HomeMy WebLinkAboutUS Filter Wastewater Group Inc; 2002-08-12; 3675 Part 4 of 5City of Carlsbad
h4F EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
SECTION 11340
AUTOMATIC SELF-CLEANING STRAINERS
PART 1 - GENERAL
1.01 DESCRIPTION
A. The MFEM shall provide all materials, equipment, and appurtenances as shown,
specified, and required to furnish automatic self-cleaning strainers, complete and
operational, as shown and specified.
B. Strainers shall be installed in the locations indicated on the Drawings.
1.02 QUALITY ASSURANCE
A. Manufacturer's Qualifications: Manufacturer shall have experience in producing
similar equipment, and shall show evidence of five (5) installations in satisfactory
operation for at least five (5) years.
B. Reference Standards: Comply with applicable provisions and recommendations of the
following, except as otherwise shown or specified.
1.
2.
3.
4.
5.
6.
I.
8.
AGMA Standards.
Standards of the Hydraulic Institute.
National Electic Code.
Standards of Institute of Electrical and Electronic Engineers.
American National Standards Institute.
Standards of American Water Works Association.
American Society of Mechanical Engineers.
Occupational Safety and Health Act.
1.03 SUBMITTALS
A. Shop Drawings: Submit for approval Shop Drawings showing the following:
1. Manufacturer's literature, illustrations, specifications, and engineering data,
including dimensions, materials, size, and weight.
I134O.AUTOMATIC SELF-CLEANNG STRAMERS.DOC 11340-1 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
2. Assembly, installation, and wiring diagrams.
3. Provide setting drawings, templates, and directions for the installation of .anchor
bolts and other anchorages.
4. Provide detailed drawings of the equipment and the adjoining concrete work.
B. Operation and Maintenance Manuals: Submit complete installation, operation, and
maintenance manuals including copies of all approved Shop Drawings, as required by
Section 01730, Operation and Maintenance Data.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. The equipment shall be completely assembled in the shop and checked for proper
operation. Prior to shipping, the equipment shall be completely inspected to assure all
equipment is complete and in compliance with all requirements. The equipment shall
be protected to prevent damage during shipping.
B. Equipment shall be shipped as complete units. All boxes, crates, or packages shall
clearly identify their contents.
C. Deliver materials to the site to ensure uninterrupted progress of the Work. Deliver
anchor bolts and anchorage devices, which are to be embedded in cast-in-place
concrete in ample time to not delay that Work.
D. Refer to Section 01610 for additional requirements.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. General
1. Strainers shall be of the motorized automatic self-cleaning type. The equipment
shall be designed to continuously remove suspended particles fiom the pumped
raw water.
2. Design and operating criteria for the strainers are included in the supplements to
the detailed system specifications following Section 11300.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Construction
1. Strainer shall be of the self-cleaning type. It shall consist of an outer cast-iron or
ductile iron body, an internal 316 stainless steel screen element sealed with an
1 I340.AUTOMATIC SELF-CLEANING STRAMERS.DOC 1 1340-2 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
upper and lower seal ring, and a rotating, hollow, ductile iron backwash arm,
which extends the full length of the filter, and discharges the backwash water
through an outlet nozzle.
The use of carbon steel for any wetted strainer surfaces is specifically prohibited.
Backwash cleaning of the screen shall be accomplished by utilizing the pressure
differential between line or atmospheric pressure, or on a time cycle. The
contoured backwash arm shall rotate slowly, creating an intense backwash flow
across a narrow, isolated vertical section of the screen element. Line flow shall
be completely uninterrupted during the backwash sequence.
The unit shall be designed so that the entire operating assembly, motor, gear
reducer, cover, backwash arm assembly, screen element, and bearing housing, lift
from the filter body as a complete unit.
The strainer shall be rated for service at 150 psi @ 100°F and ASME code
stamped. Inlet and outlet connections shall be flanged and designed and
constructed in accordance with both ANSI and ASME Section VIII, Division 1.
The strainer shall be hydrostatically tested to 1-112 times the vessel pressure
rating.
An inspection port shall be provided to permit visual inspection of filter element
without removing drum.
A drain opening shall be provided in the lower part of the strainer body to permit
drainage without removing drum.
No rubber or synthetic materials shall be used in the backwash section.
The straining element shall be low fouling wedge wire type of 3 16 stainless steel
construction with rating as noted.
The backwash operation shall provide a vigorous, reverse flow across the element
into the opening of the backwash arm. The opening shall be equal to the full
height of the filter element. The backwash arm assembly shall rotate inside the
stationary element.
The backwash system shall consist of a motor operated ball valve and shall be
furnished complete with electric motor operator. The motor operator shall run on
120 volts, 60 Hz, single phase, from the LCP.
Strainer backwashing shall be conducted with process feedwater at a minimum
pressure of 5 psig. Systems requiring a higher pressure for backwash source
water shall be equipped for connection and use of an external backwash supply.
II34O.AUTOMATIC SELF-CLEANING STRAINERS.DOC 11340-3 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
B. Motor
1. Motor shall operate on 480 volt, 60 Hz, three phase power supply.
2. Motor shall be TEFC-type with worm gear reducer.
C. Controls
1. Each automatic strainer shall be furnished with a local control panel (LCP). LCP
shall be 316 stainless steel NEMA 4X, shall conform to the requirements of
Division 13, and shall be pedestal mounted.
2. Local control panel shall include the following:
a. All door-mounted components shall be NEMA 4X, non-corrosive type.
b. The LCP shall be factory wired with the following components:
1) “Power On” lights, push-to-test, showing through cabinet door.
2) “Backwash Cycle On” lights, push-to-test, showing through cabinet
door.
3) “Differential Pressure” lights, push-to-test, showing through cabinet
door.
4) A three-position selector switch (OFF-ON-AUTO) to control the
backwash valve.
5) Manual reset pushbuttons for alarms.
6) Adjustable timers to set the backwash interval and duration.
7) Dry contacts for remote monitoring of ready status, operation, and
malfunction alarm.
3. The strainers shall accept a remote “BACKWASH INITIATE signal from the
PLC. Control signal from the PLC will be 120 VAC, 60 Hz, single phase.
Provide necessary interposing relays to interface with the strainer control circuits.
4. All necessary valves, pressure gauges, pressure switches, indicating lights,
selector switches, and other appurtenances shall be furnished and installed.
D. Spare Parts
1. The following spare parts shall be furnished:
I1340.AUTOMATIC SELF-CLEANING STF’.AMERS.DOC 1 1340-4 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
a. One set of replacement filter media for strainer.
b. One set of all gasket and O-ring seals.
E. Manufacturers
1. Hayward;
2. Fluid Engineering;
3. S.P. Kinney.
2.03 SURFACE PREPARATION AND SHOP PAINTING
A. Refer to Section 09900.
PART 3 - EXECUTION
3.01 START-UP AND TEST
A. All equipment will be given running tests by the Installation Contractor at the job site
following their installation of the equipment and controls. Should the tests indicate any
malfunction, the Installation Contractor shall make any necessary repairs and
adjustments of installation related issues. Defects revealed as a result of the tests will
be repaired by the MFEM. Such tests and adjustments shall be repeated until, in the
opinion of the Engineer, the installation is complete and the equipment is hctioning
properly and accurately, and is ready for permanent operation.
B. A factory trained field representative shall check and approve the installation before
operation. The representative shall field test and calibrate the equipment to assure that
the system operates to the District's satisfaction.
3.02 MANUFACTURER'S SERVICES
A. A factory trained representative shall be provided for startup and test services, and
training of operation and maintenance personnel. The field representative may be an
employee of the MFEM.
+ + END OF SECTION + +
1134O.AUTOMATIC SELF-CLEANING STRAMERS.DOC 11340-5 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEI'IT
SECTION 1 1370
COMPRESSED AIR SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. MFEM shall provide all materials, equipment, and incidentals as shown on the
Procurement Drawings and as specified herein for a complete and operational air
compressor system. The compressed air system shall be designed to actuate all
pneumatic valves in the system and to assist in the backwash operation of the
membrane filtration system (if required) and shall be provided by the MFEM.
2. Components of the compressed air system shall be fabricated, assembled, erected,
and placed in proper operating condition in conformity with the specifications,
engineering data, instructions, and recommendations of the equipment
manufacturer; unless exceptions are noted herein. Components of the compressed
air equipment system shall be the latest standard products of manufacturers
regularly engaged in the production of equipment of this type.
3. The MFEM shall furnish a complete air compressor system consisting of the
following major components:
a.
b.
C.
d.
e.
f.
g.
h.
Compressors.
ASME-rated Receivers.
Refrigerated Air Dryers.
Controls: Pressure switches and NEMA 4 control enclosure housing starter,
thermal overload protection, disconnect, control power transformer, and
appurtenances.
Pressure Relief Valves.
Manual Shutoff Valves.
Pressure Gauges.
Vibration Mounts and All Mounting Hardware.
I I37O.COMPRESSED NE SYSTEM.DOC 11370-1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
i. Inlet Filter-Silencer.
j. Intercooler with Drain.
k. Process Air Regulator Assembly.
1. Control Air Regulator Assembly.
m. Automatic Drain Valves.
n. Coalescing Filters.
0. Particulate Air Filters.
1.02 QUALITY ASSURANCE
A. Manufacturer's Qualifications: The manufacturer or supplier shall have experience in
producing similar type equipment, and shall show evidence of five (5) installations in
satisfactory operation for at least five (5) years.
B. Reference Standards: Comply with applicable provisions and recommendations of the
following, except as otherwise shown or specified:
1. National Fire Protection Association.
2. National Electric Code.
3. National Electric Manufacturers Association.
4. ASME Pressure Vessel Code.
1.03 SUBMITTALS
A. Shop Drawings
1. Drawings and Samples
a. Manufacturer's literature, illustrations, specifications, and engineering data,
including: dimensions, materials, size, weight, and performance curves.
b. Fabrication, assembly, installation, mounting drawings, and wiring
diagrams.
c. Provide setting drawings, templates, and directions for the installation of
anchor bolts and other anchorage.
B. Factory Test Reports
I137O.COMPRESSW AIR SYSTEM.DOC 1 1370-2 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Submit Factory Shop Test Reports for the Compressor Supplied.
C. Installation Instructions
1. Submit installation instructions with the delivery of the equipment.
2. The MFEM shall furnish a lubricant specification of the type and grade necessary
to meet the requirements of the equipment.
D. Operation and Maintenance Manuals
1. Submit in accordance with the requirements of Sections 01730, Operation and
Maintenance Data.
E. Record Drawings - (Not Used)
F. Certificates Warranties and Guarantees
1. Submit ASME Certificates.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Delivery:
1. Refer to Section 01 660 - Transportation of Handling of Goods
2. Refer to Section 0161 1, Protection of Goods
3. Air compressor shall come completely assembled.
4. Intake and discharge ports shall be protected against entry of foreign objects.
B. The Installation Contractor will store materials in accordance with the manufacturer’s
recommendations.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Temperature: 40 to 1 10 degrees F.
2. Humidity: 10 to 100 percent RH
3. Elevation: 10 meters above mean seal level.
11370.COMPRESSED AIR SYSTEM.WC 11370-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
B. Process Design Requirements
1. The air compressors shall be sized such that the air supply requirements can be
satisfied with one compressor out of service.
2. The compressed air equipment shall be designed for continuous operation.
3. For additional design and operating requirements for components of the
compressed air system, see the Process Equipment Schedules attached as
supplements to the detailed system specification sections following Section
11300.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Components of the compressor modules shall be standard products of the
manufacturer. Modules shall be completely factory assembled, requiring only
field connection of electrical power, and air discharge and condensate drain
piping.
2. Power supply to the compressors will be 480 volts, three phase, 60 Hz.
3. The compressors shall be suitable for installation in a UBC Seismic Zone 4 area.
The manufacturer shall provide calculations and details for proper anchorage of
the compressors to the concrete equipment pad.
4. All standard equipment shall be mounted on a hlly enclosed metal base of
industrial grade steel with a NEMA 3R rating (minimum) suitable for installation
outdoors on a concrete pad. Each compressor shall mount on a base plate. Set
each base mounted air compressor on a minimum of four (4) vibration isolators
that are attached to the base plate. Provide each isolator comprising steel springs,
steel top and bottom plates, leveling bolts and resilient shocks. Design the
isolators to control oscillation and to withstand all lateral forces.
5. Each compressor shall have additional moisture protection features including
mushroom caps on the inlet and outlet ducts, gasketing around all doors, and a
plexiglass shield covering the control panel. The compressor modules shall be
fully piped and assembled, including the control cubicle with starter and
aftercooler with separator/trap.
B. Equipment Design Requirements
1. . Air Compressors:
I I370.COMPRESSED AIR SYSTEMDOC 1 1370-4 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIF’MENT PROCUREMEM
a.
b.
C.
d.
e.
f.
g.
h.
2. Re6
a.
Compressors shall be rotary screw type, direct driven complete with inlet
filter/silencer, discharge check valve, motor, and automatic pressure
unloader, providing no load starting. Each element shall have an asymmetric
rotor design and a cycloid profile at the pitch diameter. The male rotor shall
be driven by a triple v-belt power transmission.
Each compressed air module shall consist of, but not necessarily be limited
to, the following: compressor, drive motor, oil system, air system, electronic
regulating controls, sound attenuating enclosure, starter cubicle and
integrated refrigerant air dryer.
Compressors of oil type shall use food grade lubricants. The oil lubrication
system installed with each module shall be of the differential pressure type
consisting of an ASME approved aidoil separator unit including, but not
limited to, the following: separator element; oil fill tube; oil level indicator;
oil filter of the spin-on type rated at 10 microns; oil cooler; and thermostatic
oil cooler bypass valve.
Air handling systems installed with each module shall consist of the
following: dry type air intake filter rated at 3 microns; pneumatically
operated air intake valve/unloader assembly; minimum pressure/check
valve; aidoil separation system; discharge air shutoff valve; and motor
driven compressor cooling fan.
Each air compressor module shall have a compact welded aluminum
combination cooler, and a moisture separatodtrap including both automatic
and manual drain lines.
The compressor shall be enclosed by sound attenuated panels designed to
limit noise to a maximum of 76 dB(A) (CAGyPneurop PNSNTC2.2).
Compressors shall use an air cooled heat exchanger.
Provide compressed air equipment from one of the following manufacturers:
1) Atlas Copco, Model GA packaged as full feature GFF.
2) Ingersol Dresser Type SSR
3) Kaeser
rigerated Air Dryer:
An integral refrigerated dryer shall be furnished with each compressor
module. Each dryer shall include the following: pre-cooler/re-heater;
refrigerant compressor; liquid separator; press-0-stat regulator of condenser
11370.COMPRESSEDAIR SYSTuI.DoC 11370-5 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
b.
C.
d.
e.
f.
3. Air
a.
b.
fan operation; expansion valve; R22 refrigerant; and pressure dew-point
indicator monitored through the control module.
Rate air dryers in accordance with the standard rating conditions of the
National Fluid Power Association for class H dryers, i.e. 33 to 39 degrees F
pressure dew point range at the specified minimum discharge pressure and
100 degrees F inlet air with a maximum pressure drop of 5 psi.
Under this rating, provide the dryers with a capacity not less than 20 percent
above the maximum total free air delivery of each dedicated air compressor.
Equip each refrigerated air dryer with a condensing unit, refrigerant
evaporator, mechanical separator, automatic condensate discharge valve,
high dischargeair temperature alarm light, and switch for actuating a remote
alarm, prefilter, and after-filter. The air dryer shall be integrated into the
compressor design and part of the compressor enclosure. .
After-filter: Equip dryers with filters to remove oil carryover, oil aerosols
and other foreign matter. Install a pre-filter near the dryer inlet and install
an after-filter near the dryer discharge. Design the prefilter for mechanical
removal of solid and liquid particles, equipped with a porous bronze filter
element with a 5 micron rating. Provide an after-filter of the coalescing type
with a 0.5 micron rating.
Acceptable Manufactures: Provide refrigerative air dryers from one of the
following manufactures:
1) Atlas Copco.
2) Ingersol Dresser
3) Kaeser
Receivers and Air Surge Tank:
The air receiver shall be a vertical tank of all welded construction with semi-
ellipsoidal heads and leg supports for mounting on a concrete base. The
receiver shall be designed and constructed in accordance with the ASME
Code for Unfired Pressure Vessels and shall bear a code stamp.
Receivers shall be complete with a pressure transmitter, pressure gage,
pressure relief valve, automatic drain valve, and appurtenances. Receivers
and surge tank shall be provided with an internal factory applied epoxy
lining.
I1370,COMPRESSED AIR SYSTFMDOC 11370-6 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c. The receiver shall be provided with piping connections for an inlet, outlet,
drain, pressure relief valve, and cleanout opening.
d. The receiver shall be suitable for installation outdoors on a concrete pad.
The manufacturer shall submit calculations documenting compliance of
vessel support and recommended anchorage according to UBC Seismic
Zone 4 requirements.
4. Coalescing Filters:
a. Coalescing type oil removal filters shall be provided as shown and specified.
The filters shall remove 99.995% of the solids and liquids 0.3 micron or
larger in size with replaceable filter elements. Filters and housings shall be
sized and selected by the MFEM to meet requirements of the system.
b. Supply air filter assemblies shall be provided by the MFEM for each
compressor. Each assembly shall include the following: filters (3); filter
support bracket; outlet valve; auto drain valve assemblies (3); and
interconnecting piping between the filters.
c. The MFEM shall provide support brackets with cutouts to the filter
housings. The support brackets shall be constructed of Type 304 stainless
steel, and shall contain labels for the filter housings as well as inlet and
outlet sides of the assemblies.
5. Particulate Air Filters:
a. Membrane air filters shall be hydrophobic with an absolute range of 0.02
micron removal. The filters shall have replaceable cartridges. Filters and
housings shall be sized and selected by the MFEM to meet requirements of
the system.
b. For air that is in intimate contact with filtered water, provide hydrophobic
particulate filters with an absolute range of 0.02-micron removal shall be
provided.
c. Air filters with a 1-micron removal rating shall be provided for instrument
air and valve actuation.
6. Process Air Regulator Assembly:
a. Provide a process air regulator assembly consisting of inlet valves, pressure
relief valve, air muffler, and outlet valve at the receiver outlet. The
regulators shall be SMC, Norgren, or equal.
I I370.COMPRESSED AIR SYSTEM.WC 11370-7 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. The process air regulator assembly shall be fabricated from copper tubing
and shall consist of the external pilot type air regulators with inlet and outlet
isolation valves, inlet and outlet pressure gauges; outlet low pressure
switches; air-flow element and transmitter; check valve; and air loading
valve. One regulator within the assembly will be in service, while the
second regulator will provide an installed spare.
7. Control Air Regulator Assembly:
a. Individual control air regulator assemblies shall be installed on each unit.
The assemblies shall consist of the following: an isolation valve; pressure
regulators with inlet and outlet isolation valves; low pressure switch; air
loading valve; outlet pressure gauge, pressure relief valve, and connecting
copper fittings and pipework. One filter and regulator within the assembly
will be in service, while the second set will provide an installed spare.
b. The filters shall be furnished complete with housing, support bracket, and
removable filter cartridge. The support bracket and associated hardware
shall be Type 304 stainless steel. Filters and housings shall be sized and
selected by the MFEM to meet requirements of the system.
C. Fabrication Requirements (Materials of Construction)
1. All mounting hardware shall be Type 304 stainless steel.
2.03 EQUIPMENT AND COMPONENTS
A. Motors
1. Drive motors shall be horizontal AC squirrel cage induction type, TEFC, NEMA
D flange mounted with a 1.15 service factor. They shall include Class F
insulation, be designed for a Class B temperature rise, and be suitable for 480 volt
service. Motors shall include a cast frame and rotor, with non-hygroscopic
insulation and corrosion resistant hardware.
2. The motor starter shall be supplied with each compressor.
3. Motors shall be equipped with magnetic contactors and internal thermal
protection.
B. Pressure Relief Valves
1. General: Provide threaded pressure relief valves of the spring-loaded, bronze,
pop-safety type designed for compressed air service. Design the valves to ‘pop’
wide open at the specified or scheduled set pressure capable of relieving the
specified or scheduled air flow at 10 percent overpressure. Mount the pressure
II370.COMPRESSEDAIR SYSTEM.WC 11370-8 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
relief valve on the air receiver to relieve the full capacity of the compressors at 10
percent overpressure above the set pressure. Furnish valves meeting the
requirements of the ASME Code for Unfired Pressure Vessels and bearing the
Code stamp.
