawing PI-6[A-D] shows pretreated feedwater entering the feed manifold
to the MF units. Depending on the system requirements of the MFEM, the
units shall be operated in either a direct flow or cross flow mode and in a
vacuum or pressure driven configuration. The main MF system equipment
shall be arranged in a compact train or skid mounted system, consisting of
the MF membrane units, compressed air system, backwash system, and
cleaning system. On skid pneumatically operated valves shall automatically
regulate flow through the MF units during cycles of filtrate production,
backwash, and cleaning on signals from the individual skid mounted PLC
and/or system supervisory PLC.
Filtrate from the MF units shall be collected in a common pipeline and
routed to the filtrate storage tank, as shown on Drawing PI-8[A-Dl. A
second sodium hypochlorite injection point shall be provided ahead of the
filtrate tank to allow periodic chlorination of RO feedwater. An additional
chlorine injection point shall be provided for the Pall and Zenon systems to
allow chlorination of reverse filtrate or backpulse water. Waste flows
generated from periodic unit backwash cycles shall be routed to waste.
Drawings PI-lO[A-Dl and PI-ll[A-Dl show the MF clean-in-place (CIP)
system. Chemical dosing systems shall be provided to allow makeup of
II3W.MEMBRANE FILTRATION (MF) SYSTEM, GENERAL.WC 1 1300-1 1
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
cleaning solutions, composed of sodium hydroxide, sodium hypochlorite,
liquid surfactant, and citric acid (depending on the individual system
requirements). The solutions shall be made up using RO permeate routed to
the tank from the RO permeate header. Prepared solutions shall be routed to
the membrane units in place through permanent piping systems.
f. The main sodium hypochlorite feed system is shown on Drawing PI-12.
Sodium hypochlorite will be stored in a new bulk storage tank located near
the point of injection on the feed line. Injection pumps will be used to
deliver sodium hypochlorite to points on the feed and filtrate pipelines.
Additional injection facilities shall be provided for the Pall and Zenon
systems for chlorination of reverse filtrate water and CJP tank dosing, as
required.
g. The MF system shall be controlled by a programmable logic controller
(PLC) which will monitor system process variables and provide the control
functionality indicated on the P&IDs and specified herein. The PLC shall
be located in a central MF system control panel (PLC-MF) located outdoors
in the MF process area. Operator control of the system shall be executed on
a graphical software interface running on a dedicated MF system computer
workstation (OIT-MF) located in the control room. The PLC shall also be
capable of communicating MF system status indicators and alarms to the
plant central control system and receiving control signals from the plant
central control system.
4. All of the equipment discussed above and shown on the P&IDs as well as the MF
system control phlosophy and control system configuration are described in
detail in this section. This detailed information does not relieve the MFEM of his
responsibility to provide a well designed and fully operable MF system as
described in this specification.
5. Equipment Numbers
a. By definition, component equipment numbers referenced herein and listed
in parentheses include numbered items up through and including the number
(e.g., P-0901-(2) represents equipment numbers P-0901-1 and P-0901-2).
B. MF Feed Pump Station
1. The MF feed pump station will provide pressurized feed to the automatic strainers
and downstream MF units.
2. Requirements for the MF feed pumps, equipment numbers P-0901-(2), are
included in Section 11213.
11300,MEMBRANE FILTRATION (MF) SYSTEM. GMERAL.DOC 1 1300-12
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C. Automatic Strainers
1. The automatic strainers will be used to provide pre-filtration ahead of the MF
units.
2. Requirements for the automatic strainers, equipment numbers M-0906-(2), are
included in Section 11340.
D. Chemical Addition Systems
1. Chemical addition systems shall be provided to inject sodium hypochlorite into
the MF feed, filtrate, and reverse flush (as required) process lines; and batch
sodium hypochlorite, citric acid, and manufacturer supplied surfactant (Memclean
EM) solutions (as required) to the MF cleaning tank.
2. The sodium hypochlorite addition system shall include a new bulk storage tank,
chemical metering pumps and accessories, in-line mixers, interconnecting piping,
valves, instrumentation and controls.
a. The sodium hypochlorite bulk storage tank along with related
instrumentation and accessories will be furnished by the Installation
Contractor.
b. Chemical metering pumps with accessories, equipment numbers MP-0982-
(2), as well as system interconnecting piping, valves, and instrumentation
will be furnished by the Installation Contractor.
c. Chemical metering pumps with accessories, equipment number MP-0983-
(2) are part of the reverse filtration system for the Pall MF system. See
Sections 11240 and 11244 for requirements.
d. Chemical metering pumps with accessories, equipment numbers MP-0939-
(3), are part of the membrane cleaning system for the Pall and Zenon MF
systems. See Sections 11240 and 11244 for requirements.
e. Sodium hypochlorite mixer, equipment number "0903, will be furnished
by the Installation Contractor.