2. For valve requirements, see Section 15101.
C. Automatic Drain Valves:
1. The air receiver(s) and oil coalescing fJters shall be supplied with adjustable
timer, automatic drain valves, and instruments.
2. Provide a block and bleed valve arrangement around each automatic drain valve,
to allow for on-line maintenance and manual drain of each assembly.
3. For valve requirements, see Section 15101.
2.04 INSTRUMENTATION AND CONTROLS
A. Controls
1. The compressors shall be controlled by a microprocessor-based controller. All
controls shall be suitable for operation throughout the ambient temperature range
specified herein. All control equipment for the air compressor modules shall be
furnished as required for a complete installation.
2. All connections between components of the compressor modules shall be made
by the manufacturer at their facility. Equipment delivered to the site shall require
only field connection of the electrical power supply and remote status and alarm
instrument wiring. The air compressor modules shall include a control panel
containing all indicators and control switches, as well as data display for
temperature, pressure, dewpoint, motor overload status, run hours, and service
indicators. The control panels shall be mounted on the compressor modules.
Panels shall be NEMA 4 rated.
3. Each module shall be equipped with a UL listed control cubicle consisting of a
direct on-line 480 volt motor starter, and a control circuit transformer for 120
VAC controls and 24 VDC for the control module:
4. The controls shall provide for automatic alternation of the compressors. (Control
of the compressor alternation may be controlled by the MFEM's PLC system.)
5. A normally closed contact that opens on alarm condition shall be provided for an
external alarm if the pressure drops below 90 psig.
11370.COMPRESSED AIR SYSTEM.DOC 11370-9 AF'RIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
6. The compressor shall be supplied with an alarm and be shut down if failure of the
oil system occurs.
2.05 SPARE PARTS
A. General: Provide one manufacturer's recommended spare parts kit for each air
compressor furnished. Provide the following additional spare parts for the air
compressor equipment:
1. Two sets of oil filters and lubricants for oil based compressors.
2. One set of intake and discharge valves for each compressor.
3. Two sets of replacement intake filters.
B. The spare parts shall be delivered carefully boxed or packaged and plainly marked for
re-ordering.
2.06 SHOP PAINTING
A. All components of the compressed air system, including motors and enclosures, shall
be shop-primed and finish painted to manufacturer's standards prior to shipment to the
site, with the following exceptions: stainless steel, nonferrous, nonmetallic surfaces are
not required to be painted; the air receiver shall be furnished with the external surface
prime painted only with a gray primer. The inside of the receiver shall be epoxy coated
to a minimum thickness of 3 mils.
B. Gears, bearing surfaces, and other unpainted surfaces shall receive a heavy application
of a rust-resistant coating which shall be maintained during storage and until the
equipment is placed into operation.
2.07 SPECIAL TOOLS - (NOT USED)
2.08 LUBRICANTS
A. Compressors shall use food grade lubricants.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. The h4FEM and Engineer shall inspect all equipment immediately upon delivery to site.
B. Installation Contractor will not install damaged equipment until repairs are made in
accordance with manufacturer's written instructions and approved by the Engineer.
11370.COMPRESSED AIR SYSTEM.DOC 11370-10 APRIL. 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
Only minor repair work shall be permitted in the field, as approved by the Engineer.
All other damaged items shall be sent to factory for repair or replacement.
C. The Installation Contractor will complete the installation in accordance with
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. The manufacturer of the air compressor shall provide 4 hours of operator training as
part of the training requirements of the project.
B. The MFEM shall provide 2 hours of training on the design and operation of the
compressed air system.
C. Training shall be conducted in accordance with Section 01731, Training of Operation
and Maintenance Personnel.
3.04 ACCEPTANCE TESTING -NOT USED
3.05 MANUFACTURERS ASSISTANCE
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 Oueration and Maintenance services shall be coordinated with the 1. Engineer. The field representative may be a factory-trained employee of the
MFEM.
+ + END OF SECTION + +
11370.COMPRESSED AIR SYSTEM.DCC 11370-1 1 APRIL 27,2001
City of carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 11375
ROTARY POSITIVE DISPLACEMENT BLOWERS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The WEM shall furnish all, materials, equipment, appurtenances, specialty
items, and services required for complete and operable rotary positive
displacement lobe type blowers as specified herein and shown and specified in the
Procurement Documents.
2. 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 equipment specified herein from a single supplier in whom
shall be vested unit responsibility for the proper fimction of the complete system.
3. The equipment covered by this specification is intended to 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 and installed in accordance with the best practice and methods,
and shall operate satisfactorily when installed as shown and specified in the
Procurement Documents.
B. Coordination:
1, The MFEM shall retain ultimate responsibility under this Procurement Agreement
for equipment coordination, installation, operation and guarantee, and the MFEM
shall furnish all, equipment, materials, appurtenances, specialty items and
services not provided by the supplier but required for a complete and operable
system.
2. The manufacturer of the equipment specified herein shall be required to review
and satisfy all relevant requirements of other Sections of the Procurement
Documents and the requirements of the Drawings. The MFEM, manufacturer,
supplier, fabricator, and/or subcontractors fumishing equipment, services, and
specialties associated with this Section shall fully coordinate their efforts to avoid
potential claims that are based on failure to review all relevant Procurement
Documents.
1.02 QUALITY ASSURANCE
II~~~.ROTARYPOS~~VEDISPLACEMENTBLOWERS.DOC 11375-1 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
A. Manufacturer's Qualifications: Manufacturer of the rotary positive displacement
blowers 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 same application of the type specified herein have been in
satisfactory operation for at least five (5) years.
1.03 SUBMITTALS
A. Shop Drawings
1. Complete fabrication, assembly, foundation, and installation drawings, and
operation, maintenance and storage instructions, together with detailed
specifications and data covering materials used, power drive assembly, 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. Data and specifications for the equipment shall include,
but shall not be limited to the following:
a. Manufacturer's literature, illustrations, specifications and engineering data.
b. Drawings showing fabrication methods, assembly, accessories, installation
details and wiring diagrams.
c. Setting drawings, templates, and directions for the installation of anchor
bolts and other anchorages.
d. Electrical motor data.
e. Protective coating data as specified in Section 09900.
f. Blower performance data in accordance with Article 2.1-B of this Section.
B. Factory Test Reports
1. Blower Tests:
a. Except as described below, test one blower of each size in accordance with
ASME Power Test Code for Centrifugal Compressors (PST-9) and
Exhaustless fTom surge to 120 percent of design volume. ASME tests,
however, are not required for standard blowers for which data on previously
tested units of equal design is available.
b. Power consumption shall be measured by a calibrated watt-meter on the
input to a calibrated test motor. Certified calibration data shall be submitted
on the meter and motor.
I I37S.ROTARY POSITIVE DISPLACEMENT BLOWERSDX 1 1375-2 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility MF EQUPMENT PROCUREMENT
c. Calibration shall be corrected back to standard conditions (68"F, 14.7 psia
and 36% RH inlet) to determine if the unit meets the flow requirement.
d. The flow shall be measured by a rotary meter on the inlet.
e. The manufacturer shall supply a certified test report that the blower meets
the performance requirements as specified herein prior to the shipment of
the blower and in accordance with the requirements of Section 01340.
f. The MFEM shall inform the District in writing of all manufacturer factory
tests at least fourteen (14) days prior to testing.
g. Curves and other test data from units previously tested shall be submitted
for approval prior to shipment of the equipment.
h. Test one blower for minimum 3 hours run-time, at the manufacturer's plant
with the job or test motor. Vibration and temperature measurements shall
be taken to determine its mechanical integrity. Vibration level shall be
limited to a maximum of 5 mils. Temperature of the bearing housing near
the end of run time shall not exceed 215°F under an artificially created
ambient temperature of 40°C.
i. Each test shall be witnessed by a Registered Professional Engineer, who
may be an employee of the manufacturer. He shall certify that the required
tests were performed. The State of his registration, registration number and
his name on the seal shall be clearly legible. The serial number of the
equipment shall also appear on all data covering the unit.
2. Shop Test Results:
a. Submit test curves of actual blowers furnished, or from standard units
previously tested in accordance with Article 1.2-B.
b. Submit an inspection report in accordance with Article 1.2-B for the routine
test of each motor and a certified motor sheet from a previously
manufactured electrically duplicate motor which was tested.
c. Submit acoustical test data in accordance with Article 2.2-5&6 of this
Section.
C. Installation Instructions
1. Furnish Installation Instruction with the Blower.
D. Operation and Maintenance Manuals: Submit operation, maintenance, lubrication
schedules, test reports, maintenance data and schedules, description of operation, spare
11315.ROTARY POSITlVEDlSPLACEMENTBMWERS.DOC 11375-3 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
parts information and troubleshooting guides shall be submitted for review in
accordance with the procedures and requirements set forth in Sections 01660 and
01730, and as specified in Divisions 13 and 16.
E. Record Drawings -Not Used.
F. Certificates Warranties and Guarantees: In accordance with Article 3.3-A of this
Section.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Service Conditions
1. Design Conditions:
a. Barometric Pressure, psia
b. Relative Humidity, %
c. Inlet Air Temperature T
14.7
100
100
B. Process Design Requirements
1. See the Process Equipment Schedules attached as supplements to the detailed
system specification sections following Section 11300.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Furnish blowers as shown on the Drawings and specified herein.
2. The blowers shall be suitable for continuous operation at the design criteria
specified. The brake horsepower required shall not exceed the rated motor
horsepower under all specified conditions.
3. The blower, when operating with motor and all appurtenances, shall not have a
noise level greater than 80 dBA emanating from the blower assembly at a
distance of three feet from the blower assembly without acoustical enclosure.
4. Design the blower for continuous 24 hour per day, 7 day per week operation.
5. All motors and drives shall be TEFC and shall be sized to be non-overloading
over the full range of operating conditions specified herein.
II37S.ROTARY POSlTlVEDISPLACEMENTBLOWERS.DOC 11375-4 APRIL 27,2001
6. All parts of mechanisms shall be amply proportioned for all stresses that may occur during fabrication, shipping, erection, and intermittent or continuous
operation.
B. Equipment Design Requirements
1. Blower unit shall be of the horizontal, two-lohe, rotary, positive displacement
type. Blower shall be rugged in construction and of such design that it may be
disassembled and all parts inspected without disturbing the inlet or outlet piping.
Identical parts shall he interchangeable.
2. Vibration at the inlet and outlet connections shall not exceed 4 mils in the vertical
plane under all operating conditions.
3. Rotating assemblies shall be statically and dynamically balanced.
4. Casing:
a. Casing shall be of close-grained gray cast iron suitably ribbed to prevent
distortion under the specified service conditions. Casing shall be able to
withstand a minimum of 25 psig at 350 OF.
b. Inlet and outlet connections shall be flanged with drilling to conform to
ANSI B16.1, Class 125.
c. Casing shall be provided with lifting lugs.
5. Impeller and Shaft:
a. Impeller shall he made from a common cast iron casting. Shaft shall be
forged steel. Impeller shall he of the straight, two lobe type and shall
operate without rubbing or liquid seals or lubrication and shall be positively
timed by a pair of accurately machined heat-treated alloy steel, spur tooth,
timing gears. Timing gears shall be mounted on the impeller shafts on a
tapered fit and properly secured.
b. Timing gears shall be fully enclosed in an oil-tight housing opposite the
driver end of the blower. Gears shall be AGMA Class 10. Each impeller
and shaft assembly shall he supported by double-row, spherical, roller
bearings sized for a minimum B-10 life of 60,000 hours.
6. Bearings & Seals:
a. Provide a lip type oil seal at each bearing, designed to prevent lubricant
from leaking into the air stream. Further provision shall be made to vent the
IIJ7S.ROTARY POSlnVEDlSPLACUlENTBLOWERS.DOC 11375-5 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
impeller side of the oil seal to atmosphere to eliminate any possible
carryover of lubricant into the air stream.
7. Lubrication:
a. The timing gears and the bearings shall be splash oil lubricated from oil
slingers mounted on the gear end and dipping in oil. Drive end shall be
grease lubricated.
b. Blowers shall be designed to gradually pressurize the trapped volume prior
to exposing it to the discharge pressure required by the MFEM. The trapped
volume shall be connected through a tangential jet design. Blowers not
incorporating this design feature may use a reduced gear and tip speed to
obtain equivalent or less noise as the comparable jet design unit.
8. The MFEM shall size the blowers in accordance to the following design criteria:
SERIES / FRAME SIZE MAXIMUM SPEED (RPM I RAI 22-24 I 3600 I
I RAI 32-36 I 3600 I I RAI42-68 & 615 I 3600 I
9. Manufacturer: Provide equipment of one of the following:
a. Dresser Industries, Roots Division
1) Series RAI (Less than 40 W).
2) Series RCS (40 HP or greater).
b. Kaeser
c. Gardner Denver.
2.03 EQUIPMENT AND COPMPNENTS
A. Acoustical Enclosure:
11375.ROTARY POSITIVE DISPLACEMEhTBLOWERS.DOC 1 1375-6 APRIL 27,2001
City of Carlsbad
MF EQLIIPMENT PROCUREMENT
Carlsbad Recycling Facility
1. MFEM shall furnish acoustical enclosure for each blower with all required
hardware and appurtenances.
2. Blower noise level including motor shall be no more than 80 dBA at a distance of
three feet in any direction while operating under the design conditions specified
herein. Octave band sound pressure level readings shall be taken and recorded
during start-up. MFEM shall submit free field tests with the blower submittal to
show free field conformance with acoustical requirements as specified herein.
3. An acoustical enclosure shall be provided for each blower to meet the above
sound level. It shall totally cover each blower assembly. It shall be louvered in a
manner to move inlet air across the blower housing for cooling purposes.
Insulation on the interior surfaces shall effect a noise reduction. Louvers shall be
provided with coarse screen closures against airborne debris. The material of
construction shall be steel, double wall with internal acoustical insulation.
Coating shall be in accordance with Division 9. Enclosure panels shall be hinged
for easy removal. All enclosure hardware shall be 316SS. External oil fillers, oil
level gauges, and oil drains shall be provided on the enclosure.
4. The hot air blown off by the pressure relief valve shall be directed to the outside
of the sound enclosure by means of flexible ducting.
5. The sound enclosure shall be designed and built by the blower manufacturer.
6. Tests shall be conducted in accordance with Compressed Air and Gas Institute
PNEUROP test code for measurement of sound from pneumatic equipment.
Tests shall include the noise from the motor.
B. Motor
1. Motor shall be heavy duty, solid shaft, horizontal, TEFC, squirrel cage induction
type and NEMA B design for the required starting torque and operating torque.
Motor shall be rated for continuous operation.
2. Motor shall be rated for 460 volts, 3 phase, 60 Hz,
3. Motor thrust bearings shall be adequate to carry continuous thrust loads under all
conditions of service, and shall have a minimum B-10 life of 100,000 hours.
C. Adjustable V-Belt Drives:
1. Each adjustable V-belt drive (if required) shall be a heavy duty, cam-operated
sheave type that maintains constant driven speed under varying torque loads.
2. The drive shall be furnished with a suitable motor base, V belt and grooved
companion sheave and handwheel operator.
1 I37S.ROTARY POSITIVE DISPLACEMENT BLOWERS.DOC 1 1375-7 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
3. Maximum design blower shaft speed shall be 1750 rpm. Minimum blower shaft
speed shall be 1150 rpm.
4. Manufacturer:
a. T.B. Wood's Sons Co., Model MS-97.
b. Or equal.
D. Common Steel Base:
1. Factory mount blower and motor, V-belt driven, on a common steel base,
properly braced to form a rigid support for the entire unit. The units shall be
factory aligned on the base prior to shipment.
2. Furnish solid neoprene anti-vibration pads or strips, elastomer type, for use when
mounting the common base on the concrete support pad, or concrete slab. Anti-
vibration pads or strips shall be Korfund Dynamics Corporation, Type "Elasto-
Grip," or equal.
E. Aeration Blower Controls
1. Each Aeration Blower shall be provided with an HAND/OFF/AUTO selector
switch located on its designated Local Control Panel (LCP).
2. Each blower shall be provided with a Remote-Off-Test switch located at the
blower. The "Remote" position enables the controls within its designated LCP.
The "Off' position shall disable all controls. The "Test" position shall be spring
loaded and be used to test the blower in the field.
3. Each blower shall be provided with a "Run" light located on its designated LCP.
4. Failure of any blower as detected by pressure switches and motor overload relay
shall send a discrete signal to initiate individual blower failure alarms or motor
overload alarm at its designated LCP, and a common "AERATION BLOWER
FAILURE" to the system PLC.
F. Silencers
1. Silencers shall be furnished and installed on each blower inlet and outlet.
2. Product and Manufacturer: Silencers shall be as manufactured by:
a. Universal.
b. Burgess Manning, Incorporated.
II37S.ROTARY POSITIVE DISPLACEMENTBLOWERS.DOC 1 1375-8 APRIL 27,2001
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Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c. Or equal.
G. Accessories: Furnish the following accessories for each blower:
1. Suitable reinforced flexible connectors for both inlet and outlet piping. Flexible
connectors shall be rated for a minimum pressure of 25 psi and for 250°F air
temperature. Flanges shall conform to ANSIB16.1, Class 125.
2. Thermometer: Inlet and outlet thermometers shall be dial type industrial quality,
having a hermetically sealed climate proof case, 3-inch glass cover, stainless steel
stem, 1/2-inch male threaded bottom connection, and external reset adjustment.
3. Air Filter: Each blower shall be equipped with a dry type air intake filter as
specified herein. Each outlet connection shall have a 125 pound ANSI flange.
Each filter shall be designed so that the face velocity does not exceed 300 fpm.
The filtering medium shall be rated, as a minimum, 99 percent efficient on 10
micron particles and larger. Headloss through housing and filter when clean shall
not exceed 1.5 inches of water at design air flowrate. Each filter shall have a
capacity of not less than 120 percent of design volume. The filter enclosure shall
be constructed of minimum 12 gage reinforced metal, painted as specified under
Section 09900 and Section 11000.
a. Product and Manufacturer: Filters shall be as manufactured by:
1) Burgess Manning
2) Universal
3) Or equal.
4. Pressure Relief Valve: Each blower shall be equipped with a relief valve
designed to relieve the full flow of the blower. The valve must start to open at
design pressure and pass design flow at maximum of 25% pressure accumulation.
5. Pressure GaugeISwitch: Provide discharge pressure gauge and high/low pressure
switch; suction pressure indication in accordance with Division 13.
2.04 SPARE PARTS
A. Furnish and deliver the following spare parts carefully boxed or packaged and plainly
marked for reordering:
1. Blower:
a. One complete set of bearings, seals and O-rings for one blower and motor.
II375.ROTARYPOSlTlVEDlSPLACEMENTBLOWERS.DOC 11375-9 APRIL 27,2001
City of Carlsbad
MF EQUPMENT PROCUREMEN?
Carlsbad Recycling Facility
b. One complete set ofgaskets for one blower and motor.
c. Two filter elements shall be furnished for air intake filter.
2.05 SHOP PAINTING
A. Refer to Section 09900, Painting.
PART 3 - EXECUTION
3.01 PIPING & VALVES
A. Piping, valves, and fittings shall be as specified in Division 15.
3.02 INSPECTION
A. The MFEM and Engineer shall inspect all equipment immediately upon delivery to site.
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.
3.03 INSTALLATION
A. The Installation Contractor will complete the installation in accordance with
manufacturer's instructions and recommendations.
3.04 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.
3.05 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 ODeration and Maintenance services shall be coordinated with the
Engineer. The field representative may be a factory trained employee of the
MFEM.
B. Sound Tests
II375.ROTARYWSlTlVEDISPLACEMENTBWWERS.DOC 11375-10 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
1. Perform an overall sound-pressure level test on one blower of each size. Test
results shall be rated in decibels in accordance with ANSI Standard S5.1.
2. Take the overall sound pressure level at points evenly spaced around the blower
and motor assembly and at five feet from the nearest part of the units without the
panels installed in the acoustical enclosure. Sound level shall not exceed 80
decibels at five foot distance measured on the A-weighted scale.
3. It is the intent of this Specification that the complete unit as finally installed shall
not exceed the sound pressure level as specified herein. Manufacturer shall
submit a statement as to the unit's conformance with the Specification, whether
remedial measures will be required, and if so, what remedial measures he
proposes.
4. MFEM shall provide all instruments, necessary labor, tools, and materials to
conduct the field tests.
5. Submit report of test results.
+ + END OF SECTION + +
11375.ROTARY POSlTlVEDISPLACEMENTBLOWERS.DOC 11375-1 1 Al'FUL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 13320
INSTRUMENTATION AND CONTROL SYSTEM, GENERAL
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. This section and related sections which follow specify the requirements for the
process control and instrumentation system for the project. Reference to this
section in other portions of the contract documents shall include and extend to the
following other sections:
Section 13325 -Control Panels
Section 13330 - Instrument Specifications
Section 13335 -Programmable Logic Controller (PLC) System
Section 13340 - Supervisory Control System
Section 13350 - Control Loop Functional Descriptions
B. Coordination
1. All MFEM implementation development and software configuration activities
shall be coordinated with the District and other suppliers to verify compliance
with the requirements stated herein and coordinate the work. The Installation
Contractor will house and conduct a minimum of five coordination meetings with
designated representatives of the District, Installation Contractor, and MFEM.
Minimum attendees will include the Installation Contractor, the follow on
instrumentation and control system supplier (ICSS) project supervisor, and
programmers from the ICSS and other manufacturers or sub-vendors providing
configuration services. For each meeting, the Installation Contractor or ICSS will
prepare an agenda to direct discussions at the meeting and cover the basic topics
for each meeting as specified below.
a. Meeting No. 1 -Project Orientation: An initial meeting will be scheduled by
the Installation Contractor within the first 30 days of the project in order to
introduce representative personnel and discuss implementation of the project
instrumentation and control system. Topics will include as a minimum the
review of key portions of the contract documents: control philosophy,
submittal requirements, inter-disciplinary coordination, and schedule.
13320.INSTRUMEhTATION AND CONTROL SYSTEM, GENERAL.WC13320-1 APRIL 27,2001
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Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Meeting No. 2 - System Configuration: The second meeting will be
scheduled once the ICSS has submitted the required control system block
diagram package. The agenda will be developed to facilitate review of the
recommended configuration, identify any unresolved issues, and solicit
input from the District’s representatives on key issues.
c. Meeting No. 3 - Software Development: The purpose of the third meeting
will be to discuss issues related to the programming of PLCs and
configuration of workstation screens and report generation. For the PLCs,
the ICSS and MFEM shall identify the bit and register data to be
communicated to the supervisory control system. The data formatting and
communication protocol shall be approved by the District before any
programming is developed. A spreadsheet listing all the points to be
communicated to/f?om the supervisory workstations shall be developed
prior to the meeting and discussed during the meeting. The overall PLC I/O
and memory mapping shall be discussed for each system. Development of
workstation graphics, alarm handling, data archiving, and system reporting
shall also be addressed.
d. Meeting No. 4 - Software Implementation: Following submittal of the PLC
and supervisory control software development packages, the Installation
Contractor will schedule a meeting to review and discuss the information
provided. A brief description of how typical control circuits are executed
shall be provided for each system.
e. Meeting No. 5 - Testing Phase Coordination: The fifth meeting will be held
three weeks prior to system checkout. The purpose will be to verify that all
testing related submittals are up to date and coordinate execution of the
required tests.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QA/QC)
A. Manufacturers’ Responsibilities
1. The MFEM shall be responsible for implementation of the project instrumentation
and controls for the MF system and integration with the plant wide supervisory
control system through coordination with the Installation Contractor and follow-
on ICSS. As a minimum, the MFEM shall provide the following:
a. Complete the design of the overall instrumentation and control system for
the MF system, including resolution of signal interface discrepancies, circuit
routings, and data highway implementation based on the selected devices.
b. Prepare and submit shop drawings for all panels and subassemblies provided
by the MFEM.
13320.MSTRUMENTATIONANDCONTROLSYSTEM. GENERAL.DOC13320-2 APRIL 27,2001
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Carlsbad Recycling Facility
MF EQUIF'MENT PROCUREMENT
C.
d.
e.
f.
g.
h.
1.
j.
k.
1.
Prepare and submit information on all proposed equipment and devices
furnished by the MFEM.
Prepare and submit project wide loop drawings for all system control loops
shown on the drawings, including those for equipment and subsystems
provided by sub-vendors or other system manufacturers. It shall be the
responsibility of the MFEM to obtain the necessary information from all
associated manufacturers needed to correctly show all interface
requirements.
Prepare and submit component installation drawings.
Prepare and submit factory and field testing related submittals.
Provide a suitable facility and perform specified unwitnessed and witnessed
factory tests on all panels, software and controls furnished by the MFEM.
Provide representatives to perform all field calibration and testing of
components following installation.
Provide representatives to attend specified coordination meetings with the
District and his representatives.
Prepare operations and maintenance manuals for the overall instrumentation
and control system as well as for components furnished by the MFEM.
Train the District's operating and maintenance personnel.
Prepare as-built record drawings.
B. Reference Standards
1. All work under this section and other sections listed above shall be conducted in
conformance with the following listed standards according to the version in effect
at the time of bid submittal. In the event of conflict between a referenced
standard and a specific requirement of the specifications, the specification
requirement shall govern.
a. ISA $54, Instrument Loop Diagrams
b. ISA S20, Specification Forms for Process Measurement and Control
Instruments, Primary Elements, and Control Valves
c. ISA FW60.3, Human Engineering for Control Centers
d. ISA W60.6, Nameplates, Labels and Tags for Control Centers
I332O.MSrrt~M7ATlONANDCONTROLSYSTEM.GENERALDOC13320-3 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
e. NFPA 70, National Electric Code
f. NEMA ICs 6, Industrial Control and Systems Enclosures
g. UL 508/508A, Industrial Control Equipment
1.03 SUBMITTALS
A. Shop Drawings
1. General: The MFEM shall provide submittals for all components of the process
instrumentation and control system for the MF system. Submittals specific to
portions.of the system specified under other sections are included under those
sections. Where possible, the MFEM shall organize submittals in discrete
packages by section.
2. Drawings: All drawings shall be produced in AutoCAD version 14 and plotted in
black ink on B-size (11-inches by 17-inches) sheets unless otherwise noted.
Drawings may be edge bound. Record drawings shall be furnished in electronic
format on CD-ROM in addition to the hard copy prints.
a. Control System Block Diagram: Prepare and submit a control system block
diagram for the MF system showing all PLC panels, operator workstations,
data highway and interface components. Identify all components to be
supplied by the MFEM and those supplied by other suppliers. For
components supplied by the MFEM, include hardware submittals in the
same package.
b. Panel Construction Drawings: Prepare construction drawings for all control
panels. See requirements in Section 13325.
c. Panel Wiring Diagrams: Prepare wiring diagrams for all control panels.
See requirements in Section 13325.
d. Loop Drawings: Prepare loop drawings for all identified MF system control
loops. See requirements in Section 13350.
3. Equipment: Equipment submittal materials shall be assembled in three-ring
binders with tabbed dividers and an index sheet. All equipment and component
information shall be preceded by a fully annotated data sheet conforming to the
requirements of ISA S20.
a. Block Diagram Package: Submit supporting documentation for ancillary
hardware components identified on the block diagram.
I3320.INSTRUMMTATlON AN0 CONTROL SYSTEM, GENERAL.WC13320-4 APRIL 27,2001
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b. Panel Hardware: Submit catalog information on hardware components of
all control panels. See requirements in Section 13325.
c. Instrumentation: Submit a fully assembled package on proposed
instrumentation for the project. See requirements in Section 13330.
d. PLC System Hardware: Submit information on all components of the PLC
control system (this information may be included with the panel hardware
submittal at the option of the MFEM). See Section 13335 for requirements.
4. Supervisory Control Hardware: Submit information on hardware components of
the supervisory control system. See Section 13340 for requirements.
5. PLC System Software: Submit supporting documentation for configuration of the
PLCs. See Section 13335 for requirements.
6. Supervisory Control Software: Submit required information on software
configuration of the supervisory control system, including report generation and
graphics packages. See Section 13340 for requirements.
B. Test Procedures
1. The following submittals shall be prepared and forwarded to the District in
keeping with the established schedule for conducting various tests, shipment,
commissioning, and startup. At a minimum, each submittal shall be furnished at
least 30 days prior to the scheduled start date of any antecedent activity (see
Article 1.05, Sequencing and Scheduling). Where applicable, provide forms and
checklists for documentingresults. All reports, forms, and checklists submitted to
the District shall be signed and dated by a representative of the MFEM
conducting the test.
a. Unwitnessed Factory Test (LTFT) Procedure: The fabricator of all project
control panels shall prepare and submit a procedure for conducting the UFT
required herein. The procedure shall be sufficient to test and certify all
point-to-point wiring, panel construction, layout, discrete and software
control functionality against the specifications and accepted shop drawings.
For PLC panels, the procedure shall include a check of all discrete and
analog inputloutput signals to the associated terminal blocks. See specific
requirements herein as well as interface to the respective supervisory control
workstation.
b. Factory Demonstration Test (FDT) Procedure: The fabricator of all project
control panels shall prepare and submit a procedure for conducting the
required FDT to be witnessed by the District and/or his designated
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Carlsbad Recycling Facility
representative. The scope of testing shall be sufficient to demonstrate
compliance with specified requirements.
c. Operational Readiness Test (ORT) Procedure: The MFEM shall prepare and
submit a proposed test procedure for conducting various portions of the
ORT test to demonstrate proper installation and setting of all components
and controls. The procedure shall include a means of organizing
termination, calibration and loop tuning records for archive purposes.
d. Loop Function Test (LFT) Procedure: The MFEM shall prepare and submit
a procedure for conducting the LFT. The procedure shall contain forms
customized to each loop for documentation. Nanative instructions shall be
provided on how various loop functions will be verified.
C. Operation and Maintenance Manuals
1. The MFEM shall prepare materials for the operations and maintenance of the
system and components supplied, including hardware and software. Software
documentation shall be complete to document all project specific configuration.
See requirements in Section 01730. Provide the following as a minimum:
a. Complete list of supplied system hardware parts with full model numbers
referenced to system part designations, including spare parts and test
equipment provided.
b. Copy of all approved submittal information and system shop drawings in
AutoCAD format as specified herein with corrections made to reflect all
shop drawing review comments and the actual system as tested and
delivered to the site for installation.
c. As-built system software in a suitable binder labeled with the system
supplier's name, the date, and the project name.
d. Manufacturer supplied manuals for all control system components. Manuals
shall include the following information:
1) General descriptive information covering the basic features of the
equipment.
2) Physical description covering layout and installation requirements and
all environmental constraints.
3) Standard technical documentation covering the procedures for
programming, start-up, and shutdown of the PLC and computer
station equipment including instruction set descriptions and
programming procedures.
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MF EQUIPMENT PROCUREMENT
4) Principles of operation explaining the logic of operation; provide
information covering operation to a component level.
5) Maintenance procedures covering checkout, troubleshooting, and
servicing. Checkout procedures shall provide the means to verify the
satisfactory operation of equipment. Troubleshooting procedures shall
serve as a guide in determining faulty components. Servicing
procedures shall cover requirements and recommended time schedule
for calibration, cleaning, lubrication and other preventive
maintenance procedures.
6) Wiring, schematic, and logic diagrams.
7) Safety considerations relating to operation and maintenance
procedures.
8) Manufacturer's recommended spare parts list with model numbers.
e. All information shall be tailored for the project by indicating all options or
accessories provided and/or deleting or crossing out non-applicable options
or information.
D. Record Drawings
1. Revise all system shop drawings, submittals, and software documentation to
reflect as-built conditions.
2. A sufficient number of all revised shop drawings and documentation shall be
submitted to the District to replace previously issued drawings incorporated in the
operating and maintenance manuals. Specific instructions for drawing removal
and replacement shall be provided with the record drawing submittal.
3. Full-size black line prints of wiring diagrams applicable to each control panel
shall be placed inside a clear plastic envelope and stored in a suitable print pocket
or container inside each control panel.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING, - NOT USED
1.05 SPECIAL PROJECT CONSIDERATIONS
A. Site Conditions
1. The equipment furnished under this section shall be installed at the locations
indicated on the Drawings or as specified herein. The ambient temperatures are
expected to range between 40 degrees F and 100 degrees F with relative humidity
that varies between 10 and 100 percent.
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2. All equipment shall be of high quality designed for use in a rigorous industrial
environment. Electrical enclosures, conduit fittings, and related components for
locations subject to immersion (including pipe trenches) shall be rated NEMA 6
as a minimum.
B. Scheduling
1. The Installation Contractor will consult with the ICSS, MFEM and other primary
equipment sub-vendors required to meet provisions of this section and integrate
key activities in the base line schedule for each. The MFEM shall prepare an
initial schedule for work required for the MF system. Specific activities shall be
included for the following:
a.
b.
C.
d.
e.
f.
g.
h.
i.
Design activities, to include production of panel layouts, wiring diagrams,
loop diagrams, and other system development tasks.
Specific submittals for panels not furnished with other identified equipment
packages.
Dates for factory tests-both UFT and FDT-for all panels.
Proposed date for shipment of panels and other control system equipment to
the project site.
Installation activities.
Field testing activities, including the ORT and LFT.
Operations and maintenance manuals.
Coordination meetings.
Training.
C. Sequencing
1. Following is a list of activities with identified prerequisite activities which require
completion prior to completing the listed activity. No activity will be considered
complete until all identified prerequisite activities have been satisfactorily
completed.
a. Submittal Reviews by District
1) Prerequisites: Approval of Contractor’s base line schedule
incorporating required activities associated with the instrumentation
and control system.
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b. Panel Fabrication
1) Prerequisites: All associated shop drawings and equipment submittals
approved.
c. Factory Tests (UFT and FDT)
1) Prerequisites:
a) Factory test procedure approved.
b) Panel fabrication complete.
' c) Notice provided to District a minimum 14 days in advance.
d. Shipment to the Site
1) Prerequisites:
a) For components not involved in the UFT and FDT, all
associated shop drawings and equipment submittals must be
approved.
b) For components involved in the UFT and FDT, testing must be
complete and test reports accepted by the District.
2) System wide loop drawing submittal (see Section 13350) approved.
e. Installation
1) Prerequisites:
a) Field wiring diagrams for the applicable components must be
approved.
b) Manufacturer's O&M information for the applicable
components must be approved.
f. OR'I
1) Prerequisites:
a) Installation of the applicable components must be complete.
b) ORT procedure including forms and checklists approved.
g. LFT
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1) Prerequisites:
a) ORT complete and test reports and documentation accepted by
the District.
b) LFT procedure including forms and checklists approved.
h. Training
1) Prerequisites:
a) Training plan approved by District.
b) Applicable portions of the project O&M manual approved by
District.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Scope
1. Components of the instrumentation and control system shown on the drawing are
diagrammatic and supplemented by specific functional and performance
requirements specified.
2. The MFEM shall complete the design and furnish all components and services
necessary to achieve the specified functionality.
B. System Performance
1. Furnish all instrumentation and control fimctionality shown on the Drawings and
specified herein.
2. For the plant discrete and continuous process and process equipment variables,
provide measurement, monitoring and control.
3. Provide for the receipt of all status and alarm signals and furnish necessary
controls.
4. The system shall incorporate means for plant operators to control all equipment
and processes, both manually and fully automated.
5. Specific fimctional requirements shall be as shown on the P&IDs and control
diagrams, included with the loop functional descriptions in Section 13350, and
specified elsewhere.
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C. System Reliability
1. Arrange all system components for maximum reliability and safety.
2. All discrete alarms and control circuits shall be configured to “fail safe”.
3. Discrete and analog I/O shall be segregated on PLC cards by discrete process unit
where possible, such that loss of an individual card will not affect ongoing
operation of the entire treatment system.
4. Power supply to all PLC and supervisory control system components shall be
through an unintermptible power supply (UPS) system.
D. System Expandability
1. The system shall be designed for installation and operation of identified future
equipment items. Specific expansion allowances for individual control panels are
specified separately in Section 13325.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. General
1. Like equipment items used throughout the instrumentation and control system
shall be the product of a single manufacturer in order to achieve standardization
of appearance, maintenance, and replacement parts. All instruments which use a
common measurement principle (e.g., differential pressure transmitters, pressure
transmitters, dp type level transmitters) shall be furnished by a single
manufacturer. All instruments performing similar functions (e.g., pH, ORP, and
conductivity measurement) shall be of the same type, model, or series and shall
be from a single manufacturer.
2. All components proposed for use in the instrumentation and control system shall
be the end product of a manufacturer regularly engaged in the production of said
component for a minimum of five years.
3. All proposed components shall meet the requirements specified. All products
shall be new and in good condition. No product shall be selected for which there
is insufficient operating history (less than two years) in similar application, or for
which there is not a local service organization.
B. Signal Levels
1. Analog Devices:
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a. Analog signals shall vary in direct linear proportion to the measured
variable.
b. Electrical signals external to control panels shall be 4 to 20 mA dc. Signals
within control panels may be 1 to 5 volts dc.
c. Where available, transmitters shall be two-wire type powered by 24 VDC
loop power originating from the control panel. The use of four-wire devices
shall be minimized.
d. Analog Inputs:
1) Signal level to the PLC shall be an isolated 4 to 20 mA dc.
2) All instrument shields shall be terminated at the PLC control panel.
e. Analog Outputs:
1) Signal from the PLC panel shall be isolated 4 to 20 mA dc at 24 volts.
2) Signal power supply shall be from the PLC panel.
2. Discrete Devices:
a. Discrete control signals shall be 120 VAC, single phase, 60 Hz.
b. Discrete Inputs:
1) Signal level to the PLC shall be 120 VAC.
2) Signal power shall be from the PLC panel.
3) Status and alarm signals from external devices or control panels
reporting to PLC panels shall be isolated dry contacts.
c. Discrete Outputs:
1) Signal from the PLC shall be a dry contact.
2) If required to interface with the receiving device control circuits,
provide interposing relays with 120 VAC coil and contacts rated
minimum 10 amps at the interfacing voltage.
2.03 FACTORY TESTING
A. General
APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
1. All electrical panels furnished under this section or related equipment sections
shall be tested at the factory to demonstrate proper construction and operation
prior to delivery to the site.
2. No panel shall be shipped to the site without prior written authorization kom the
District. In addition, a complete factory test of the PLC control system, including
the supervisory control workstations, is required.
B. Unwitnessed Factory Test (UFT)
1. Each panel shall be tested at the factory by personnel of the panel fabricator
according to its approved procedure. Submit documentation of the completed test
to District with supporting forms and check lists. The test shall confirm the
following:
a. Proper construction and labeling in accordance with approved shop
drawings, including wiring.
b. Proper installation of all required components and accessories.
c. Verification of all point-to-point wiring and wire numbers between terminal
blocks and panel components in accordance with the approved panel wiring
diagram.
d. Proper functionality of all safety devices, such as circuit breakers.
e. Proper operation of all discrete control and alarm circuits.
f. For PLC panels, a complete check of PLC inputs and outputs, including
analog values at four points (4 mA, 8 mA, 12 mA, and 16 mA).
g. For PLC panels, proper register assignment of all points in accordance with
approved shop drawings.
h. For integrated tests, proper communication and operation in conjunction
with the supervisory workstation.
i. Other tests recommended by the fabricator for the specific panel.
C. Factory Demonstration Test
1. The FDT shall be witnessed by representatives of the District.
2. Each panel shall be tested by the fabricator at the place of manufacture unless
otherwise approved by the District.
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3. Tests shall be conducted in accordance with the approved procedure.
4. Two copies of all approved shop drawings and equipment submittals shall be
provided at the FDT for use by the District’s representative.
5. Minimum requirements for the test shall be demonstration of proper construction
and operations in accordance with specified requirements. The test may involve a
duplication of all or portions of the UFT at the District’s discretion. Specific
requirements are as follows:
a. All system hardware components shall be tested to verify proper operation.
Tests shall include, but not be limited to, the following:
1) ACDC power checks.
2) Power faillrestart tests.
3) Diagnostics checks.
b. Control panel and enclosure construction and wiring shall be checked to
verify compliance with Specifications and approved shop drawings.
Inspection shall include, but not be limited to, the following:
1) Nameplates and tags.
2) Wire sizes, color coding and numbering.
3) Terminal block layout, identification and allocated spares.
4) Proper wiring practices and grounding.