3. The citric acid dose system shall include a mixing tank, mixer, chemical metering
pump and accessories, interconnecting piping, valves, instrumentation and
controls.
a. Citric acid mix tank with accessories, equipment number T-0940, is
specified in Section 11250.
li3W.MEMBRANE~LTRATlON(M~SYSTEM,GENERAL.DOC 11300-13
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Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
b. Citric acid tank mixer, equipment number “0940-1, is specified in Section
11245.
c. Chemical metering pumps with accessories, equipment numbers MP-0940-
(2), are specified in Sections 11240 and 11245.
4. The liquid surfactant chemical dosing system is part of the membrane cleaning
system required for the Memcor MF system. See Sections 11240 and 11246 for
requirements.
E. Membrane Filtration Units
1. The membrane treatment system shall be divided into ‘identical’ Units. ‘Identical’
consists of functionally independent (independent electrical and hydraulic
control), and of the same hydraulic capacity. Differences in what appears to be
unit symmetry (hand) are acceptable.
2. Units shall be configured for continuous operation and may utilize dead end,
crossflow, recirculation, and ‘feed and bleed’ hydraulic configurations.
3. Units may be designed to use pressure or partial vacuum as a method to transport
water across the membrane surface.
4. Units shall incorporate a Membrane Integrity Test System to verify the integrity
of membrane modules.
a. The membrane integrity test system shall use air pressure to verify the
integrity of the membranes.
b. The applied test pressure of the membrane integrity test system shall be
established so that passage of particles greater than 1.0 microns or larger can
be detected.
c. The non-pressurized side of the membrane unit shall be vented to
atmospheric pressure.
d. The MFEM shall provide documentation of methodology used to establish
the integrity test pressure.
e. The integrity test system shall be manually or automatically initiated and
automatically sequenced by the PLC system.
f. The integrity test system shall verify the integrity of the hollow fiber and
upon successful completion of the integrity verification, return the Unit to
service.
11300.MEMBRANE FILTRATION (MF) SYSTEM, GENERAL.WC 11 300-14
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MF EQUIPMENT PROCUREMENT
g. If the integrity test does not pass the integrity verification, the Unit shall be
removed from service and an alarm shall be annunciated from the Unit PLC
to the System PLC.
5. Unit support frames shall be designed to resist gravity and seismic forces of the
pressure vessels, piping and other related equipment supported by the frame. The
frame shall be designed in conformance with the latest edition of the Uniform
Building Code (UBC) Seismic Zone 4 design criteria and signed by a Registered
Professional Engineer currently licensed in the State of California.
6. Detailed requirements for the MF units are unique to each manufacturer and are
included in the Detailed System specifications:
a. Refer to Section 11305, Memcor CMF System
b. Refer to Section 11306, Memcor CMFS System
c. Refer to Section 11307, Pall System
d. Refer to Section 11308, Zenon System
F. Compressed Air System
1. System Components
a. Requirements for components of the MF compressed air system are unique
to each manufacturer and are included in the Detailed System specifications:
1) Refer to Section 11305, Memcor CMF System
2) Refer to Section 11306, Memcor CMFS System
3) Refer to Section 11307, Pall System
4) Refer to Section 11308, Zenon System
2. Pneumatic Systems
a. Pneumatic solenoid valves shall have a pilot indicator and a manual
override.
b. Pneumatic lines shall be of copper or stainless steel construction.
c. Compressed air that is in contact with filtered water shall pass through a
hydrophobic membrane filter with a retention efficiency of 0.02 microns or
less.
I13W.MEMBRANEFlLTRATlON(M~SYSTEM,GENERAL.DOC 11300-15
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d. Plastic valves and other appurtenances are not permitted on compressed air
lines.
e. A regulator shall control the pressure of the compressed air supply. An
isolation ball valve shall be located at each Unit. A separate compressed air
pressure regulator shall be used for the membrane test pressure at each unit.
f. The MFEM shall install flow controls as required to regulate valve actuation
in order to prevent hydraulic shock.
G. Membrane Cleaning System
1. Requirements for the MF membrane cleaning system are unique to each
manufacturer and are included in the Detailed System specifications:
a. Refer to Section
b. Refer to Section
c. Refer to Section
d. Refer to Section
1305, Memcor CMF System
1306, Memcor CMFS System
1307, Pall System
1308, Zenon System
H. Membrane Cyclic Regeneration Systems
1. Requirements for cyclic regeneration systems associated with the MF system are
unique to each manufacturer and are included in the Detailed System
specifications:
a. Refer to Section 11305, Memcor CMF System
b. Refer to Section 11306, Memcor CMFS System
c. Refer to Section 11307, Pall System
d. Refer to Section 11308, Zenon System
I. Excess Feed Recirculation System
1. Requirements for the excess feed recirculation system (if required) associated
with the MF membrane system are unique to each manufacturer and are included
in the Detailed System specifications:
a. Refer to Section 11305, Memcor CMF System
b. Refer to Section 11306, Memcor CMFS System
II300.MEMBRANEFILTRAnON(MF)SYS~M,GENUIAL.DOC 11300-16
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C. Refer to Section 11307, Pall System
d. Refer to Section 11308, Zenon System
J. MF Filtrate Storage Tank
1. The MF Filtrate storage tank is used to provide intermediate storage and
equalization of flow between the MF and RO systems.