5) Enclosure flatness, finish, and color.
c. All PLC input/output devices shall be tested to verify proper operation and
basic calibration. Fabricator shall provide copies of signed and certified
check lists or other documentation from the UFT to demonstrate the
completion of I/O testing. A random sampling of I/O (both’digital and
analog), in an amount approximately equal to five percent of the total VO
count, shall be selected by the District’s representative and tested during the
FDT. PLC I/O testing shall include, as a minimum, the following:
1) Simulate a field digital input for each PLC input point at the terminal
strip of the control panel and verify PLC response.
2) Simulate a field analog input for each PLC analog input point at the
terminal strip of the control panel and verify PLC response.
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3) Force an output for each PLC digital output point and verify the
signal presence at the terminal strip in the control panel.
4) Simulate an analog output for each PLC analog output point and
verify signal presence at the terminal strip in the control panel.
d. PLC Ethernet communication, computer local area network, PLC remote
I/O, and serial communications shall be tested to verify communication
module operation and to verify that communication between units is
'operating properly. Remote I/O communications shall be tested by
simulating I/O at the remote rack and verifymg PLC processor response.
Data highway communications shall be tested by transferring blocks of data
to and from each station and verifying transmissiodreception.
e. Where required, an integrated system test between the PLC and supervisory
workstation with representative system equipment connected (excluding
field sensors and instruments) shall be performed to verify that all
equipment and software is performing properly as an integrated system. All
field connections should be capable of being simulated in the shop.
1) Demonstrate all system software utility and security programs
incorporated into the system to illustrate the various functions and
capabilities specified.
2) Demonstrate the operation of all PLC and workstation applications
software based on a simulation of approximately 25 percent of total
input/output count, both digital and analog, as selected by the
manufacturer. In addition, Engineer shall randomly select, at the time
of the test, additional inputs and outputs to be simulated in an amount
approximately equal to 5 percent of total input/output count.
Demonstration shaIl show that the monitoring and control application
software associated with the input/output points performs the
intended function.
3) Demonstrate software features illustrating the following:
a) Program generation.
b) Operating system commands.
c) Demonstrate generation of all system displays and reports.
d) Process alarming.
e) Historical data archiving and retrieval.
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4) Demonstrate all automatic control programs. All control programs
shall be tested to verify proper outputs are generated when process
inputs are simulated. Demonstrate that the graphic displays
accurately reflect the automatic control operations and simulated
inputs.
6. Test Report: At the conclusion of testing, the panel fabricator shall make
necessary corrections to panels and components and prepare a test report. Panel,
software and control component modifications and corrections required as a result
of testing shall be completed and documented before shipment of the panels.
Panels shall not be shipped from the factory until a certified factory test report
indicating satisfactory performance has been submitted to and approved by the
District. The report shall be signed and dated by an authorized representative of
the fabricator. Factory test reports shall include the following information:
a. List of tests performed.
b. Certified check lists or documentation verifying all I/O has been tested, as
specified above.
c. Documentation verifying all panel wiring has been checked.
d. List of required modifications or corrections identified during the FDT and
corrective action taken.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION - NOT USED
3.02 COMMISSIONING
A. Operational Readiness Test (ORT)
1. Following installation, the MFEM in coordination with the Installation
Contractor, equipment manufacturers and other system suppliers as appropriate
shall conduct the ORT to demonstrate the instrumentation and control system is
ready for operation. The District shall have the right to have a representative
present to witness all tests. Tests shall be conducted on a loop-by-loop basis
using approved forms and checklists. The ORT shall consist of the following:
a. Verification of Proper Installation
1) Each loop component shall be inspected for proper installation,
including conformance with approved shop drawings and installation
details.
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2) Wire numbers and terminations at each end shall be checked against
the approved field wiring diagram.
3) Continuity of all associated circuits shall be checked.
4) Power supply and polarity shall be checked against the approved loop
drawing. Analog wiring shall be checked for proper polarity and
ground continuity at each termination point in the loop.
5) Device tag numbers and model designation shall be checked against
the approved loop drawing.
b. Component Calibration: Calibrate or otherwise verify proper setting of all
components in conformance with the approved loop drawings.
For analog gauges, confirm span.
For transmitters, verify outputs at 0, 10, 50, 75, and 100 percent of
span, rising and falling.
For discrete switches, verify trip and reset points.
For indicators, verify readings at 0, 10, 50, 75, and 100 percent of
span, rising and falling.
For analytical instruments, calibrate in accordance with
recommendations of the device manufacturer using approved
standard solutions.
Perform a wet test of all leak detection sensors.
For potentiometers, confirm control at the local display at 0, 10, 50,
75, and 100 percent of span, rising and falling.
c. PLC Inputs and Outputs: Verify all signals to and fiom the PLC between the
field device and the workstation graphic display.
1) Switch all discrete input devices from the field.
2) Verify control voltage at the field terminals for all discrete outputs.
3) For analog inputs, force outputs from the field device at 0, 10,20, 75,
and 100 percent of span.
4) For analog outputs, force outputs from the PLC and verify signal at
the receiving device at 4 mA, 8 mA, 12 mA, 16 mA, and 20 mA.
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2. Test Reports: At the conclusion of the ORT, prepare a test report signed by the
MFEM, equipment vendors, and other suppliers as appropriate certifying
completion. Attach copies of all completed forms and checklists. The report
shall be organized in three ring binders (maximum 3-inches per binder) with an
index sheet and tabbed dividers for each loop.
3.03 OPERATOR TRAINING
A. General
1. The MFEM shall be responsible for providing and coordinating all required
training at times acceptable to the District.
2. For equipment items not manufactured by the MFEM, the Contractor shall
provide for onsite training by an authorized representative of the equipment
manufacturer. The manufacturer's representative shall be fully knowledgeable in
the operation and maintenance of the equipment.
3. All training shall be conducted in accordance with Section 01731.
B. Primary Sensors/Transducers and Field Instruments
1. Provide onsite operation and maintenance training prior to placing the equipment
in continuous operation. Training shall be provided for a minimum of four (4)
hours for each type of instrument provided.
2. Training shall accomplish the following:
a. Provide instruction covering use and operation of the equipment to perform
the intended functions.
b. Provide instruction on procedures for routine, preventive, and
troubleshooting maintenance, including equipment calibration.
c. Explain procedures for placing the equipment in and out of operation and
explain necessary actions and precautions to be taken.
C. Control Panels
1. Provide onsite operation and maintenance training prior to placing the control
panels in continuous operation. Training shall be provided for a minimum of eight
(8) hours for each PLC control panel and four (4) hours for each remaining panel.
Training on panels which are functionally duplicate may be limited to a single
panel of that type.
2. Training shall accomplish the following:
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a. Provide instruction covering the use and operation of the control panels and
all items contained on or within the control panels.
b. Provide instruction on procedures for routine, preventive, and
troubleshooting maintenance including component replacement.
c. Describe the control panel's operational and functional capabilities.
D. PLC Control System
1. Provide five (5) days of operations and maintenance training covering all system
components prior to the start of the system wide performance demonstration test.
2. The training course shall accomplish the following:
a. Provide all instructions necessary to operate and utilize all system
components. Include instruction on configuration of parameters, data base
organization, adjustment of primary control elements, and development of
control strategies.
b. Provide all instruction necessary to monitor and control the system
processes both locally and from the operator interface stations. Provide
instruction for both automatic and manual process control from the interface
stations, where appropriate.
c. Explain procedures for control of the system during scheduled or non-
scheduled shutdown and the subsequent start-up.
d. Describe the system's operational and functional capabilities and sequences.
e. Describe the preventive and troubleshooting maintenance for the PLC and
computer system components.
f. Explain the diagnostic capabilities of the system, both hardware and
software.
E. Supervisory Control System Software Training
1. Provide a standardized, structured training course at the District's facility.
2. The training session shall be staffed with instructors certified by the manufacturer.
3. The training course shall be a minimum period of five (5) days.
4. ' Course material shall include as a minimum:
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a. Database entry and modification.
b. Graphic display creation and modification including linking to VO.
c. Report creation and modification including real-time and historical reports.
3.04 ACCEPTANCE TESTING
A. Loop Function Test (LFT)
1. The purpose of LFT is to demonstrate the functionality of each control loop.
2. Loop functional requirements are set forth in Section 13350.
3. Testing shall be conducted on a loop-by-loop basis.
4. To the maximum extent possible, tests shall be conducted during equipment and
subsystem functional and performance test periods during actual operations.
Functions documented during the ORT do not need to be duplicated.
5. The testing shall be conducted in accordance with the approved test procedure.
6. Verification of Device Readings: The readings and measurements of all devices
shall be checked in the field and all associated graphical interfaces for
consistency, proper scaling, and units.
7. Verification of Device Accuracy: The measuring accuracy and calibration of
installed devices shall be verified during operation.
a. Flow meters shall be checked by comparing and balancing the total flow
between related devices. If an imbalance is detected and cannot be
definitively isolated and corrected by field inspection, the MFEM shall
procure the services of an outside testing agency to diagnose the problem.
b. Pressure measuring systems shall be checked by comparing readings of
analog and electrical devices where possible, or between corresponding
devices of the same type.
c. Analytical instruments shall be checked against readings of calibrated hand
held devices.
d. Level measuring systems shall be checked against visual readings where
possible.
e. Discrete devices shall be checked for proper actuation and reset under
operating conditions.
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8.
9.
10.
11.
12.
13.
14.
f. Controllers shall be checked for response, accuracy and stability.
Verification of Device Controls: The specified control functionality associated
with individual devices in both manual and automatic modes as specified shall be
confirmed. Associated graphic displays shall be observed and field inspections
made to verify proper response to requested control actions.
Verification of Operating Sequence Controls: The proper operation and execution
of all specified operating sequences (e.g., startup, shutdown, etc.) shall be
demonstrated. In most cases, this will require a coordinated test of multiple
loops. Each sequence shall be tested over various ranges and input conditions to
verify proper operation. Associated graphic displays shall be observed and field
inspections made to verify proper response to automatic control operations.
Verification of Shutdown Interlocks: All specified control interlocks between
devices and the operation or related equipment shall be demonstrated. Where
possible, an upset condition triggering the response shall be simulated on actual
process streams.
Verification of Alarm Handling: The proper system response to all alarms shall be
demonstrated. Alarm conditions shall be simulated in operating process devices
to the greatest extent possible. Proper alarm handling, including
acknowledgement and reset, shall be observed at all associated graphical
interfaces or other annunciation devices. In addition, the ability to configure
alarms shall be demonstrated where specified.
Verification of Data Handling: All historical data collection, trending,
computation, totalization, and reporting functions shall be checked and tested to
confirm proper operation and accuracy.
Verification of System Communications: Communications, including PLC data
highway, computer local area network, PLC remote I/O, and serial
communications shall be tested between all related components, including
existing equipment where required.
Test Reports: At the conclusion of the LFT, prepare a test report signed by the
MFEM, equipment vendors, and other suppliers as appropriate certifying
completion. Attach copies of all completed forms and checklists. The report
shall be organized in three ring binders (maximum 3-inches per binder) with an
index sheet and tabbed dividers for each loop.
+ + END OF SECTION + +
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SECTION 13325
CONTROL PANELS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. This section specifies requirements for project control panels as shown on the
Drawings and specified herein. The provisions of the section apply to all control
panels furnished, including those specified with individual equipment in other
sections unless specifically indicated otherwise in those sections.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC) - NOT USED
1.03 SUBMITTALS
A. Shop Drawings
1. Panel Construction Drawings: Submit drawings showing proposed construction
features of each panel. Include the following as a minimum:
a. A summary of panel construction features, including materials, gauge,
NEMA rating and other details.
b. Front, rear, end, plan and interior sub-panel views to scale. Scale shall be
identified on the Drawings.
c. Dimensional information.
d. Tag number and functional name of components mounted in and on panel,
console, or cabinet. Identify all terminal strips by assigned terminal strip
number.
e. A complete panel bill of materials correlated to item number call outs on the
construction drawings, listed with manufacturer and model information.
f. Product information on all panel components, as specified below,
g. Nameplate location and legend including text, letter size, and colors to be
used.
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h. Location of anchoring connections and holes.
i. Location of external wiring andor piping connections.
j. A description of panel finishes, wire color schemes, wire ratings, and wire
numbering and labeling scheme.
k. Mounting and installation details. Include drawings for support stanchions
or rack assemblies where required.
1. For panels with liquid sample tubing mounted on a common support
assembly, include scaled drawings showing all piping, tubing, valves,
sensors, and panel interface connections.
m. For panels with pressure instruments mounted on a common support
assembly or other devices requiring the routing and support of pneumatic
tubing, include scaled drawings showing the proposed tubing runs and
interconnections.
n. Heat calculations indicating conformance with cooling requirements of
installed devices based on specified environmental conditions.
2. Panel Wiring Diagrams: Submit drawings showing internal panel wiring and
designated terminals for connection to/from field devices. The drawings shall be
prepared in ladder diagram format, annotated by designated rung numbers. Scope
of the drawings shall be total and represent all devices installed or interconnected
to the panel. Show all circuits completely. No “typical” diagrams will be
excepted. Include the following as a minimum:
a. Clearly identify voltage across ladder rungs on each sheet. Reference all
continuations by sheet number and corresponding ladder rung number.
b. Show all wires and identify each by wire number and color. Include ground
wires.
c. Show all terminals discrete symbol and identify by assigned terminal strip
number and terminal block number. Indicate fused terminals by unique
designation and list the fuse rating.
d. Identify all devices by assigned name or identification number
corresponding to the panel construction drawings.
e. Clearly show and identify terminals for power entry and other connections
for field wiring terminations.
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f. Identify all external components which interface with the panel by tag
number and location (e.g., field, panel number, MCC number, etc.). Show
and identify terminals on each remote device.
g. Show the switching action of all discrete devices, including external
components.
h. For PLC panels, show all inputs and outputs to/from the modules. Identify
each point by PLC rack and slot number, YO tag number, I/O address, and
narrative descriptor (e.g., “Pump No. 1 Run”). For analog signals, indicate
the calibrated range of the associated transmitter or receiving device.
i. Identify all relay coils by assigned number and provide a narrative
descriptor of its function (e.g., “High Pressure Alarm Time Delay”). On the
right side of where the coil is located, list all associated contacts by rung
number of the corresponding contact is location. Reference numbers for all
normally closed contacts shall be underlined.
j. Identify all relay contacts by number of the associated coil, with multiple
contacts differentiated by alphanumeric suffix (e.g., CR-lA, CR-lB, etc.).
On the right side of where the contact is located, reference the coil location
by its associated rung number.
3. Equipment:
a. Submit clearly marked and annotated catalog information for all
components associated with each control panel, with the exception of
instruments specified under Section 13330 and PLC system components
specified under Section 13340.
b. Include the equipment information in the same submittal package as the
corresponding panel drawings.
c. Information submitted shall be sufficient to fully document compliance with
specified requirements.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Enclosures
1. Panel enclosures shall conform to the following environmental ratings unless
otherwise noted:
a. Outdoor Locations: NEMA 4X, Type 316 stainless steel.
13325.CONIROL PANELS.DOC 13325-3 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
b. Indoor LocationsProcess Area: NEMA 4X, Type 3 16 stainless steel.
c. Indoor Locations/Non-Process Area: NEMA 12 painted steel.
B. Device Ratings
1. Front of panel mounted devices shall meet or exceed the rating of the enclosure
on which they are installed.
2. Installation of the devices shall not compromise the rating of the enclosure as a
whole.
C. Power Supplies
1. All panels shall be designed to operate on 60 Hz alternating current power at a
nominal 115 volts *lo%, unless othenvise noted or shown.
2. If a different voltage or closer regulation are required by an installed device, a
suitable regulator or transformer shall be provided.
3. Where voltage regulation is required, constant voltage transformers shall be
supplied.
2.02 GENERAL
A. Panel Schedules
1. Panel schedules are included by system. See the individual system specifications
following Section 11300.
B. Nameplates
1. Furnish nameplates for all panels listing panel number and name as well as
individual nameplates for all panel external and internal devices, including
terminal strips.
2. All nameplates shall be 3/32-inch thick, black with white inscribed lettering of
laminated plastic material. Edges of the nameplates shall be beveled.
Nameplates shall be affixed directly to panel surfaces using stainless steel
machine screws. Adhesives are not allowed.
3. Nameplate size and configuration shall conform to the following:
a. Panel nameplates shall have minimum 1/2-inch high lettering with two lines
corresponding to panel number and name.
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b. Nameplates for front of panel mounted devices shall have minimum
dimensions of 1-inch x 2-1/2 inches with 3/16-inch lettering.
c. Nameplates for internal panel components shall have minimum 3/16-inch
high lettering.
4. Inscriptions for nameplates shall be as shown on approved shop drawings.
C. Standard Pushbutton and Light Colors
1. Lens and pushbutton face colors shall conform to the following:
a. RED for ‘‘RUN”, “OPEN”, “ON”, “START”, “HIGH’, or other similar.
b. GREEN for “STOP”, “CLOSED, “OFF”, “LOW’ or other similar
c. AMBER for alarm.
d. BLACK for reset.
D. Mechanical Systems
1. Components of panel assemblies associated with bypass sample lines for process
stream analyzers shall be as shown on the Drawings and specified under
applicable sections of Division 15.
2. Mechanical systems associated with the installation of individual instrumentation
systems shall be as specified in Section 13330.
2.03 PANEL HARDWARE COMPONENTS
A. General
1. Certain panel face mounted and accessory devices are identified by unique
component code alphanumeric tags for cross-reference in other portions of the
specifications.
B. Pushbutton/Switch/Light, WatertightlOiltight
1. Component Code: CPl
2. Function: Provide interface for operator indicated on the Drawings or specified
herein.
3. Type:
a. Rating: NEMA 4 (watertight) and NEMA 13 (oil tight),
1332S.CONIROLPANELS.DOC 13325-5 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
b. Size: 30mm.
c. Configuration: Light, pushbutton, or selector switch as indicated on the
Drawings or noted herein.
4. Pushbuttons:
a. Type: Non-illuminated, full guard with flush button.
b. Configuration: As shown on the Drawings or noted herein.
5. Selector Switches:
a. Type: Black non-illuminated standard knob on switch, manual return unless
otherwise noted.
b. Configuration: As shown on the Drawings or noted herein.
6. Lights:
a. Type: Push-to-test transformer, 50/60 Hz.
b. Lamp: 6 VAC, 150 mA for operation form 120 VAC.
c. Lens Color: As required.
7. Contact Blocks:
a. Rating: 10 amps continuous at 120 VAC.
b. Arrangement: NONC as required to perform the specified function.
c. Terminals: Screw type with strap clamp,
8. Manufacturer:
a. Allen Bradley, Bulletin 800H;
b. Square D, Class 9001, Type K,
c. Or equal.
C. PushbuttodSwitchnight, Corrosion-Resistant
1. Component Code: CP2.
13325.CONTROLPANELS.DOC 13325-6 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
2. Function: Provide interface for operator indicated on the Drawings or specified
herein.
3. Type:
a. Rating: NEMA 4X (corrosion resistant).
b. Size: 30mm.
c. Configuration: Light, pushbutton, or selector switch as indicated on the
Drawings or noted herein.
4. Pushbuttons:
a. Type: Non-illuminated, full guard with flush button.
b. Configuration: As shown on the Drawings or noted herein.
5. Selector Switches:
a. Type: Black non-illuminated standard knob on switch, manual return unless
otherwise noted.
b. Configuration: As shown on the Drawings or noted herein.
6. Lights:
a. Type: Push-to-test transformer, 50/60 Hz.
b. Lamp: 6 VAC, 150 mA for operation form 120 VAC.
c. Lens Color: As required.
7. Contact Blocks:
a. Rating: 10 amps continuous at 120 VAC.
b. Arrangement: NO/NC as required to perform the specified function.
c. Terminals: Screw type with strap clamp.
8. Manufacturer:
a. Allen Bradley, Bulletin 800H;
b. Square D, Class 9001, Type SK,
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c. Or equal.
D. Potentiometer
1. Component Code: CP3.
2. Function: Adjust analog set point.
3. Type: Heavy-duty, corrosion-resistant, industrial.
4. Performance
a. Resistance: 5,000 ohms, unless otherwise noted.
b. Resolution: 1 percent.
c. Linearity: Plus or minus 5 percent.
d. Dissipation: 2 watts, unless otherwise noted.
5. Features
a. Mounting: 30.5 mm single round hole. Panel thickness 1/16-inch to
1/4-inch.
b. Dial Plate: Standard size square style laminate field and white markings,
unless otherwise noted.
c. Scale: 0 to 100 percent, unless otherwise noted.
d. Terminals: Screw with strap clamp.
6. Signal Interface: Three-wire.
7. NEMA Rating: NEMA 4X, watertight and dusttight.
8. Manufacturers:
a. Allen-Bradley, Bulletin 800H;
b. Square D Co., Class 9001, Type SK;
c. Or equal.
E. Digital Indicators
1. Component Code: CP4.
I3325.CONTROLPANELS.DC 13325-8 APRIL 27,2001
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2. Function: Display analog process input in engineering units
3. Type: Minimum 6 digit LCD display, heavy-duty, corrosion-resistant, industrial
suitable for panel mounting.
4. Performance
a. Voltage Drop: 2.5 V maximum.
b. Maximum Error: +O. 1 percent of reading.
c. ReadRate: 2.51s.
d. Input Resistance: 12.5 ohms at 4 - 20 mA.
5. Features
a. Mounting: Rectangular cutout, 1.77-in x 3.62-in. Panel thickness 1/16-inch
to ll4-inch.
b. Display:
1) Type: 7-segmnet LCD.
2) Height: 0.50-in.
3) Symbols: 3-112 active digits plus two jumper-selectable dummy right
hand zeros.
4) Decimal Points: Five positions, jumper selectable.
5) Overrange Indication: Three least-significant active digits blink.
c. Scale: In engineering units noted.
d. Terminals: Plug in screw-clamp connector.
6. Signal Interface: Two-wire.
7. Power Supply: Not required; power from input 4 - 20 mA input.
8. NEMA Rating: NEMA 4, watertight and dusttight.
9. Manufacturers:
a. Precision Digital, Model PD697;
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b. Or equal.
F. Rotary Manual Disconnect Switches
1. Component Code: CP5.
2. See Section 16100 for requirements.
G. Power Supplies
1. Function:
a. Convert 120 VAC, 60 Hz power or other supply as noted or specified into
appropriate AC or DC voltage required by devices.
b. Provide sufficient voltage regulation such that power to devices is within
their required tolerance(s).
2. Protective Circuits:
a. Provide over-voltage and over-current protection to protect power supply
and powered devices from outside component failure.
3. Rating of Power Supply Enclosure: NEMA 1
4. Size: As required for driven devices, plus 20 percent spare capacity.
5. Mounting:
a. Install within applicable control enclosure on suitable interior panel.
b. Locate within panel such that dissipation of heat from the power supply will
not adversely affect other panel components.
6. Circuits:
a. Provide an individual fuse for the ac or dc supply line to each component.
b. Fuses shall be indicating type, mounted for easy observation and
replacement.
7. Performance Requirements:
a. Overload Protection: Minimum 120% with auto reset.
b. Eficiency: 85 percent minimum.
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c. Line Regulation: 0.4 percent maximum.
d. Load Regulation: 1.5 percent maximum.
e. Output Ripple: Maximum 2 percent peak-to-peak.
f. Ambient Operating Temperature Range: -10 "C to +60 "C.
8. Manufacturer:
a. Idec, Model PS5R-E24;
b. Or equal.
H. Terminal Blocks
1. General:
a. Mount terminal blocks in segregated strips on standard DIN rail with copper
or treated brass current bar.
b. Identify individual terminal strips by identification tag, white lettering on a
black background, with the number shown on approved shop drawings.
c. Identify individual terminal blocks on each side by adhesive markers, white
lettering on black background, with numbers corresponding to approved
shop drawings.
d. Provide end stops at each end of the rail.
e. Connections shall be screw type connection clamp.
2. General Purpose Terminal Blocks:
a. Rating: 600 VACNDC, 30 A.
b. Maximum Wire Size: No. 10 AWG.
c. Color: Grey.
d. Manufacturer: Entrelec, Type M4/6.T; or equal.
3. Fused Terminal Blocks - 24 VDC
a. Rating: 600 VDC, 10 A.
b. Maximum Wire Size: No. 12 AWG,
I332S.CONTROLPANELS.WC 13325-11 APRIL 27,2001
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c. Color: Grey.
d. Indication: LED diode.
e. Manufacturer: Entrelec, Type M4/8.SFDT; or equal.
4. Fused Terminal Blocks - 120 VAC
a. General Service:
1) Rating: 600 VAC, 16 A.
2) Maximum Wire Size: No. 12 AWG.
3) Color: Grey.
4) Indication: Neon lamp.
5) Manufacturer: Entrelec, Type M4/8.SFLT; or equal.
b. High Current:
1) Rating: 600 VAC, 35 A.
2) Maximum Wire Size: 8 AWG.
3) Color: Grey.
4) Manufacturer: Entrelec, Type MB10/24.SF; or equal.
5. Signal Metering Terminal Blocks
a. Rating: 300 VAC at 4 A.
b. Maximum Wire Size: No. 12 AWG.
c. Test Socket: Configured for current monitoring test plug.
d. Test Plug: Configured for interconnection of terminal block and test meter.
e. Manufacturer: Entrelec, Type M4/6.ST.AU with Type BNT3 plug; or
equal.
6. Ground Terminal Blocks:
a. Rating: 600 VACNDC, 30A.
13325.CONTROLPANELS.DC 13325-12 APRIL 27,2001
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b. Maximum Wire Size: NO. 12 AWG.
c. Color: Green and yellow.
d. Manufacturer: Entrelec, Type M4/6.P; or equal.
I. Circuit Breakers
1. General:
a. Provide circuit breakers where noted or required.
b. Identify circuit breakers by identification tag, white lettering on a black
background, with the number shown on approved shop drawings.
2. Type: Molded case.
3. Mounting: DIN Rail.
4. Amperage Rating: As required.
5. Number of Poles: 1.
6. Short Circuit Capacity: 10,000 amps LC. minimum.
7. Manufacturer:
a. Cutler Hammer, Type QC;
b. Or equal.
J. Analog Signal Isolators
1. General: Provide where shown or where required to provide analog signal
isolation between system components.
2. Type: Isolated dc current transmitter.
3. Enclosure: Hermetically sealed.
4. Power Supply: 24 VDC; 3 watts maximum.
5. Mounting: DIN Rail.
6. Accuracy: Factory calibrated for fO.l percent of span.
7. Isolation: 1 kV peak-to-peak, minimum.
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8. Hysteresis: 0.10 percent maximum.
9. Ambient Operating Temperature Range: -20 "C to +60 "C.
10. Manufacturer:
a. AGM Electronics, Model DIN 4000;
b. Or equal.
K. Relays
1. General:
a. Provide relays where shown on the Drawings or specified herein; or where
required for signal switching (e.g., interposing relays).
b. Identify relays by identification tag, white lettering on a black background,
with the number shown on approved shop drawings.
c. All relays shall have integral neon or LED type indicator lamps to signal
when the relay is energized.
2. Mounting:
a. All relays shall be plug-in socket type with dust covers.
b. Socket base shall be standard rail mount retained by clips.
3. Control Relays:
a. Coil Voltage: As noted or shown on approved shop drawings.
b. Contacts:
1) Type: Form C, dry type, DPDT minimum.
2) Control Circuit Relays: Silver cadmium oxide contacts rated 10 A at
120 VAC.
3) Electronic Switching Duty Relays: Gold plated or gold alloy contacts
suitable for use with low level signals.
4) Other: Relays used for PLC input, alarm input, or indicating light
service shall have contacts rated not less than 3 A.
13325.CONTROLPANELS.LXX 13325-14 APRIL 27,2001
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c. Latching and special purpose relays shall be as required for the specific
application.
d. Manufacturer: Releco, Series RH; or equal.
4. Time Delay Relays
a.
b.
C.
d.
e.
f.
g.
Type: Adjustable time delay.
Control: Potentiometer knob mounted on dust cover.
Range: Provide multi-range type to allow adjustment over 4 separate time
ranges, minimum.
Coil Voltage: As noted or shown on approved shop drawings.
Timing Repeatability: lt2% of setting.
Contacts: 2 Form C, minimum, rated 4A at 250 VAC.
Manufacturer: Idec, Series GT3F; or equal.
2.04 PANEL FABRICATION
A. General
1. Assemble all control panels at the MFEM’s facility. No fabrication or installation
of components other than correction of minor defects or transit damage shall be
allowed at the site without express written approval of the District.
B. Panel Interior Arrangement
1. Size and mange all panel internal equipment, including wiring duct, receptacles,
lights, and PLC components to allow sufficient space for conduit entry and
routing of internal panel wiring, including field wiring.
2. In no case shall variance from specified panel wiring requirements be permitted
due to insufficient space in panels.
C. Panel Heat Dissipation
1. Design panels to adequately dissipate heat generated by internal components such
that a threshold limit of 80 percent of the maximum allowable operating
temperature of any component is not exceeded during continuous operation at the
worst case ambient temperature and humidity conditions specified.
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2. Freestanding panels of NEMA 12 construction may incorporate fans and louvers
for the dissipation of heat.
3. Free standing panels of NEMA 4X construction shall be sized to adequately
dissipate heat or provided with heat dissipation facilities which maintain the panel
rating.
4. Non-freestanding and frame mounted panels shall be sized to adequately dissipate
heat.
D. Panel Finishing
1. Type 3 16 stainless steel panels shall not be coated.
2. Other panels shall be coated as specified in Section 09900. External surfaces
shall be gray. Internal surfaces shall be white.
E. Freestanding Panel Construction
1. Panel rating and materials shall be as required by panel location under Article
2.01-A herein unless otherwise specified.
2. Fabricate panel fronts from a single piece of sheet metal, without visible welds,
seams or bolt heads. Provide stiffeners as required to prevent deflection under
load of front-of-panel mounted devices. All cutouts shall be smoothly finished
with edges rounded.
3. The panel interior framework shall consist of structural members matching the
panel materials of construction, designed to permit lifting of the assembled panel
without excessive deflection or distortion.
4. Lifting rings shall be provided to allow simple, safe rigging and lifting of panel
during installation.
5. Doors shall be full height, fully gasketed type in accordance with the NEMA
rating of the panel, with continuous piano type hinges. Doors shall be sized and
configured such that when fully open, they extend no further than 36-inches
beyond the panel face in the 90 degree open position.
6. A sufficient quantity of interior panel lights shall be provided to illuminate all
components, but no less than one light for every four feet of panel width. Lights
shall be switched fluorescent type with cover, 40 watts maximum.
7. . Provide duplex utility receptacles, one for every four feet of panel width but no
less than two per panel. Receptacles shall be 3-wire type rated 120 VAC, 15A.
13325.CONTROLPANELS.WC 13325-16 APRIL 27,2001
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MF EQUIPMENT PROCUREMEN?
8. Additional Components:
a.
b.
C.
d.
e.
f.
g.
h.
Control power circuit breakers.
Terminal smps for all wiring entering and exiting control enclosure.
PLC with power supply, I/O modules, memory and accessories required to
operate the system.
Power supplies as required for analog monitoring and/or control loops.
Control and time delay relays.
Analog signal isolators.
Pushbuttons.
Lamps.
F. Non-Freestanding Panel Construction
1. General: Where listed or not otherwise specified, provide enclosure mounted on
aluminum channel support frame or related equipment support frame (for panels
supplied integral to equipment mounting skids). External frames constructed of
steel or galvanized steed channel and plate and/or unistrut-type support members
will not be permitted.
2. Support Frame:
a.
b.
C.
d.
Frame shall be constructed of aluminum channel (4 x 2.16), with welded
aluminum plate (minimum 1R-inch thick) for anchorage to the concrete
equipment pad.
Enclosures having a frontal area not greater than 2 feet square shall be
pedestal mounted, with the enclosure attached to a welded aluminum flat
panel (minimum ll4-inch thick).
Enclosure centerline shall be 3 feet above the operating floor.
Fasteners shall be Type 316 stainless steel, with split-lock washers under all
nuts.
3. Enclosure:
a. Panel rating and materials shall be as required by panel location under
Article 1.03-A herein unless otherwise specified.
13325.CONTROLPANELS.lXK 13325-17 APRIL 27,2001
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b. Metal thickness shall be 14-gauge, minimum.
c. Doors shall rubber-gasketed with a continuous piano type hinge meeting the
requirements of specified panel NEMA rating.
d. Manufacturers:
1) Rittal;
2) Hoffman;
3) Or equal.
2.05 PANEL WIRMG
A. General
1. Wiring methods and materials for all panels shall be in accordance with NEC
requirements for General Purpose (no open wiring) unless otherwise specified.
2. All wiring shall be arranged to allow for adequate component access for testing,
removal, and maintenance.
3. All wiring shall be routed in plastic ducts to the greatest extent possible. Where
the use of duct is not feasible, wires shall be grouped in neat bundles using nylon
wire ties. Tied bundles shall be secured using adhesive mounts.
4. All wiring shall be arranged neatly, cut to the proper length, with surplus wire
removed.
5. Provide support and abrasion protection for all wires at panel hinge points, cut
opening, or exposed metal surfaces. At panel hinges, secure wire bundles at both
sides to form a hinge loop, such that the conductors are not strained at the
terminals through the full range of motion.
6. Splicing of wires between terminal blocks is not permitted.
7. All external wiring shall interface to internal devices via terminal strips. Direct
wiring to device terminals is not allowed.
8. Terminal blocks for all 24 VDC circuits (including analog circuits) shall be
located on a dedicated terminal strip separate from all 120 VAC circuit terminal
blocks. All associated 24 VDC wiring shall be separated from 120 VAC wiring
by at least 6-inches.
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9. All circuits powered from sources external to the panel shall be terminated from
the field on a dedicated terminal strip separate from other panel circuits. On the
panel .face, provide a nameplate inscribed “CAUTION - FOREIGN VOLTAGE
PRESENT” or other similar to alert operators that disconnection of the main
panel power supply will not de-energize all panel circuits.
10. For case grounding, all panels shall be provided with a 1/4-inch by 1-inch copper
ground bus complete with solderless connector for one No. 4 AWG bare stranded
copper cable for interconnection to the system ground loop.
B. Power Distribution
1.
2.
3.
4.
5.
6.
Make provisions for the proper entry of all conduits associated with panel feeder
circuits.
Provide an externally operable disconnect for all primary supply circuits. Where
noted or where required to comply with NEC requirements based on installed
device locations, the disconnect shall be a lockable rotary manual type interlocked
with the panel access handle.
Furnish a separate terminal strip and dedicated terminals for all feeder circuit
wires.
Provide a main circuit breaker and separate circuit breakers on all branch circuits
from each power supply. Coordinate the size of breakers such that a fault in any
single branch circuit will only trip the branch breaker but not the main.
Devices fed from the same panel and associated with a single unit, train, or
subsystem (e.g., a chemical feed system) may be connected to a single branch
circuit, provided that no more than 20 devices are fed ftom a single circuit and the
overall branch circuit loading does not exceed 10 amps. Common items not
associated with any individual unit process or subsystem may be connected to a
single branch circuit subject to the above provisions.
All individual supply circuits to devices mounted external to the panel shall be
fused at the panel.
C. Wire Type and Sizes
1. All conductors shall be flexible stranded copper machine tool wire (UL listed
MTW) rated 600-volts.
2. General circuit wire shall be twisted pair or triads constructed of No. 16 AWG
signal wires with THWN or THHN insulation.
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3. Wiring for analog circuits shall be twisted shielded pairs constructed of No. 16
AWG signal wires and a copper drain wire for the bundle provided with a wrap of
aluminum polyester shield. The overall bundle jacket shall be PVC.
4. For special signal circuits use manufacturer’s standard cables.
D. Wire Insulation Colors
1. Wires supplying 120 VAC power on the line side of a disconnecting switch shall
have black insulation for the ungrounded conductor and white insulation for the
grounded conductor.
2. Wires supplying 120 VAC power to devices on the conditioned supply shall have
red insulation, with white insulation on the neutral and green insulation on the
ground.
3. All wires energized by a voltage source external to the control panel shall have
yellow insulation.
4. Insulation for all 24 VDC circuits shall be blue.
E. Wire Marking
1. All wires shall be marked at each termination with their designated wire number.
2. Wire markers shall be standard commercial type made from plastic coated cloth
(Brady, Type B500, or equal) or heat shrink plastic with machine printed
markings and numbers.
F. Terminations
1. Provide the necessary number of terminals to terminate all internal and external
panel circuits along with 25 percent spare terminals on each terminal strip for the
termination of future conductors.
2. Wire all spare or unused panel elements to terminal blocks.
3. Install only one wire per terminal. At connections to screw type terminals,
locking-fork-tongue or ring-tongue lugs may be used. Manufacturer
recommended tools shall be used to make all crimp lug terminations. Only one
wire shall be terminated in a crimp lug. Up to two lugs may be installed on a
screw terminal.
G. Special Requirements for PLC Panels
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1. Provide separate feeder circuits for UPS and unconditioned supplies. Use
unconditioned power for panel receptacles and lights. Use WS power for all
other internal and external electrical devices powered from the panel.
2. All devices associated with the PLC shall be powered from a dedicated branch
circuit.
3. Provide a minimum of 16-inches of space for cable entry at the top or bottom of
the panel, depending on location of conduit entry. The space allowance shall
extend the full width of the enclosure and shall be free of all wire duct, terminals,
or other devices.
2.06 SPARE PARTS AND MAINTENANCE EQUIPMENT
A. For each panel, fumish the following in accordance with the requirements of Section
01750:
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Scope
1. The MFEM shall supply all specified MF system panels.
2. Panels not integral to equipment skids provided by the MFEM will be installed by
the Installation Contractor.
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B. Installation
1. Mounting Locations:
a. Select final mounting locations to provide a clear view of all panel mounted
indicators, lights, and displays.
b. All panels shall be fully accessible for routine maintenance of associated
devices.
c. All panel doors shall open freely without impediment. Panel locations shall
not hinder access to other equipment or devices, nor obstruct walkways.
C. Instrumentation Tubing
1. Tubing shall be Type 316 stainless steel seamless. The use of plastic tubing will
not be allowed.
2. Differential pressure transmitters shall be connected with 1/2-inch 0.d. by 0.049-
inch wall tubing. All other tubing shall be I/4-inch 0.d. by 0.035-inch wall
tubing.
3. Tubing runs shall be neatly installed on horizontal and vertical alignment. All
bends, where possible, shall be 90 degree angles. Multiple runs of tubing shall be
properly supported with standard commercial spacers such that the tubing runs
are in the same plane and uniformly spaced. The maximum distance between
supports shall be five feet.
4. Tubing runs to differential pressure transmitters shall continuously slope upward
to the pressure taps on the process piping. High points in these tube runs will not
be allowed.
5. All tubing fittings shall be stainless steel double fermle type, Swagelok or equal.
6. Pipe threads shall be used only where absolutely necessary. Pipe thread joints
shall be made up with Teflon tape.
3.02 WIRING
A. All wiring shall be installed as specified herein and other applicable sections of
Division 16.
+ + END OF SECTION + t
I332S.CONTROLPANELS.DC 13325-22 APRIL 27,2001
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SECTION 13330
INSTRUMENT SPECIFICATIONS
PART 1 - GENERAL
1.01
A.
B.
C.
DESCRIPTION
Description of Work
1. This section specifies requirements for project instruments and related devices.
Coordination
1. Instruments are identified in this section by name and unique component code
alphanumeric tags for cross-reference in other portions of the specifications.
Special Considerations
1. Device Ratings:
a. Electrical compartments on all devices shall be rated NEMA 4X as a
minimum.
b. All components which will be installed beneath pipe trench grating or other
areas subject to incidental submergence shall be rated NEMA 6 as a
minimum.
c. Devices installed in control panels shall not reduce the associated NEMA
rating for the panel.
2. Signal Interference:
a. Devices will be installed in an environment subject to high ac energy fields,
dc control pulses, and varying ground potentials between instruments and
other system components.
b. Instruments shall be selected and installed to provide suitable protection
against potential sources of interference.
3. Materials:
a. All field-mounted instruments, related components, and accessories shall be
designed for installation in a humid, corrosive environment.
13330.MSTRUMENT SPECIFICATIONS.DC€ 13330-1 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
b. Where not otherwise specified:
1) Metal components shall be Type 316 stainless steel.
2) Elastomeric components shall be EPDM.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC) - NOT USED
1.03 SUBMITTALS
A. Shop Drawings
1. For each component, submit manufacturer’s catalog information in sufficient
scope to document compliance with the requirements specified along with
external power and signal connections.
2. Include information on all components furnished under this section in a single
submittal. Organize the information in a D-ring binder, with separate tabbed and
indexed dividers for each component.