2. The filtrate storage tank, equipment number T-0919, including related instruments
and accessories will be furnished by the Installation Contractor.
2.03 INTERCONNECTING PIPING AND VALVES
A. Scope
1. The MFEM shall provide all piping and valves on the MF units, as well as
specified automatic and manual valves for other portions of the system. See
requirements in the individual system specifications, Section 11305, 11306,
11307 and 11308. All pipe and valves shall be provided in accordance with
applicable sections under Division 15. The Installation Contractor will fiunish all
interconnecting piping between system components as well as remaining system
valves not furnished by the MFEM.
B. General Requirements
1. The MFEM shall use piping materials that are suitable for the intended service.
"L" (Low carbon) grade stainless steel is required for welded pipe and fittings.
2. A maximum fluid velocity of 8 feet per second shall be used for the design of all
pressure piping systems, unless otherwise allowed by the Engineer.
3. Unit piping shall be arranged in order to assure that a straight run of pipe is used
for the flow meters in compliance with the Division 13 Specifications. The flow
from each Unit shall be measured directly or through addition or subtraction of
two or more flow meters.
4. 2-1/2", 3-1/2" and 5" pipe sizes are not permitted.
2.04 INSTRUMENTATION AND CONTROLS
A. General
1. The MF system will be controlled by a PLC based control system. The system
shall consist of a master PLC housed in panel PLC-MF, with additional slave
PLCs mounted in the MF unit electrical control panels (CP-0912-(2)). An
II~~~.MEMBRANEF~LTRAT~ON(MF~SYSTEM.GENERAL.DOC 11300-17
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MF EQUIPMENT PROCUREMENT
operator graphical interface (OIT-MF) shall be provided to communicate with the
system.
2. The unit mounted panel and PLC-MF will be located in the MF process area. The
MF System Workstation will be located in the Control Room.
3. The MF control system will be required to communicate with the plant
supervisory control system for monitoring and control.
B. Scope
1. The MFEM shall provide PLC-MF, the master PLC, individual unit PLCs and
control panels, and other local control panels not provided by equipment vendors.
The MFEM shall also provide the MF System Workstation (OIT-h4F) specifically
configured to operate the system. See the Detailed System specifications Section
11305,11306, 11307 and 11308 for requirements.
2. The Installation Contractor will furnish all hardware and software associated with
the plant supervisory control system. The Installation Contractor will also be
responsible for all software programming associated with the plant overall
supervisory control system.
3. The Installation Contractor will be responsible for installation of all control
system hardware. In addition, the Installation Contractor will provide all
interconnecting field wiring. This includes internal data link wiring for the MF
system and between PLC-MF and the supervisory control system interface; plant
wide data highway cable; all instrumentation and control system power and signal
wiring; and all other connections shown on the Drawings or otherwise required to
provide a complete and functional system.
4. The Installation Contractor will be responsible for all field instrumentation not
provided by the MFEM. For identification of instruments to be provided by the
MFEM, see the instrument lists provided as an attachment to Sections 11305,
11306, 11307,and 11308.
C. Requirements
1. For PLC and OIT functional requirements specific to each system, see Section
13350 and the Detailed System specification Sections 11305, 11306, 11307, and
11308, as applicable.
2. For general control system and requirements, see Section 13320.
3. For control panel and accessory device requirements, see Section 13325
4. For process instrumentation, see Section 13330.
I lJW.MEMBRANE FlLTRATlON (MF) SYSTEM, GENERAL.DC€ 1 1300-1 8
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5. For PLC requirements, see Section 13335.
6. For OIT requirements, see Section 13340.
7. All wiring shall be installed in accordance with the applicable requirements of
Division 16.
2.05 MISCELLANEOUS COMPONENTS
A. Anchor Bolts:
1. Anchor bolts shall be Type 316 stainless steel and at least 1/2-inch in diameter.
See Section 05503 for requirements.
B. Lifting Lugs
1. All equipment items or component assemblies weighing in excess of 100 pounds
shall be furnished with lifting lugs.
C. Identification Tags
1. All equipment items, instrumentation, and valves shall be furnished with a
securely mounted or attached Type 316 stainless steel plate bearing its assigned
identification number as referenced on the Drawings and/or listed in the
specifications.