3. Catalog information shall be preceded by an ISA data sheet as specified.
4. Include information on the data sheet not evident in the manufacturer’s literature,
including individual device tag numbers, specific model numbers for multiple
devices, ranges, setpoints, etc. List also the name, address, and telephone number
of the manufacturer’s local service organization.
PART 2 - PRODUCTS
2.01 ANALYTICAL INSTRUMENTS
A. Turbidity Analyzer and Transmitter
1. Component Code: A1 .
2. Function:
a. Measure and indicate locally the turbidity of a continuous process sample
stream.
b. Transmit measured signal to designated PLC panel.
3. Operator Interface Module:
a. Type: Multichannel.
b. Display: Digital, eight character.
1333O.MSTRUMENI SPECIFICATI0NS.wC 13330-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
C. Keypad: Tactile, capable of performing parameter adjustment and system
diagnostics.
d. Output Signal: Linear, 4-20 mA dc.
e. Number of Outputs: 1.
f. Alarm Relays: When noted or shown:
1) Number: Two set point alarms, instrument warning and system shut
down, adjustable to any point within the measured range.
2) Form: SPDT, dry type.
3) Rating: 5 A resistive at 230 VAC.
g. Enclosure Class: NEMA 4X, plastic.
h. Power Supply: 120 VAC, 60 Hz
4. Turbidimeter Body with Sensor:
a. Style: Flow through with integral bubble trap.
b. Features:
1) The sensor shall use the nephelometric method of measurement and
utilize a single photocell to detect 90 degree scattered light.
2) A tungsten-filament light source operating at a color temperature of
approximately 2700" Kelvin shall be used.
3) Light shall be directed through the surface of the water sample and
the detector shall be immersed in the sample, eliminating the use of a
glass window or flow cell.
4) Optical components shall be mounted on a head assembly which can
be removed easily for servicing without disturbing sample flow.
c. Input Conditioning:
1) Bubble Rejection Circuit: Provide an adjustable sampling circuit to
eliminate spikes in measurement due to transient sample conditions.
2) Pure Water Offset: The instrument shall be capable of offsetting the
measured turbidity of pure, particle f?ee water to 0.000.
1333O.MSTRUMPITSPECIFICATIONS.DOC 13330-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUrPMENT PROCUREMEM
5. Power Supply: Remote, 25 watts output from 95 - 240 VAC input.
6. Performance Characteristics:
a.
b.
C.
d.
e.
f.
g.
h.
Range: 0.001-100 NTU.
Accuracy: *2% of reading or +0.020 (whichever is greater), 0 - 40 NTU;
+5% of reading, 40 - 100 NTU
Resolution: 0.001 NTU.
Repeatability: Better than 0.002 NTU.
Response Time: Initial response in 1 minute, 15 seconds at 500 mL/min
flow rate.
Sample Flow Range: 250 - 750 mL/min, 4.0 - 11.9 gph.
Operating Temperature: 0 to 40 "C (32 - 104 OF).
Signal Averaging: User selectable over a 6,30,60,90 second period.
7. Accessories:
a. Interconnecting Cables: Furnished by manufacturer in lengths to suit device
locations.
b. External Bubble Trap: Furnish where indicated on the Drawings.
c. Calibration: Furnish one Formazin Calibration Kit for use with all installed
units, consisting of calibration cylinder, pipet, and 500 mL bottle of stock
formazin solution.
d. Mounting: Furnish accessories required fo,r panel mounting. All external
supports and fasteners shall be Type 316 stainless steel.
8. Manufacturers:
a. Hach, Model 1720D;
b. Or equal.
B. Conductivity Analyzer and Transmitter
1. ' Component Code: A2.
2. Function:
13330-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Measure and indicate locally the conductivity and temperature of a
continuous process sample stream.
b. Transmit measured signal(s) to designated PLC panel.
3. Transmitter/Control Unit:
a. Type: Single channel.
b. Display: Digital, four digit dot matrix LCD, blue on gray-green. Include
simultaneous display of conductivity, temperature, current output and alarm
setpoints. Provide separate dedicated LEDs for each alarm relay.
Conductivity output shall be in the engineering units noted.
c. Keypad: Tactile membrane type, capable of performing parameter
adjustment and system diagnostics.
d. Output Signals: Linear, galvanically isolated 4-20 mA dc into 600 ohms
maximum load.
e. Number ofoutputs: 2.
f. Alarm Relays: Where noted or shown:
1) Number: Three set point process alarms adjustable to any point
within the measured range (one process alarm shall be configurable
as a timer to allow indication for periodic maintenance). One fault
alarm.
2) Form:
a) Process Alarms: Epoxy sealed form A, SPST, normally open.
b) Fault Alarm: Epoxy sealed form C, SPDT.
3) Rating: 5 A resistive at 230 VAC.
g. Signal Conditioning:
1) Hold Output Mode: Hold the current output at a preset or last
measured process value to allow routine sensor maintenance.
2) Temperature Compensation: Provide 0-5%/"C temperature slope
adjustment. The control unit shall automatically calculate the
temperature slope for any given solution, or permit manual
adjustment of the temperature slope if already known.
I333O.lNSTRuMENT SPECIFICATIONS.DOC 13330-5 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
3) Cell Constant Variation: The control unit shall automatically
correct for cell constant variations for better measurement accuracy.
h. Enclosure Class: NEMA 4X, epoxy coated cast aluminum
i. Power Supply: 120 VAC, 60 HZ,
4. Sensor Type 1 -High Range:
a. Style: Submersiodinsertion screw-in.
b. Features:
1) Type: Inductive (toroidal)
2) Cell Constant: 3.0/cm (typical).
3) Full Scale Range:O - 2,000,000 pS/cm.
4) Temperature Sensor: Integral Pt 1000 RTD
5) Materials of Construction: Polypropylene.
6) Operating Temperature: To 230°F.
7) Process Connection Type: 5/8"-11 UNC thread with EPDM gasket
for use with mounting adapter.
8) Mounting Adapter: PEEK conduit adapter with Type 304 SST nut
and 1-1/2" MNPT Type 316 SST process connection.
c. Power Supply: From transmitter/control unit.
5. Sensor Type 2 - Low Range:
a. Style: Submersiodinsertion screw-in.
b. Features:
1) Type: Contacting.
2) Cell Constant: O.l/cm.
3) Full Scale Range: 500 pS/cm.
4) Temperature Sensor: Integral Pt 1000 RTD.
13330.INSTRUM~SPECIRCATIONS.DOC 13330-6 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
5) Materials of Construction:
a) Electrode: Titanium palladium.
b) Process Connector: Stainless steel.
c) Insulator: PEEK.
d) Process Seals: EPDM.
6) Operating Temperature: To 2 12'F.
7) Process Connection Type: 3/4" MNPT Type 3 16 SST.
c. Power Supply: From transmitter/control unit.
6. Performance Characteristics:
a. Range:
1) Conductivity: As noted.
2) Temperature: 5 - 392 OF.
b. Accuracy: i0.5% of reading.
c. Stability: *0.25% of output range/month, non-cumulative.
d. Repeatability: i0.25% of reading.
e. Ambient Temperature Coefficient: *0.01% of readingPC.
f. Temperature Compensation: -15 to 200 "C (automatic or manual).
7. Accessories:
a. Interconnecting Cables: Furnished by manufacturer in lengths to suit device
locations.
b. Calibration: Provide 500 mL each of stock standardizing solutions for
conductivities of 10 pS/cm, 200 pS/cm, 2,000 pS/cm and 20,000 pS/cm.
c. Mounting: Furnish accessories required for panel mounting. All external
supports and fasteners shall be Type 316 stainless steel. If required, furnish
gasketing or panel window kit to maintain the NEMA rating of the panel.
8. Manufacturers:
13330.MSTRLMENT SPECIf1CATlONS.DOC 13330-7 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Rosemount:
1) Transmitter Control Unit: Model 54C.
2) Type 1 Sensor: Model 228.
3) Type 2 Sensor: Model 400.
b. Or equal.
C. pH Analyzer and Transmitter
1. Component Code: A3.
2. Function:
a. Measure and indicate locally the pH and temperature of a continuous
process sample stream.
b. Transmit measured signal(s) to designated PLC panel.
3. Transmitter/Control Unit:
a.
b.
C.
d.
e.
f.
Type: Single channel.
Display: Digital, four digit dot matrix LCD, blue on gray-green. Include
simultaneous display of pH, temperature, current output and alarm setpoints.
Provide separate dedicated LEDs for each alarm relay.
Keypad: Tactile membrane type, capable of performing parameter
adjustment and system diagnostics.
Output Signals: Linear, galvanically isolated 4-20 mA dc into 600 ohms
maximum load.
Number of Outputs: 2.
Alarm Relays: Where noted or shown:
1) Number: Three set point process alarms adjustable to any point
within the measured range (one process alarm shall be configurable
as a timer to allow indication for periodic maintenance). One fault
alarm.
2) Form:
13330.MSTRUMENTSPECIFICATIONS.DOC 13330-8 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a) process Alarms: Epoxy sealed form A, SPST, normally open.
b) Fault Alarm: Epoxy sealed form C, SPDT.
3) Rating: 6 A resistive at 230 VAC.
g. Signal Conditioning:
1) Hold Output Mode: Hold the current output at a preset or last
measured process value to allow routine sensor maintenance.
2) Temperature Compensation: Compensate glass impedance for better
measurement accuracy. Allow tracking of processes with pH changes
related to temperature using a programmable temperature coefficient
of isopotential point.
3) Automatic Buffer Recognition: The control unit shall store buffer
values and their associated temperature curves for common
commercial buffer standards. The analyzer shall recognize any two
of the three selected buffer values for the two point calibration and
perform a self-stabilization check on the sensor in each buffer.
h. Enclosure Class: NEMA 4X, epoxy coated cast aluminum.
i. Power Supply: 120 VAC, 60 Hz.
4. Sensor Type 1 - F’rocess:
a. Style: Submersiodinsertion flow through.
b. Features:
1) Type: Glass electrode; double junction gel filled reference cell;
dual impedance preamplifier; stainless steel solution ground; and
flow powered cleaner.
2) Full Scale Range: 0 - 14 pH.
3) Conductivity Limit: 75 pS, minimum,
4) Temperature Sensor: Integral Pt 100 RTD.
5) Materials of Construction:
a) Body, Cover and Flow Cell: Polyether Sulfone (PES)
I3330.MSTR~MTSPECIFICATIONS.DOC 13330-9 APRIL. 27,2001
City of carlsbad Carlsbad Recycling Facility MF EQUIPMENT PROCUREMEN
b) O-ring Seals: Viton.
C) Measuring Electrode: Glass.
d) Liquid Junction: Kynar/ceramic.
e) Solution Ground: Type 316 stainless steel.
6) Operating Temperature: To 212°F.
7) Process Connection Type: 2" MNF'T.
8) Flow Powered Cleaner: Consisting of flow chamber and four Teflon
balls.
c. Power Supply: From transmitter/control unit.
5. Sensor Type 2 -Disposable:
a. Style: Submersiodinsertion flow through.
b. Features:
1) Type: Combination electrode; triple junction gel filled reference
cell; and integral preamplifier.
2) Full Scale Range:O - 14 pH.
3) Conductivity Limit: 75 pS, minimum.
4) Materials of Construction:
a) Body: Tefzel.
b) O-ring Seals: Viton.
c) Measuring Electrode: Glass.
d) Liquid Junction: Ceramic.
5) Operating Temperature: 32 - 185°F.
6) Process Connection Type: 1" MNPT.
c. Power Supply: From transmitter/control unit.
6. Performance Characteristics:
13330.MSTRUMENT SPECIFICATIONS.DC€ 13330-10 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Range:
1) pH: Asnoted.
2) Temperature: 5 - 248 OF.
b. Accuracy: *0.01 pH.
c. Stability: iO.01 pwmonth, non-cumulative.
d. Repeatability: iO.01 pH.
e. Temperature Coefficient: Input *0.003 pH /OC; Output *0.006 pH /OC.
f. Temperature Compensation: -15 to 120 "C (automatic or manual).
7. Accessories:
a. Interconnecting Cables: Furnished by manufacturer in lengths to suit device
locations.
b. Calibration: Provide 500 mL each of stock buffer solutions.
c. Mounting: Furnish accessories required for panel mounting. All external
supports and fasteners shall be Type 3 16 stainless steel. If required, furnish
gasketing or panel window kit to maintain the NEMA rating of the panel.
8. Manufacturers:
a. Rosemount:
1) Transmitter Control Unit: Model 54 pWORP.
2) Type 1 Sensor: Model 381+.
3) Type 2 Sensor: Model 389.
b. Or Equal
D. Chlorine Residual Analyzer and Transmitter
1. Component Code: A4.
2. Function:
a. Measure and indicate locally the chlorine residual (total or free, as required)
of a continuous process sample stream.
13330,NSTRUMENT SPECIFICATIONS.DOC 13330-1 1 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
ME EQUIPMENT PROCUREMENT
b. Transmit measured signal to designated PLC panel.
3. Transmitter/Control Unit:
a. Type: Single channel.
b. Display: Digital; four digit LCD numeric display; 16 character LCD
alphanumeric display.
c. Keypad: Tactile, capable of performing parameter adjustment and system
diagnostics.
d. Output Signal: Linear, 4-20 mA dc.
e. Number of Outputs: 1.
f. Alarm Relays: When noted or shown:
1) Number: Three set point alarms, adjustable to any point within the
measured range.
2) Form: SPDT, dry type.
3) Rating: 5 A resistive at 230 VAC.
g. Signal Conditioning:
1) Contaminant Rejection Circuit: The unit shall compare the
potential of the measuring electrode to that of the reference electrode
and automatically bias the measuring electrode to maintain a fixed
potential to screen out interferences from contaminants, even at very
low readings.
2) Temperature Compensation: Automatic temperature compensation
shall be included.
3) Zero Effect: The unit shall not lose sensitivity due to extended
periods measuring samples with a zero chlorine residual.
h. Enclosure Class: NEMA 4X.
i. Power Supply: 120 VAC, 60 Hz.
4. Sensor and Sample Flow System:
a. Style: Flow through amperometric.
13330.MSTRUMENT SPECIFICATIONS.DOC 13330-12 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
b. Features:
1) A three electrode amperometric cell consisting of a bare platinum disc
working electrode, a second bare platinum disc counter electrode, and
a silvedsilver chloride reference electrode shall be provided to give
stability and sensitivity down to 1 part per billion, regardless of
changes in sample characteristics. The three electrode cell shall
produce an electrical current proportional to the oxidant concentration
in the sample.
2) The analyzer shall have the capability of on-site conversion to either
free or total residual chlorine analysis by plant personnel.
3) A continuous sample shall be delivered to the analyzer:
A flushing type y-strainer and throttling valve shall be provided
in the sample line.
The y-strainer shall divide the sample into two streams. The
larger stream shall continuously flush the strainer element while
the larger stream shall flow to the analyzer.
A small portion of the smaller stream shall be regulated and
delivered to the analyzer cell through a valveless peristaltic
Pump.
The pump shall also deliver liquid reagents for pH buffering
and residual measurement in a fixed proportion to the sample.
4) A motor driven impeller in the analyzer cell shall be provided to
maintain stable sample velocity and provide constant grit
bombardment for cleaning electrode surfaces.
c. Power Supply: From transmitter/control unit.
5. Performance Characteristics:
a. Range: Adjustable in fixed increments, from 0 - 0.10, 0 - 0.20, 0 -
0.50, 0 - 1.0, 0 - 2.0, 0 -5.0, 0 - 10.0, 0 -20.0, and 0 - 50.0 mg/L free or
total chlorine.
b. Accuracy: 0.001 mg/L or *1?4 of full scale, whichever is greater,
c. Resolution: 0.001 ma.
d. Repeatability: 0.001 ma or il% of full scale, whichever is greater.
13330,lNSTRLMENT SPECIFICATIONS.WC 13330-13 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
e. Response Time: 90 seconds at a sample flow of 8 -10 L/min.
f. Sample Flow Range: 800- 1000 mumin.
g. Operating Temperature: 26 to 125 OF.
6. Accessories:
a. Interconnecting Cables: Furnished by manufacturer in lengths to suit device
locations.
b. External Bubble Trap: Furnish where indicated on the Drawings.
c. Calibration: Furnish one amperometric titrator for use with all installed
analyzers.
d. Expendables: Furnish a one year supply of required buffer and detergent
solutions/compounds; one tube of grit for electrode cell cleaning.
e. Mounting: Furnish accessories required for modular panel mounting. All
external supports and fasteners shall be Type 316 stainless steel.
7. Manufacturers:
a. Wallace & Tieman, Micro 2000;
b. Or equal.
2.02 FLOW MEASURING INSTRUMENTS
A. Magnetic Flow Sensor and Transmitter:
1. Component Code: F1.
2. Function:
a. Measure and indicate locally the flow of water in a process pipeline.
b. Transmit measured signal to designated PLC panel.
3. Transmitter:
a. Display: 16 digit alphanumeric LCD (rate and total)
b. Outputs: Simultaneous analog and digital
1) Analog: 4 - 20 mA dc into 800 ohms, max.
13330,MSTRUMENT SPECIFICATIONS.DOC 13330-14 APW 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2) Digital: Scaled pulse or frequency (selectable)
c. Alarm Relays: Not required.
d. Signal Conditioning:
1) Low Flow Cutoffi Adjustable from 0 - 9% full scale.
2) Selectable Damping: Adjustable &om 0 - 99 seconds.
3) Output Current Check: Include a hction which will increment the
current from 4 to 20 mA to allow the checking of attached
instruments without the running of liquids through process pipes.
4) Input Simulator: Incorporate a built-in input simulator to allow the
simulation of a fixed flow tube signal to the front-end of the
electronics without externally connected devices or the running of
liquids through process pipes.
e. Enclosure Class: NEMA 4X epoxy coated cast aluminum.
f. Mounting: Integral or remote, as indicated or shown.
g. JunctionBox: Required for remote mounting, NEMA 7 epoxy coated
cast aluminum.
h. Power Supply: 120 VAC, 60 Hz.
4. Flow Sensor:
a. Type: DC bipolar pulsed coil excitation with automatic re-zero
after every cycle.
b. Features:
1) F1ow:Bi-directional.
2) Pre-amp Impedance: 10’’ ohms minimum.
3) Pressure Rating: 150 psig.
c. Materials of Construction:
1) Flow Tube: Type 316 stainless steel.
2) Flanges: Type 316 stainless steel.
13330.MSTRUMWT SPECIFICAT1ONS.DOC 13330-15 APRIL. 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
3) Flow Tube Liner: Teflon or PTFE.
4) Electrodes: Type 316 stainless steel.
d. Process Connections: Flanged, ANSI Class 150 unless otherwise noted or
shown.
e. Junction Box: Required for remote mounted transmitter, NEMA 7 epoxy
coated cast aluminum.
f. Power Supply: From transmitter.
5. Performance Characteristics:
a. Accuracy: *0.5% of rate for velocities of 1 - 30 ft/s; ;tO.01 ft/s for
velocities below 1 Ws.
b. Temperature Effect: *0.025% full scale/"C.
c. Minimum Velocity: 0.3 Ms.
d. Minimum Conductivity of Process Fluid: 5 pS/cm.
e. Repeatability: *O. 1 % of full scale.
f. Ambient Temperature Limits: -20 to 140 OF.
6. Accessories
a. Interconnecting Cables: Furnished by manufacturer in lengths to suit device
locations.
b. Mounting: Furnish accessories required for pipe kame mounting of
transmitter. All fasteners shall be Type 316 stainless steel.
7. Manufacturers:
a. Endress + Hauser, Promag F;
b. Or equal.
B. Flow Indicator, Rotameter
1. Component Code: F4.
2. Function:
13330.MSTRUMENT SPECIFICATIONS.DC€ 13330-16 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Measure and indicate locally the flow of a sample stream in a bypass
pipeline.
3. Transmitter: None.
4. Flow Sensor:
a. Type: Guided float, direct reading, with integral valve.
b. Features:
1) Scale Length 10-inch.
2) Body: Solid cast acrylic with integral direct reading scale.
3) Connections: Horizontal for panel mounting.
c. Materials of Construction:
1) Body: Acrylic.
2) FloaVGuide: Type 3 16 stainless steel.
3) Fittings: Type 316 stainless steel.
4) O-rings: EPR.
d. Process Connections: 1/2" MNPT.