2. Plates shall be 16-gauge minimum. Identification numbers shall be die stamped
with 1/4-inch minimum characters.
D. Miscellaneous Fasteners
1. Bolts, nuts, washers, flange backing rings, and other miscellaneous metal
components not specifically addressed elsewhere in these specifications shall be
Type 316 stainless steel.
2.06 SPARE PARTS AND SPECIAL TOOLS
A. Spare parts and special tools associated with the MF system shall be provided in
accordance with Section 01750 and specific requirements included in the Detailed
System specifications Sections 11305, 11306 11307, and 11308, as applicable.
2.07 SHOP PAINTING
A. Refer to Section 09900 - Painting.
2.08 LUBRICANTS
11300.MEMBRANE FILTRATION (MF) SYSTEM, GENERAL.DOC 1 1300-1 9
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MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
A. The MFEM shall provide all lubricants needed for equipment startup and initial
operations.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Refer to Section 01620, Installation of Membrane Equipment.
3.02 COMISSIONING
A. Refer to Section 01660, Commissioning of Membrane Equipment.
3.03 ACCEPTANCE TESTING
A. Refer to Section 01670, Acceptance Testing of Membrane Equipment.
3.04 OPERATIONAL. ASSISTANCE
A. Refer to Section 01680, Operations Assistance During Correction Period.
+ + END OF SECTION + +
11300.MEMBRANE FILTRATION (MF) SYSTEM, GENERAL.DC€ 11 300-20
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 11305
MEMCOR CMF SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. This Detailed Specification Section covers the continuous membrane filtration
(CMF) treatment system equipment as supplied by US. FilterMemcor.
2. The CMF system shall consist of two (2) 66M10C continuous microfiltration
(CMF) units, compressed air system, membrane cleaning (CIP) system, backwash
collection system, piping, valves, controls and instrumentation.
B. Coordination
1. The MFEM shall furnish the majority of equipment items associated with the
CMF system and shall participate in the commissioning, startup, testing, and
training of District’s personnel in operation of the CMF system as a whole.
2. The Installation Contractor will unpack, assemble, and install equipment items
furnished by the MFEM as shown on the Drawings and as specified herein. In
addition, the Installation Contractor will also furnish and install additional
equipment items, interconnecting piping, valves, instruments, power and control
wiring, and other appurtenances not furnished by the MFEM.
3. The Installation Contractor in association with the MFEM will be responsible for
acceptance testing of individual items of equipment as defined in the individual
equipment specifications. The Installation Contractor will also participate in the
startup ofthe CMF system as described in Section 01670.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. See Section 11300 for requirements.
B. Process Design Requirements
1. See Section 11300 for requirements.
11305,MEMCOR CMF SYSV3.wC 11305-1 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
2.02 EQUPMENT DESIGN AND FABRICATION
A. General
1. The following subsystems and components are included in the MF membrane
system:
a. Two 66M10C CMF units, equipment numbers M-0912-(2) consisting of the
following:
1) 66 MlOC microfiltration modules;
2). Module support frame;
3) Skid mounted piping, valves, and instrumentation;
4) Electrical control panel (equipment numbers CP-0912-(2)); and
pneumatic control panel (equipment numbers CP-0911-4-(2)).
b. All required components for installation, including but not necessarily
limited to, appropriate anchor bolts, skid-mounted piping supports,
hardware, surface preparation, and shop painting.
B. Membrane System Requirements
1.
2.
3.
4.
5.
6.
7.
The CMF units shall be a product of the Memcor Division of U.S. Filter
Corporation.
All CMF units provided shall be Memcor 66M10C units in a right or left hand
configuration; final configuration to be selected by the Engineer within 15 days of
the Notice to Proceed.
Each unit shall consist of 66 hollow fiber membrane modules. Each module shall
contain a sufficient number of fibers to provide a nominal surface area of 15
square meters based on the internal fiber diameter.
The hollow fiber membrane modules shall be polypropylene with 'a 0.2 micron
nominal pore size.
The membrane modules and supporting pipe work shall be designed for a direct
flow configuration.
The units shall incorporate an aidwater backwash system to maintain filter flow
performance.
Equipment furnished under this section shall be fabricated in full confonnity with
the drawings, specifications, engineering data, instructions, and recommendations
of the MFEM except as modified herein.
II305.MEMCORCMFSYSTEM.DOC 11305-2 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
C. support Structure
1. All pressure vessels, piping, valves, instrumentation, control panels, and other
appurtenances which make up a single CMF unit shall be supported on a single
structural frame. The frame shall be of fabricated carbon steel construction and
shall have a surface finish comprising a zinc primer, an epoxy coating and final
coat of urethane.