5. Performance Characteristics:
a. Flow Range: 0 - 2 gpm, full scale.
b. Accuracy: i2% of full range.
6. Accessories:
a. Metering Valve:
1) Designation: Type NDVl.
2) Type: Needle valve, three piece design.
3) Materials: Type 3 16 stainless steel.
4) Features: Heavy duty, long grip, CNC machined valve knob for
regulation; integral travel stop.
13330.MSTRUMENTSPEClFICATlONS.DOC 13330-17 APRIL 27,2001
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Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Mounting: Furnish accessories required for panel mounting of monitor,
All fasteners shall be Type 316 stainless steel.
7. Manufacturers:
a. King Instrument Co., Model 7530;
b. Or equal.
C. Flow Switch, Piston Type
1. Component Code: F5.
2. Function: Actuate a relay contact on flow detection for remote indication.
3. Components:
a. Body and wetted ports.
b. Externally adjustable flow distribution vane.
c. Spring biased magnetic piston.
d. Hermetically sealed reed switch.
4. Switch:
a. Type: Hermetically sealed reed switch, actuated by magnet within piston.
b. Alarm Relays:
1) Number: One.
2) Form: SPDT, dry type.
3) Rating: 20 VA.
c. Operating Temperature: -20 OF to +225. OF
d. Rating: NEMA 4X.
5. Cable:
a. Type: No. 18 AWG, polymeric lead wires.
b. Length: 24-inches.
13330.JNSTRUMENT SPECIFICATIONS.DOC 13330-18 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
C. Accessories: 1/2-inch NPT conduit connector.
6. Performance Characteristics:
a. Repeatability: 1% maximum deviation.
b. Set Point Accuracy: k 10% maximum.
c. Set Point Differential: 15% maximum.
7. Mounting:
a. Orientation: In-line.
b. Process Connections: 1/2-inch FNPT in and out.
8. Materials of Construction:
a. Housing: Type 316 stainless steel.
b. Piston: Polysulfone.
c. Spring: Type 316 stainless steel.
d. O-ring: Viton.
9. Manufacturer:
a. Gems Sensors, Series FS-10798;
b. Or equal.
D. Flow Element and Transmitter, Variable Area
1, Component Code: F7.
2. Function:
a. Measure and indicate locally the flow of air in a process line.
b. Transmit measured signal to the designated control panel.
3. Transmitter:
a. Display: Dial Indicator scaled in engineering units of flow.
b. Outputs: Linear, 4-20mAdc, HART compatible.
13330.MSTRUMENT SPEC1FICATIONS.DOC 13330-19 APRIL 27.2001
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MF EQUIPMENT PROCUREMENT
c. Alarm Relays: When noted or shown:
1) Number: 2 set point alarms, adjustable to any point within the
measured range.
2) Form: SPDT, dry type.
3) Rating: 5 A resistive at 125VAC.
d. Enclosure Class: NEMA 4X
e. Mounting: Integral.
f. Power Supply: 24VDC, loop powered.
4. Flow Sensor:
a. Type: Magnetic coupled float.
b. Materials of construction:
1) Housing: Grit blasted Type 316L stainless steel.
2) Metering Tube: Type 316L stainless steel
3) Float: Type 3 16L stainless steel.
4) Window: Glass. .
c. Process Connections: As required by the MFEM for his system.
5. Performance Characteristics:
a. Operating Range: As required by the MFEM for his system.
b. Pipe Size Range: 0.5 to 4 in.
c. Repeatability: *0.25% of full scale.
d. Linearity: Less than 1% at maximum current.
e. Accuracy: *2% full scale from 100% to 10% of scale reading.
6. Manufacturers:
a. Brooks Instrument Model 3809;
1333(1.MSTRUMENTSPECLFICATIONS.WC 13330-20 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
b. Or equal.
E. Flow Element and Transmitter, Rotary Type
1. Component Code: F8.
2. Function:
a. Measure and indicate locally the flow of process stream in a pipeline.
b. Transmit measured signal to the designated control panel.
3. Transmitter:
a. Display: None.
b. Outputs: Pulsed, frequency of 25 to 225 Hz proportional to flow.
c. Enclosure Class: NEMA 4X.
d. Mounting: Integral.
e. Power Supply: 24VDC, loop powered.
4. Flow Sensor:
a. Type: Magnetized rotary element with Hal effect sensor.
b. Features:
1) Output Signal: 4.5VDC - 24VDC
2) Output Frequency: 25-225 Hz.
3) Pressure Rating: 100 psig at 70°F
c. Materials of Construction:
1) Body: Polyproylene.
2) Shaft: Titanium
3) Rotor: Nylon composite
4) O-rings: Viton
d. Process Connections: 1/4" FNPT
I3330.MSTXLGUENT SPECIFICATIONS.DOC 13330-21 APRIL 27,2001
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Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
5. Performance Characteristics:
a. Operating Range: 0.5 - 5.0 gpm.
b. Accuracy: *7% of full scale
6. Accessories:
a. Interconnecting Cables: Furnished by manufacturer in lengths to suit
device locations.
b. Mounting: Fumish accessories required for in-line mounting.
7. Manufacturers:
a. Gems RotorFlow Electronic Type
b. Or equal.
2.03 LEVEL MEASURING INSTRUMENTS
A. Level Switch, Float Type
1. Component Code: L1.
2. Function: Actuate relay contact at a fixed liquid level within a storage tank or
sump for alarm indication andor pump control.
3. Float:
a. Type: Foam filled with integral mercury-to-electrode tilt switch.
b. Alarm Relays:
1) Number: One.
2) Form: SPDT, dry type.
3) Rating: 4.5 A resistive at 115 VAC.
c. Actuation: On rising or falling liquid level; less than 1-inch of level change
from setpoint and within 1-inch of horizontal centerline of clamp.
d. Operating Temperature: 0 to 180 OF.
e. Rating: NEMA 4X.
13330.INSTRGUW SPECIFlCATlONS.DOC 13330-22 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
4. Cable:
a. Type: SO, heavy duty, fine stranded, AWG #18 .
b. Float Connection: Potted.
c. Length: As required to run un-spliced to the local control panel.
5. Mounting: Attach to 1-inch pipe or suspend from top, as noted.
6. Materials of Construction
a. Float: Molded polyethylene.
b. Cable: Synthetic jacket compatible with the stored fluid.
c. Clamps (for pipe mounting): PVC or polypropylene.
d. Chain, link and fasteners (for top suspension): Type 3 16 stainless steel.
e. Weight (for top suspension): Plastic coated cast iron.
7. Manufacturer:
a. Consolidated Electric Co., Model LS;
b. Or equal.
B. Level Switch, Side Mount Type
1. Component Code: L2.
2. Function: Actuate relay contact at a fixed liquid level within a storage tank or
sump for alarm indication and/or pump control.
3. Float:
a. Type: Side mount magnetic float-to-reed tilt switch.
b. Alarm Relays:
1) Number: One.
2) Form: SPDT, dry type.
3) Rating: 20 VA.
13330.MSTRUM~SPEClFICATIONS.M)C 13330-23 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c. Actuation: On rising or falling liquid level; less than 1-inch of level change
from setpoint.
d. Operating Temperature: -40 to 300 OF.
e. Rating: NEMA 4X.
4. Cable:
a. Type: No. 22 AWG, polymeric lead wires.
b. Length: 24-inches.
c. Accessories: 1/2-inch NPT conduit connector.
5. Mounting:
a. Configuration: Mount through 4-inch blind flange on tank side wall.
b. Connections: 1/2-in MNT'T.
6. Materials of Construction:
a. Float: Type 3 16 stainless steel.
b. Body: Type 316 stainless steel,
7. Manufacturer:
a. Gems Sensors, Model Series LS-7, Type 9;
b. Or equal.
C. Level Transmitter, Ultrasonic:
1. Component Code: L3.
2. Function:
a. Measure and indicate locally the level in a below grade concrete clearwell or
sump.
b. Transmit the measured signal to the designated PLC panel.
3. , Sensor:
a. Type: Detect liquid level by sounding and receiving echo.
13330.MSTRUMENT SPECIFICATIONS.WC 13330-24 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
b.
C.
d.
e.
f.
g.
h.
Measuring Range: As required to suit installation.
Blocking Distance: 12-inches, maximum.
Operating Temperature: -40 to 203 "F.
Operating Pressure: Atmospheric.
Relative Humidity: Up to 100%.
Mounting Connection: 1-inch MNPT.
Sensor Cable:
1) Type: No. 18 AWG, 2-wire with shield.
2) Length: As required to suit device locations.
4. Transmitter:
a. Display: 4-digit LCD.
b. Output Signal: 4 - 20 mA dc.
c. Number of Outputs: 1.
d. Signal Conditioning:
1) Signal Generation: Convert sonic signal to a 4 - 20 mA output
signal.
2) Adjustments: Provide fine zero, span, alarm set, coarse zero and
calibration check.
e. Enclosure Class: NEMA 4.
f. Mounting: Stanchion (2-inch pipe) remote from sensor.
g. Power Supply: 120 VAC, 60 Hz.
5. Materials of Construction:
a. Sensor: PVDF.
b. Transmitter Housing: ABSiPC body with polycarbonate transparent
cover.
I3330,MSTRUMENI SPECIFICATIONS.WC 13330-25 APW 27.2001
City of carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
6. Manufacturer:
a. Endress + Hauser, Prosonic;
b. Or equal.
D. Level Transmitter, Indirect Magnetic Type
1. Component Code: I.4.
2. Function:
a. Measure and indicate locally the level in an above ground storage tank.
b. Transmit the measured signal to the designated PLC control panel.
3. Gauge Assembly:
a. Type: Hermetically sealed glass tube with magnetic indicator
coupled to gauge tube with magnetic float. The magnetic float and gauge
tube are in contact with the process liquid, while the glass indicating
chamber is isolated from the process liquid.
b. Float Chamber (Gauge Tube):
1) Size: 2-1/2" diameter pipe.
2) Length: To .adequately measure maximum and minimum tank
operating levels.
3) Process Connections: 2-inch ANSI Class 150 flanges.
4) Float: Sealed with integral 360" magnet assembly.
c. Indicator Tube:
1) Type: Hermetically sealed glass.
2) Length: To suit gauge length.
3) Scale: Feet and inches with 1/2-inch scale divisions; resolution
of 1M-inch.
4) Indicator: Bright red color; 7/8-inch diameter by 1-1/4-inches long;
magnetized for coupling to float.
4. Transmitter (when noted or shown):
13330.lNSTRUMENT SPECIFICATIONS.DOC 13330-26 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Display: None.
b. Output Signal: 4 - 20 mA dc.
c. Number of Outputs: 1.
d. Signal Conditioning:
1) Signal Generation: Convert variable resistance to a 4 - 20 mA
output signal.
2) Adjustments: Provide fine zero, span, coarse zero and calibration
check.
e. Enclosure Class: Explosion proof, Class 1, Division 1, Groups B,C&D.
f. Mounting: Threaded to sensor tube.
g. Power Supply: 24 VDC loop powered.
5. Sensor (for use with transmitter):
a. Type: Tube containing string of resistors and magnetically
operated reed switches actuated by gauge float.
b. Resolution: 1/2-inch.
c. Length: To cover full range of gauge tube.
d. Mounting: Attached to gauge tube with manufacturer supplied mounting
brackets and clamps. All components shall be Type 3 16 stainless steel.
6. Alarm Switches (when noted or shown):
a. Type: Hermetically sealed mercury tilt, coupled to gauge
chamber and actuated by float magnet.
b. Features: "Break-before-make'' action to latch switch into place until float
passes in the opposite direction.
c. Number: As noted or shown.
d. Form: SPDT, Form C.
e. Rating: 5 A resistive at 120 VAC.
f. Deadband: 1/2-inch.
13330.MSTRUME~SPECIFICATIONS.DOC 13330-27 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
g. Enclosure Class: Explosion proof, Class 1, Division 1, Groups B,C&D.
7. Materials of Construction:
a. Gauge Tube:
1) Sulfuric Acid Service: Alloy 20.
2) Sodium Hypochlorite Service: Hastelloy C.
3) Balance ofplant: Type 316 stainless steel.
b. Magnetic Float:
1) Selected by manufacturer for corrosion resistance to the measured
fluid.
c. Indicator Tube: Glass.
d. Sensor Tube: Type 316 stainless steel.
8. Manufacturer:
a. ISE Magtech:
1) Gauge Assemb1y:Model LG-Series.
2) Transmitter: Model LT-1.
3) Alarm Switches: Model MLS-3EX.
b. Or equal.
E. Level Transmitter, Capacitance Probe
1. Component Code: L5.
2. Function:
a. Measure and indicate locally the level in a below grade concrete cleanvell or
sump.
b. Transmit the measured signal to the designated PLC control panel.
3. Sensor:
a. Type: RF capacitance probe.
13330.MSTRUMENTSPECIFICATIONS.DOC 13330-28 APRIL 27.2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Measuring Range: As required to suit installation.
c. Operating Temperature: -10 to 50 OC.
d. Operating Pressure: Atmospheric.
e. Relative Humidity: Up to 100%.
f. Mounting Connection: Provide stainless steel mounting flange for
attachment to sump grating.
4. Transmitter:
a. Display: 4-digit LCD.
b. Output Signal: 4 - 20 mA dc.
c. Number of Outputs: 1.
d. Enclosure Class: NEMA 4X.
e. Mounting: Stanchion (2-inch pipe) remote from sensor.
f. Power Supply: 24 VDC.
5. Materials of Construction:
a. Sensor: TFE rod with Type 316 stainless steel stilling well.
b. Transmitter Housing: Cast aluminum.
6. Manufacturer:
a. Magnetrol Kotron Series 82 CE transmitter with Series 41 probe;
b. Or equal.
F. Level Switch, Vibrational Type
1. Component Code: L6.
2. Function: Actuate relay contact at a fixed liquid level within a storage tank or
sump for alarm indication and/or pump control.
3. Sensor:
a. Type: Tuned fork.
13330.MSTRLMENT SPECIFICATIONS.WC 13330-29 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Alarm Relays:
1) Number: One.
2) Form: SPDT, dry type.
3) Rating: 20 VA.
c. Actuation: On rising or falling liquid level; less than 1-inch of level change
from setpoint.
d. Operating Temperature: -40 to 300 OF.
e. Rating: NEMA 4X.
4. Cable:
a. Type: No. 22 AWG, polymeric lead wires.
b. Length: 24-inches.
c. Accessories: 1/2-inch NPT conduit connector.
5. Mounting:
a. Configuration: Mount through 1-inch blind flange on tank side wall.
b. Connections: 1/2-in MNPT.
6. Materials of Construction:
a. Sensor: Type 316 stainless steel.
b. Process Connection: Type 316L stainless steel.
7. Manufacturer:
a. Endress + Hauser, Liquifphant M;
b. Or equal.
2.04 PRESSURE MEASURING INSTRUMENTS
A. Pressure Transmitter
1. Component Code: P1.
13330,INSTRUMENT SPEClFICATIONS.DOC 13330-30 AF'lUL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Function:
a. Continuously measure and indicate locally the gauge pressure of a process
stream.
b. Transmit the measured signal to the designated PLC panel.
3. Transmitter:
a. Display:
1) 4-digit LCD in engineering units noted.
2) Plug-in mounting configuration.
b. Outputs:
1) Number: 1.
2) Type: Smart, 4 - 20 mA dc, user selectable for linear or square
root output. Superimpose digital process variable on 4 - 20 mA
signal for interface with highway addressable remote transducer
WT) compatible host.
c. Alarm Relays: Not required.
d. Signal Conditioning:
1) Span and Zero: Span and zero shall be continuously adjustable.
2) Zero Elevation and Suppression: Available within prescribed range
limits.
e. Enclosure Class: NEMA 4X epoxy coated cast aluminum, explosion proof.
f. Mounting: Bracket, 2-inch pipe mount.
g. Power Supply: 24 VDC loop powered.
4. Pressure Sensor:
a. Type: Diaphragm, where deflection of the sensing diaphragm is
measured by capacitor plates on either side. The differential capacitance
between the sensing diaphragm and capacitor plates is converted
electronically to the specified output signal.
b. Features:
1333O.INSTRuMENT SPECIFICATI0NS.DOC 13330-31 APW 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUPMENT PROCUREMENT
1) Wetted components shall be separated from electronic and wiring
connections in separate compartments.
2) Sensor components shall include an isolating diaphragm, internal fill
fluid, capacitor plates, sensing diaphragm, lead wires, process flanges
(high and low side), and draidvent plugs.
3) The internal fill fluid shall be separated from the measured process
stream by the isolating diaphragm. The process fluid shall be in
direct contact with the isolating diaphragm at the sensor, without the
use of a secondary diaphragm seal assembly.
5. Performance Characteristics:
a. Temperature Limits:
1) Electronics: - 40 to 85°C.
2) Sensor: - 40 to 104°C.
3) Transmitter: -20 to 70°C.
b. Output Range: Adjustable, minimum range as noted.
1) The maximum noted operating range shall fall between 40 and 60
percent of the maximum adjustable range of the instrument.
2) The minimum span shall be 1/15 the maximum adjustable range.
c. Indication Accuracy: *0.25% of calibrated span *1 digit.
d. Display Resolution: *0.5% of calibrated span -+I digit.
6. Accessories:
a. Mounting Bracket: Furnish bracket for mounting transmitter on 2-inch
pipe.
b. Isolation Root Valve: Provide an isolation valve at the connection to the
process pipeline, Type BV2 unless otherwise noted.
c. Stanchion Support: For instruments not mounted on a common
framework, provide a standalone stanchion support constructed of welded
Type 316L stainless steel plate and 2-inch pipe. The assembly shall be
electropolished after fabrication to match system piping. The support shall
be located on a concrete pad and secured with concrete anchors. As
13330.MSTRUMENT SPECIFICATIONS.DOC 13330-32 APRIL. 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
installed, the transmitter display shall be between 4'-6" and 5'-0" above
finished grade.
7. Materials of Construction:
a. FlangedAdapters: Type 3 16 stainless steel (including low side).
b. DrainNents: Type 316 stainless steel.
c. Diaphragms: Type 316L stainless steel.
d. Body Bolting: Type 316 stainless steel.
e. Seals: Viton.
f. Sensor Fill Fluid: Silicone.
g. Mounting Bracket: Polyurethane coated carbon steel bracket with Type
316 stainless steel bolts.
8. Manufacturer:
a. Rosemount, Alphaline Model 1151GP;
b. Or equal.
B. Differential Pressure Transmitter
1. Component Code: P2.
2. Function:
a. Continuously measure and indicate locally the differential pressure between
two process streams, process tank level, or process stream flow as noted or
shown.
b. Transmit the measured signal to the designated PLC panel.
3. Transmitter:
a. Display:
1) 4-digit LCD in engineering units noted.
2) Plug-in mounting configuration.
1333O.INSTRuMENT SPECIFICATIONS.DOC 13330-33 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUPMENT PROCUREMEW
b. Outputs:
1) Number: 1.
2) Type:Smart, 4 - 20 mA dc, user selectable for linear or square root
output. Superimpose digital process variable on 4 - 20 mA signal for
interface with highway addressable remote transducer (HART)
compatible host.
c. Alarm Relays: Not required.
d. Signal Conditioning:
1 j' Span and Zero: Span and zero shall be continuously adjustable.
2) Zero Elevation and Suppression: Available within prescribed range
limits.
e. Enclosure Class: NEMA 4X epoxy coated cast aluminum, explosion proof.
f. Mounting: Integrally mount transmitter for flow applications-coordinate
with the flow element provided; Remote mount all others with bracket for
2-inch pipe mounting.
g. Power Supply: 24 VDC loop powered.
4. Pressure Sensor:
a. Type: Diaphragm, where deflection of the sensing diaphragm is
measured by capacitor plates on either side. The differential capacitance
between the sensing diaphragm and capacitor plates is converted
electronically to the specified output signal.
b. Features:
1) Wetted components shall be separated from electronic and wiring
connections in separate compartments. ..
2) Sensor components shall include high and low side isolating
diaphragms, internal fill fluid, capacitor plates, sensing diaphragm,
lead wires, process flanges (high and low side), and draidvent plugs.
3) The fill fluid shall be separated from the measured process streams by
the isolating diaphragms. The process fluid shall be in direct contact
with the isolating diaphragm at the sensor, without the use of a
secondary diaphragm seal assembly.
13330.MSTRUMENTSPECIFEATIONS.DOC 13330-34 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
C. Mounting configuration: The sensor inlet taps shall be located below
the corresponding taps on the process lines
5. Performance Characteristics
a. Temperature Limits:
1) Electronics:- 40 to 85°C.