2. The support frame shall be designed to resist the gravitational and seismic forces
of the pressure vessels, piping, and other related equipment supported from the
structure. The frame shall be designed to be in conformance with the latest
edition of the Uniform Building Code for Seismic Zone 4, with a seismic
importance factor of 1.0. The MFEM shall submit calculations documenting
compliance with these requirements.
D. MF Module Assemblies
1. The membrane modules shall be designed for direct flow operation, with feed and
filtrate entering through the module end caps.
2. The modules shall be Memcor MlOC modules enclosing approximately 20,000
individual hollow membrane fibers. Each fiber shall have a nominal outside
diameter of 550 pm and inside diameter of 250 bm. Module housings shall be
constructed of high-grade nylon.
3. The membrane modules shall be supported by a steel framework in a vertical
orientation. The modules shall be connected to each other and to their manifolds
with stainless steel tie rods. Each module shall be sealed with food grade EPDM
O-rings.
4. Sixty-six (66) modules shall be incorporated in each unit. The modules shall be
connected in manifolded blocks and supported by the CMF unit framework. Each
block, once fully piped and assembled, shall be tested at the MFEM's facility.
This testing shall incorporate a pressure decay test function to verify the integrity
of the membrane fibers installed in each module. The MFEM shall furnish a
certificate certifying the integrity of each 66 module block for each unit furnished
prior to shipment. The District reserves the right to have a representative present
to witness the testing.
E. Compressed Air Backwash
1. The CMF units shall utilize a compressed air backwash to remove accumulated
particulate and maintain the design filtrate production rate. Compressed air at 90
psig shall be introduced into the filtrate side of the system and released through
the walls of the hollow fibers. Dislodged solids shall be flushed from the
membrane surface using feedwater at a flow rate between 15 and 20 gpm per
module.
I lJOJ.MEMCOR CMF SYSTFJ4.LK.C 11305-3 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
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2. The backwash cycle shall be initiated through the PLC control system at fixed
time intervals. The design backwash frequency shall be 20 minutes. The
backwashing process shall be camed out automatically through the PLC.
3. The compressed air system supplying compressed air for air backwashing and for
pneumatic actuated valves on the CMF unit shall be provided by the MFEM. See
Article 2.03-B, Compressed Air System.
4. The compressed air system components within the CMF units shall include the
following:
a. A control air manifold which supplies compressed air to a pilot regulator
and solenoid valves for control of automatic process valves;
b. A stainless steel pipework connection with a pressure regulator to supply
process air to the modules.
5. Pneumatic tubing to on-skid valves shall be Type 316 stainless steel. The use of
nylon tubing external to panels is not allowed.
F. Instrumentation and Controls
1. Each CMF unit shall be equipped with the following:
a. Control enclosure containing the CMF unit PLC and related equipment,
b. Pneumatic enclosure containing solenoid valves for the on-skid pneumatic
valve operators and related equipment.
c. Pressure indicating transmitters on the feed and filtrate manifolds.
d. Filtrate magnetic flow meter.
e. Filtrate manifold high level switch
f. Control air low pressure switch.
2. All control, power, and instrument wiring external to unit electrical panels shall
be run in PVC coated rigid galvanized steel conduit and fittings, flexible PVC
coated, steel core liquid tight conduit, or cable tray with wiring secured by nylon
ties. See Section 16100 for requirements.
G. Piping
1. Piping interfaces on the CMF units shall be designed such that the two units can
be arranged in a single row and connected on common interconnecting pipe
manifolds.
I I3OS.MEMCORCMF SYSTEM.WC 11305-4 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
2. The MFEM shall provide all piping integral to the CMF units to terminations at
the envelope of the support framework. The Installation Contractor will supply
all interconnecting pipe work to terminal flanges outside the unit envelope.
3. All termination points shall be flanged ANSI Class 150 in sizes 2-inches and
larger; or NPT pipe threaded in sizes less than 2-inches.
4. Terminations shall be provided for the services listed below. Pipe sizes at the
points of connection shall be per the MFEMs design.
a.
. b.
C.
d.
e.
f.
g.
h.
i.
MF feed inlethackwash inlet.
MF backwash inlet.
MF filtrate outlet.
MF filtrate exhaust outlet.
MF backwash outlet (four terminations per unit).
MF process air inlet.
MF control air inlet.
MF cleaning solution inlet.
MF cleaning solution outlet.
5. Piping materials for each service shall be per the MFEM's design. See
requirements for candidate piping systems in Division 15.
H. Valves
1. For a list of automatic flow valves to be furnished on each unit, see Supplement
4.01-B, Valve Schedules.
2. In addition to the valves listed in Supplement 4.01-B, the MFEM shall provide the
following manual CMF unit mounted valves:
a. One 6-inch CIP feed isolation valve (Type BFV3 with limit switch).
b. One 6-inch filtrate isolation valve (Type BFV3 with limit switch).
c. One 4-inch process air inlet isolation valve (Type GV2).
d. One 1-inch control air inlet isolation valve (Type BV3).
e. One 1/4-inch filtrate sample valve (Type SV2).
IIJOS.MEMCORCMF SYSTEM.WC 11305-5 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
f. One 3/4-inch ball check valve (Type BCV4).
g. One 1-inch disc type check valve (Type DCV2)
3. For valve requirements, see Section 15100.
2.03 EQUIPMENT AND COMPONENTS
A. Feed Delivery System
1. The feed delivery system includes the MF feed pump station; automatic strainers;
interconnecting piping, valves, instrumentation and controls.
2. Design and operating requirements for components of the feed delivery system
are included in Supplement 4.01-A, Process Equipment Schedules.
3. Requirements for the MF feed pumps are specified in Section 11213.
4. Requirements for the automatic strainers are specified in Section 11340.
B. Compressed Air System
1. The compressed air system shall consist of two air compressors with integral
dryers and outlet filters; two supply air filter assemblies; one air receiver with
accessories; one process air regulator assembly; one control air regulator
assembly; one plant pneumatic control panel; two CMF unit mounted pneumatic
control panels; interconnecting piping, valves, instrumentation and controls.
2. The compressed air system shall be suitable for supply of process air used in the
compressed air backwash system for the CMF units and control air used for the
pneumatically operated valves fiunished with the MF system.
3. Design and operating requirements for components of the compressed air system
are included in Supplement 4.01-A, Process Equipment Schedules.
4. Components of the compressed air system are specified in Section 11370.
C. Membrane Cleaning System
1. The cleaning system shall include dual CIP tanks and accessories, CIP pump, CIP
tank heater control panel, heaters and controls, citric acid dose system, Memclean
C dose system, sodium hydroxide dose system, instrumentation, interconnecting
piping and valves.
2. Design and operating requirements for components of the membrane cleaning
system are included in Supplement 4.01-A, Process Equipment Schedules.
3. The CIP tanks are specified in'Section 11250.
II305.MEMCORCMFSYS7UI.DOC 11305-6 APRIL 27.2001
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4. The CIP pump is specified in Section 1121 1.
5. Cleaning chemical dosing systems are specified in Section 11240 and related
system sections.
6. Valves
a. For a list of automatic flow valves to be supplied by the MFEM, see
Supplement 4.01-B, Valve Schedules.
b. In addition to the valves listed in Supplement 4.01-B, the MFEM shall
provide the following manual CIF’ system valves:
I TAG NUMBER TYPE SIZE [INCHES] V-0925-10
BFV3 2 V-0925- 16
BFV3 10
V-0925-26
BFV3 8 V-0926-8
scv3 8 V-0926-7
BFV3 6 V-0925-28
BFV3 2 V-0925-27
BFV3 2
V-0925-17
BFV3 10 V-0925-20
BFV3 6 V-0925-18
BFV3 2
- -
c. For valve requirements, see Section 15 100.
7. Instrumentation and Controls
a. Cleaning of individual CMF units shall be manually initiated but controlled
automatically through the PLC thereafter. Cleaning solutions shall be made
up of RO permeate and the appropriate cleaning chemicals. Tank charging
shall be conducted automatically through the PLC.
b. For instrument component specifications, see Section 13330. .
D. Backwash Collection System
1. The backwash collection system shall consist of a backwash tank, valves,
instrumentation and controls.
2. Design and operating requirements for components of the backwash collection
..system are included in Supplement 4.01-A, Process Equipment Schedules.
3. The backwash tank is specified in Section 11250.
4. Valves
11305.MEMCOR CMFSYSTEM.DOC 11305-7 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
2.04
A.
B.
C.
D
a. For a list of automatic flow valves to be supplied by the MFEM, see
Supplement 4.01-B, Valve Schedules.
b. In addition to the valves listed in Supplement 4.01-B, the MFEM shall
provide the following manual backwash system valves:
TAG NUMBER TYPE SIZE [INCHES1
V-0920-1
BFV3 2 V-0920-3
BFV3 2 V-0920-2
BFV3 8
c. For valve requirements, see Section 15100.
INSTRUMENTATION AND CONTROLS
General
1. For general instrumentation and control system requirements, see Section 11300.
Instrumentation
1. The MFEM shall provide specified instrumentation for the MF membrane system
and related subsystems.
2. For identification of MFEM supplied instruments, see the instrument list provided
in Supplement 4.02-B.
Control Panels
1. The MFEM shall provide the following control panels:
2. All panels shall be constructed in accordance with Section 13325.
Controls
11305-8 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
2.05
A.
B.
1. The MFEM shall provide all software configuration and discrete controls for the
system provided, including interface and control of components not furnished by
the MFEM.
2. For requirements, see the control fimctional descriptions provided in Supplement
4.02-C, Loop Function Data Sheets.
SPARE PARTS
A list of recommended spare parts and all special tools required for normal operation
and maintenance of all components furnished by the MFEM shall be submitted for
approval within sixty (60) days following Notice to Proceed. All items on this list shall
be hrnished prior to the beginning of preoperational tests. The list shall include items
specified hereinbefore and the following additional items as a minimum:
DESCRIPTION QUANTITY
Coalescer, Control Air Regulator Assembly
4 Membrane, Supply Air Filter Assembly
4 Coalescer, Supply Air Filter Assembly
2
For additional spare parts requirements related to the instrumentation and control
system, see Section 13320.
IIJOS.MEMCORCMFSYSTEM.DC€ 11305-9 APRIL 27,2001
City of Carlsbad
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MF EQUIPMENT PROCUREMENT
PART 3 - EXECUTION -NOT USED
PART 4 - SUPPLEMENTAL. INFORMATION
4.01
A.
B.
4.02
A.
B.
C.
Supplements listed below are attached following “END OF SECTION” and are a part
of this Specification.
EQUIPMENT SCHEDULES
Process Equipment Schedules
Valve Schedules
INSTUMENTATION AND CONTROL SCHEDULES
PLC Inputloutput List
Instrument List
Loop Function Data Sheets
+ + END OF SECTION + +
I1305.MEMCOR CMFSYSTEM.DOC 11305-10 APRIL 27,2001
City of Carlsbad
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MF EQUPMENT PROCUREMENT
TABLE 11305.4.01A-1
MF FEED PUMPS
(P-0901-1, P-0901-2)
ITEM DESIGN CONDITIONS
Maximum motor full load speed (rpm) 1800
Motor Size (Hp) 100
Motor Enclosure Type TEFC
Pump Design Speed (rpm) 1750
Drive Variable Speed
Minimum Discharge Size (inches) 8
Minimum pump shutoff head at design speed (feet) 200
Design Capacity (gpm)*
Design TDH (feet)*
1,785
140
Minimum pump efficiency at design capacity ("h) 82.0
Minimum NPSH available at design capacity (feet, absolute) 34
ITEM MATERIAL AND CONSTRUCTION REQUIREMENTS
Head Cast iron, ASTM A48 or Fabricated steel ASTM A53, Grade B
Bowls Cast iron, ASTM A48
Impellers Cast iron, ASTM A48
Impeller Wear Rings Cast iron, ASTM A48
Bowl Wear Rings Cast iron, ASTM A48
Bowl and Suction Case Bearings Bronze, ASTM B584, Alloy 932
Lineshaft Open Type; Stainless steel, ASTM A276, Type 416
Lineshaft Bearings Bronze, ASTM B584, Alloy 836
Head Shaft
Impeller Shaft Stainless steel, ASTM A276, Type 416
Stainless steel, ASTM A276, Type 416
Shaft Sleeves Stainless steel, ASTM A276, Type 410, hardened
Shaft Seal Mechanical Type * Point must be at or near the best efficiency point
Column Steel, ASTM A53, Grade A
11305.4.01A.PRa'ESSEQUlPMENTSCHEDULES.DOC 11305SlA-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01A-2
AUTOMATIC STRAINERS
("0906-1, "0906-2)
ITEM DESIGN CONDITIONS
Maximum motor full load speed (rpm) 1800
Motor Size (Hp) 0.25
Motor Enclosure Type TEFC
Inlet and Discharge Size (inches) 10
Screen Rating (microns) 500
Design Capacity (gpm) 1,785
Design Clean Pressure Drop 1 .o
..
11305.4.01A.PROCESS EOULPMENT SCHEDULES.DOC 1 1305s 1A-2 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01A-3
AIR COMPRESSORS
("0911-1, "091 1-2)
ITEM DESIGN CONDITIONS
Maximum motor full load speed (rpm) 3600
Motor Size (Hp) 15
Motor Enclosure Type TEFC
Design Capacity (sch) 45
Design Pressure (psig) 175
11305.4.01A.PRM3ESS EQUIPMENT SCHEDULESWC 1 1305s 1A-3 APRIL 27,2001
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TABLE 11305.4.01A-4
AIR RECEIVER
(T-0911)
ITEM DESIGN CONDITIONS
Volume (gallons) 2,180
Design Pressure @sig) 175
11305.4.01A.PROCESSEQUIPMENTSCHEDULES.MX: 11305SlA-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01A-5
MF BACKWASH TANK
(T-0920)
ITEM DESIGN CONDITIONS
Capacity (gallons) 3,100
Materials FRP
Nominal Diameter (feet) 8
Nominal Straight Shell Height (feet) 10.5
Accessories Mist Arrester
CONNECTION SCHEDULE
m Vent with Mist Arrester
Filtrate Exhaust Inlet
24-in flanged
6-in flanged
- Side
Siphon Drain 8-in flanged
Overflow with Internal Downcomer 10-in flanged
Backwash Inlet Connections (two) 12-in flanged
Level Switch Connections (two) 3-in flanged
Level Transmitter Connection 3-in flanged
Level Sight Gauge Connections (two) 2-in flanged
11305.4.01A.PROCESSEQUlPMENTSCHEDULES.DOC 11305SlA-5 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01A-6
MF CIP TANKS
(T-0925-1, T-0925-2)
ITEM DESIGN CONDITIONS
Capacity (gallons) 2,600
Materials FRP
Nominal Diameter (feet) 8
Nominal Straight Shell Height (feet) 9.8
Accessories Immersion Heater
CONNECTION SCHEDULE
rn Dosing Inlet
Cleaning Return Inlet
Manway
Vent
Permeate Fill Inlet
- Side
Siphon Outlet
Overflow
Siphon Drain
Immersion Heater
Heater RTD
Level Switch Connections (two)
Level Transmitter Connection
Level Sight Gauge Connections (two)
3-in flanged
6-in flanged
24-in flanged
6-in flanged
2-in flanged
10-in flanged
8-in flanged
6-in flanged
6-in flanged
3-in flanged
3-in flanged
3-in flanged
2-in flanged
11305.4.01A.PROCESSEQUlPMENTSCHEDULES.DOC 11305SlA-6 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01A-7
MF CP PUMP
(P-0926)
ITEM DESIGN CONDITIONS
Maximum motor full load speed (rpm) 1200
Motor Size (Hp) 25
Motor Enclosure Type TEFC
Pump Design Speed (rpm) 1150
Drive Constant Speed
Minimum Discharge Size (inches) 4
Minimum pump shutoff head at design speed (feet) 100
Design Capacity (gpm)* 975
Design TDH (feet)* 60
Minimum pump efficiency at design capacity (%) 80.0
Minimum NPSH available at design capacity (feet, absolute) 34
ITEM MATERIAL AND CONSTRUCTION REQUIREMENTS
Casing Stainless steel, Type 316
Impellers Stainless steel, Type 316
Shaft Stainless steel, Type 316
Shaft Sleeve Stainless steel, Type 316
Shaft Seal Mechanical Type
* Point must be at or near the best efficiency point
11305.4.01A.PROCESS EQUIPMENT SCHEDULES.MX: 1 1305s 1A-7 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
TABLE 11305.4.01A-8
MF CIP PUMP DISCHARGE STRAINER
("0926)
ITEM DESIGN CONDITIONS
Inlet and Discharge Size (inches)
Screen Rating (microns)
Design Capacity (gpm)
6
5 00
975 - Design Cldan Pressure Drop . ~" ~ 1 .o
ITEM MATERIAL AND CONSTRUCTION REQUIREMENTS
Body Stainless steel, Type 316
Screen Stainless steel, Type 316
Seals EPDM
11305.4.01A.PROCESSEQUIPMENTSCHEDULES.DOC 11305S1A-8 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01A-9
MF CP CHEMICAL DOSING SYSTEMS
ITEM DESIGN CONDITIONS
Minimum Storage Tank Capacity (gallons)
Minimum Dosing Pump Operating Capacity (gallons per hour)
250
10 - 100
IlJOS.4.OIA.PROCESSEQUlPMENTSCHEDULES.DOC 11305SlA-9 APRIL 27,2001
TABLE 11305.4.01B-1
AUTOMATED VALVE SCHEDULE
Notes:
1. Valve furnished by strainer manufacturer. See equipment specification for requirements.
2. To be designed by MFEM. See specifications for requirements.
3. Valve furnished by pump manufacturer. See equipment specification for requirements.
4. Not all flow valves are listed. MFEM shall provide required on-skid valves for his
1130S.4.01B.VALVESC11EDULES.DOC I1305SlB-1 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
TABLE 11305.4.01B-2
SELF-CONTAINED VALVE SCHEDULES
3. Relief valves with unique equipment numbers shown on the Drawings but not listed above
lIJO5.4.OIB.VALVE SCHEDULES.DOC 11305SlB-2 APRIL 27,2001
d
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
TABLE 11305.4.02B-1
INSTRUh4ENT LIST
Notes:
1. Instrument furnished by strainer manufacturer.
2.
3.
Indicator is integral to storage tote wall and/or supplied by tote manufacturer.
Provide manufacturer’s standard instrument.
11305.4.02B.lnsmunct tirt.doc 11305S2B-1 APRIL 27,200 1
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