2) Sensor: - 40 to 104OC.
3) Transmitter: -20 to 70%
b. Static Pressure Limit: 0.5 psia to 2,000 psig.
c. Output Range: Adjustable, minimum range as noted.
1) The maximum noted operating range shall fall between 40 and 60
percent of the maximum adjustable range of the instrument.
2) The minimum span shall be 1/15 the maximum adjustable range.
d. Indication Accuracy: +0.25% of calibrated span *l digit,
e. Display Resolution: i0.5% of calibrated span *1 digit.
6. Accessories:
a. Mounting Bracket: Furnish bracket for mounting transmitter on 2-inch
pipe, or integral mounting accessories for flow applications.
b. Isolation Root Valve: Provide an isolation valve at the connection to the
process pipeline, Type BV2 unless otherwise noted.
c. Three Valve Manifold: Provide a blockhleed three valve manifold at the
instrument; Anderson, Greenwood & Co. M4 Manifold or equal.
d. Stanchion Support: For instruments not mounted on a common
framework or integrally mounted, provide a standalone stanchion support
constructed of welded Type 316L stainless steel plate and 2-inch pipe. The
assembly shall be electropolished after fabrication to match system piping.
The support shall be located on a concrete pad and secured with Type 3 16
stainless steel anchors. As installed, the transmitter display shall be between
4'-6" and 5'-0" above finished grade.
7. Materials of Construction:
IJ330.MSTRUMENT SPECIFICATIONS.DOC 13330-35 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEm
a.
b.
C.
d.
e.
f.
g.
h.
F1angedAdapters:Type 316 stainless steel.
DrainNents: Type 3 16 stainless steel.
Diaphraps: Type 316L stainless steel.
Body Bolting: Type 316 stainless steel.
Seals: Viton.
Fill Fluid: Silicone.
Mounting Bracket: Polyurethane coated carbon steel bracket with Type
316 stainless steel bolts.
Three-Valve Manifold:
1) Body, Bonnet and Stem: Type 316 stainless steel.
2) Seat: Teflon.
3) Packing: Viton O-ring with Teflon backup ring.
8. Manufacturer:
a. Rosemount, Alphaline Model 1151DP;
b. Or equal.
C. Pressure Switch
1. Component Code: P3.
2. Function:
a. Actuate relay contact at a fixed pressure within a process or chemical
injection pipeline for alarm indication and/or process control.
3. Element:
a. Type: Single switching element, diaphragm sealed, force-
balance, spring-piston actuated.
b. Deadband: Fixed.
1) For adjustable range up to 30 psig, the maximum deadband shall
not exceed *2.0 psig.
13330.MSTRUMENT SPECIFICATIONS.DOC 13330-36 APRIL 27,2001
City of Carlsbad
MF EQlJIi"ENT PROCUREMENT
Carlsbad Recycling Facility
C.
d.
e.
f.
g.
h.
1.
2) For an adjustable range up to 100 psig, the maximum deadband shall
not exceed i4.0 psig.
3) For an adjustable range up to 550 psig, the maximum deadband shall
not exceed *12.0 psig.
Setpoint: Adjustable. Initial setpoint as noted. Select such that the
indicated setpoint falls between 40 and 60 percent of the adjustable range.
Alarm Relays:
1) Number: One.
2) Form: SPDT, dry type.
3) Rating: 15 A at 120 VAC.
Terminals: Screw type.
Actuation: On rising or falling pressure; outside specified deadband from
setpoint.
Process Connection: ll4-inch or 1/2-inch FNPT, to suit installation.
Operating Temperature: 32 to 400 "F.
Enclosure: NEMA 4X, cast aluminum with right and left hand electrical
outlets.
4. Materials of Construction:
a. Sulfuric Acid Service:
1) O-ring (wetted): Viton.
2) Diaphragm (wetted primary): Teflon coated polyamide.
3) Pressure Port (wetted): Alloy 20.
b. Sodium Hypochlorite Service:
1) O-ring (wetted): Viton.
2) Diaphragm (wetted primary): Teflon coated polyamide.
3) Pressure Port (wetted): Hastelloy C.
I3330.MSTRUMENT SPECIFICATIONS.DOC 13330-37 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
C. Balance of Plant:
1) O-ring (wetted): EPR.
2) Diaphragm (wetted primary): Teflon coated polyamide.
3) Pressure Port (wetted): Type 316 stainless steel.
5. Manufacturer:
a. SOR Inc., Static "0" Ring type;
b. Or equal.
D. Pressure Gauge, General Service
1. Component Code: P4.
2. Function: Measure and indicate locally the pressure in a process pipeline.
3. Sensor:
a. Type: Direct drive, helically wound bourdon tube actuated.
b. Range: As noted.
c. Zero Set Point: Adjustable.
4. Gauge:
a. Dial Size: 4-112 inches, nominal.
b. Engineering Units: psig.
c. Pointer: Needle edged.
d. Process Connection: 1/4-inch or 1/2-inch MNPT, located in the bottom
or back to suit installation.
e. Mounting: Panel or lower stem, to suit installation. Panel mounted gauges
shall be furnished with a front flange to permit flush mounting of dial face.
5. Performance Characteristics:
a. Accuracy: *0.5% of span at mid-range; *l% overall.
b. Ambient Temperature: -54 to 88°C.
13330.MSTRUMENTSPECIFICATIONS.WC 13330-38 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c. Fluid Temperature: -54 to 204°C.
d. Proof Pressure Without Shift: 150% of maximum rated pressure.
e. Sensor Burst Pressure: 500% of scale pressure.
f. Life: 250,000 cycles minimum, 80% of full scale.
6. Materials of Construction:
a. Bourdon Tube Sensor: Inconel X-750.
b. Case and Ring: ABS Plastic.
c. Pointer: Annodized aluminum.
d. Connecting Capillary: Type 316 stainless steel.
e. Crystal: Acrylic.
f. Fittings: Type 316 stainless steel.
g. Front Flange (when required):ABS Plastic.
7. Manufacturer:
a. 3D Instruments Inc., TLG Process Gauge;
b. Or equal.
E. Pressure Gauge, Chemical Service
1. Component Code: P6.
2. Function: Measure and indicate locally the pressure in a chemical pipeline.
3. Sensor:
a. Type: Direct drive, helically wound bourdon tube actuated.
b. Range: As noted.
c. Zero Set Point: Adjustable.
4. Gauge:
a. Dial Size: 2-1/2 inches, nominal.
13330.MSTRUMfNT SPECIFICATIONS.WC 13330-39 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
b. Engineering Units: psig.
c. Pointer: Needle edged.
d. , Process Connection: Gauge isolator, 1/4-inch or 1/2-inch FNF'T.
e. Mounting: Lower stem, with factory installed gauge isolator.
5. Gauge Isolator:
a. Type: Metallic diaphragm.
b. Size: 1-1/2" diameter, maximum.
c. Components: Upper body (non-wetted), diaphragm, and lower body
(wetted).
d. Coordination: Manufacturer shall provide custom span adjustment to
suit pressure range of gauge.
6. Performance Characteristics:
a. Accuracy:
1) Gauge: io.% of span at mid-range; *l% overall.
2) Gauge Isolator: il% overall.
b. Diaphragm Displacement: 0.08 cubic centimeters, maximum.
c. Ambient Temperature: -73 to 93°C.
d. Fluid Temperature: -54 to 204°C.
e. Proof Pressure Without Shift: 150% of maximum rated pressure.
f. Sensor Burst Pressure: 500% of scale pressure.
g. Life: 250,000 cylces minimum, 80% of full scale.
7. Materials of Construction, Gauge:
a. Bourdon Tube Sensor: Inconel X-750.
b. Pointer Shaft: Stainless steel.
c. Movement: Stainless steel.
13330.MSTRUMENTSPECIFlCATIONS.DOC 13330-40 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
d. Pointer: Aluminum alloy.
e. Connecting Capillary: Type 316 stainless steel.
f. Case: Type 316 stainless steel.
g. Crystal: Acrylic.
h. Fittings: Type 316 stainless steel.
8. Materials of Construction, Gauge Isolator:
a. Sulfunc Acid Service:
1) Upper Body: Type 316 stainless steel.
2) Diaphragm: Alloy 20.
3) Sea1s:Viton.
4) Lower Body: Alloy 20.
5) Fill Fluid: Silicone Oil.
b. Sodium Hypochlorite Service:
1) Upper Body: Type 316 stainless steel.
2) Diaphragm: Hastelloy C.
3) Sea1s:Viton.
4) Lower Body: Hastelloy C.
5) Fill Fluid: Silicone Oil.
c. Balance of Plant:
1) Upper Body: Type 316 stainless steel.
2) Diaphragm: Type 316 stainless steel.
3) Sea1s:EPR.
4) Lower Body: Type 3 16 stainless steel.
5) Fill Fluid: Silicone Oil.
13330.MSTRUMENT SPEClFlCATlONS.DOC 13330-41 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
9. Manufacturer:
a. 3D Instruments, Inc. TLG Process Gauge with GP140 metallic diaphragm;
b. Or equal.
2.05 TEMPERATURE MEASURING INSTRUMENTS
A. Temperature Gauge
1. Component Code: T1.
2. Function:
a. Measure and indicate locally the temperature in a chemical pipeline.
b. Where required, actuate an alarm switch for local annunciation or control.
3. Sensor:
a. Type: Direct drive, N-type bourdon coil actuated.
b. Range: Asnoted.
c. Compensator: Case mounted, bimetal for head and line as a unit.
4. Gauge:
a. Dial Size: 4 inches, nominal.
b. Engineering Units: As noted.
c. Dial Colors: Black on white.
d. Pointer: Needle edged.
e. Process Connection: Factory connected to capillary.
f. Mounting: Remote panel mount, with front flange for flush face.
5. Capillary:
a. Type: Flexible metallic, liquid filled, with bulb.
b. Capillary Length: As required to suit device locations; 2 feet minimum, 33
feet maximum.
I3330.MSTRUMENI SPEClFlCATLONS.DOC 13330-42 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
c. Bulb Length: To suit required range.
d. Bulb Style: Sliding union type (thermowell required).
e. Process Connections:
1) a. Bulb: 1/2" MNPT.
2) b. Thermowell: 5/8" to 1" MNPT, to suit installation.
6. Alarm Relays (when noted or shown):
a. Number: One.
b. Form: SPDT, dry type.
c. Rating: 5A at 125 VAC.
d. Setpoint: Initial setpoint as noted, externally adjustable over the full range
of the gauge.
e. Actuation: On rising temperature via mechanical microswitch directly
coupled to the gauge assembly.
f. Enclosure: NEMA 4 rated, aluminum alloy.
7. Performance Characteristics:
a. Accuracy: *l% of full scale.
b. Overtemperature Protection: 150% of maximum rated temperature without
shift.
8. Materials of Construction
a. Bourdon Tube Sensor: Inconel X-7504b.
b. Pointer Shaft: Eligiloy.
c. Shaft Bearings: Synthetic sapphire.
d. Pointer: Type 316 stainless steel
e. Connecting Capillary: Type 316 stainless steel.
f. Case: Aluminum alloy.
13330.MSTRUME~SWCIFICATIONS.DOC 13330-43 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
g. Crystal: Glass.
h. Fittings: Type 316 stainless steel.
i. Bulb: Type 316 stainless steel.
j. Thermowell: Type 316 stainless steel.
9. Manufacturer:
a. 3D Instruments, Model 136X with specified accessories;
b. Or equal. ..
B. Temperature Transmitter
1. Component Code: T2.
2. General:
a. Function: Measure temperature and transmit signal proportional to
temperature.
b. Type: RTD input, two-wire transmitter.
3. Performance:
a. Range: As noted.
b. Maximum Adjustable Range: Such that &e noted range shall lie between
40 percent and 80 percent of the maximum adjustable range.
c. Accuracy: Plus or minus 0.2 percent of calibrated span.
d. Temperature: Minus 20 degrees F to plus 200 degrees F, minimum.
e. Fluid As noted.
4. Sensor:
a. Type: Platinum RTD, single element, 4 wire.
b. Sheath: 316 stainless steel.
c. Lead Wire: Teflon insulated, nickel coated? 22-gauge stranded copper wire.
d. Process connection: 1/2-inch MNPT.
~
I333O.MSTRUMENT SPECIFICATIONS.WC 13330-44 AF'W 27,2001
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MF EQUIPMENT PROCUREMENT
5. Transmitter:
a. Power Supply: 24 VDC.
b. Span: 45 to 135 degrees F.
c. Output: 4 to 20 mA, isolated to 500 VDC.
d. Display: Digital LCD.
e. Enclosure: NEMA 4X, aluminum.
f. Mounting: Integral to sensor.
6. Thermowell:
a. Inside Diameter: Sized to match sensor, for easy removal and maximum
heat transfer.
b. Type: Straight style.
c. Process Connections: 1/2-inch FNPT for sensor; 3/4-inch MNPT for
process line.
d. Materials: Type 316 stainless steel.
7. Manufacturers:
a. Rosemount:
1) Transmitter: Model 444.
2) Sensor: Series 68.
3) Thermowell: Series 79.
b. Or equal.
2.06 SPARE PARTS AND MAINTENANCE EQUIPMENT
Provide the following in accordance with Section 01760:
A. Analytical Instruments
1. One spare chlorine residual analyzer (component code A4).
2. One spare pH sensor of each type (component code A3).
13330,lNSTRUMENI SPECIFICATIONS.DOC 13330-45 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility m EQUIPMENT PROCUREMENT
3. One spare conductivity sensor of each type (component code A2).
B. Other
I. One electronic magnetic flow meter calibration device furnished by the meter
manufacturer.
2. One portable instrument calibrator current simulator with charger and carrying
case, as manufactured by Fluke, Model RIS 4500, or equal.
3. One pressure transmitter for each range of pressure transmitters used on the
project.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. General Requirements
1. The root tap to all process sensors and analyzers shall be isolated with a valve at
the process line connection, whether shown on the Drawings or not.
a. For general process service, valves shall be stainless steel (Type BV2)
unless otherwise noted or shown. Connecting nipples shall be Type 316
stainless steel.
b. For chemical service, valves shall be diaphragm type, manufactured to
match the service. Connecting nipples shall be per the chemical piping
requirements.
2. All flow meters shall be installed in strict accordance with manufacturer’s
guidelines and tolerances. Unit piping shall be arranged so as to eliminate the
entrainment of air.
3. Isolating diaphragms, where required, shall be furnished by the manufacturer of
the isolated device to insure accurate calibration and performance.
+ + END OF SECTION + +
13330,INSTRUMENT SPECIFICAT7ONS.WC 13330-46 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 13335
PROGRAMMABLE LOGIC CONTROLLER (PLC) SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. MFEM shall furnish all labor, materials, and components, and shall provide all
design, assembly, programming, configuration, testing, start-up services, and
training required to provide a complete and operational programmable controller
(PLC) based system as specified and shown on the Drawings. The system
includes, but is not necessarily limited to the following:
a.
b.
C.
d.
e.
PLC processors.
PLC I/O modules, chassis, communications modules, and power supplies.
PLC communications systems to remote I/O racks, to operator interface
terminals, between processors, and to the Operator Interface Terminal (OIT)
Stations.
PLCs shall be mounted in enclosures in accordance with Section 13330.
The programmable controller system processors, communications modules,
input/output racks, input/output modules, and operator interface computer
stations shall be configured as substantially indicated on the Drawings and
as specified herein.
2. The PLC system is designed around the Allen Bradley SLC 5/05 and related
devices.
B. Coordination
1. The Process and Instrumentation Diagrams (P&ID’s), Division 11, and the
specifications of this Division illustrate and describe the overall instrumentation
and control system functional and operational requirements.
2. All PLC and computer station equipment shall be constructed specifically for the
demanding requirements of real-time process management and control on a
continuous basis for use in a municipal water treatment plant.
1333S.PROORA”ABLELOGICCONTROL(PLC)SYSTEM.DOC13335-1 APRIL 27,2001
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1.02 QUALITY ASSURANCE / QUALITY CONTROL
A. General
1. See the factory demonstration and design coordination requirements in Section
13320.
1.03 SUBMITTALS
A. General
1. Comply with the requirements of Sections 01340 and 13320.
B. Shop Drawings
1. Hardware:
a. Submit catalog information for hardware components of the PLC system,
including processors, power supplies, backplanes, remote communications
modules, inputloutput modules, communication cables, and the like.
b. Provide a block diagram showing all PLC system components and their
interconnections. Include all interface accessories.
c. Indicate requirements for physical separation between components of the
PLC system and foreign voltage power sources, including cables.
2. Software:
a. Provide manufacture's standard catalog information and users manual for
the PLC software configuration program.
b. Prepare and inputloutput listing for the complete PLC system incorporating
the following:
1) List each point reporting to the PLC system as an input or an output.
2) Provide a narrative descriptor of each point and identify by project tag
number.
3) Reference each point by rack, slot, and terminal number.
c. Document the PLC application software program, including the following as
a minimum:
APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
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Provide a ladder diagram listing, fully annotated with a narrative
comment at each rung and a description for each element.
Provide a ladder diagram description, in which the major sections of
the program are discussed. Cross reference portions of the
description to applicable portions of the ladder diagram listing.
Prepare cross-reference lists for all programmed elements, including
timers, counters, and data registers. List each element by a narrative
descriptor and its memory address. Cross-reference each element to
all ladder diagram rung numbers where that element appears.
Provide a listing of all PID controllers. For each, identify all status
and data registers used.
Provide a listing of all PLC data registers. For each, list the memory
address, narrative description, and contents.
1.04 EQUIPMENT DELIVERY, HANDLING, AND STORAGE
A. Comply with the requirements of Sections 01610 and 13320.
PART 2 - PRODUCTS
2.01 PROCESS DESIGN REQUIREMENTS
A. Service Conditions
1. The PLC system shall be designed, constructed and tested in conformance to
NEMA Standard ICs 3-304 for programmable controllers, and shall be suitable
for use under the following environmental conditions:
a. Operating Temperature: 32°F to 110°F.
b. Relative Humidity: 5% to 95% non-condensing.
2.02 EQUIPMENT DESIGN AND FABRICATION REQUIREMENTS
A. General Design Requirements
1. Provide a complete PLC system with local and remote VO components. All PLC
and software components shall be configured to perform the functions required by
the MFEM.
2. The PLC shall be a complete system of modular design consisting of the
following major components:
t333S.PROORA"ABLELOGlCCONTROL(PLC)SYSTEM.DOC13335-3 APRIL 27,2001
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a. PLC processor modules.
b. Digital communications to remote I/O racks.
C. Ethernet type communications to the Operator Interface Terminal Stations.
d. Discrete and Analog I/O modules of the types and quantities of dedicated,
designated future, and expansion (spare) I/O point capacity requirements.
e. I/O chassis and 120 VAC system power supply for providing operating
power to the chassis, processor, I/O modules, and communication modules.
3. The PLC chassis design shall be suitable for sub-panel mounting inside control
panels. All system modules shall be designed for easy removal from and
replacement in the chassis. All discrete and analog YO modules shall be designed
to permit module removal and re-installation without disturbing or disconnecting
any field wiring terminations. Terminations to field devices shall ‘be clearly
marked.
4. Except for a processor slot, the VO chassis design shall provide any card, any slot,
plug-in packaging, with locking bars andor screws to hold the I/O modules in
place. Personality keying shall be used to prevent insertion of an I/O module into
the wrong chassis slot, once the slot assignments and module layouts are
finalized.
5. Designations for the types of input/output points are as follows:
a. DI - Isolated Discrete Input, 115 VAC.
b. DO - Isolated Discrete Output, 115 VAC.
c. RDO - Isolated Relay Discrete Output.
d. AI - Analog Input, 4-20 mA DC.
e. A0 - Analog Output, 4-20 mA DC.
6. I/O Configuration
a. The PLC system shall be provided with sufficient AI, AO, DI, DO/RDO
module cards to support all of the I/O for all of the process system and
support facilities that requires integrating in this Contract, plus 25% spare
capacity in master I/O racks and 15% spare capacity in remote I/O modules
of all types. A minimum of 4 spare I/O shall be provided in each PLC.
Some variations in the configuration will be considered provided the
I3335.PROGRA”ABLELOGlCCO~ROL(PLC)SYSTEM.DOC~3335-4 APRIL 27,2001
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physical and functional constraints as intended for the various system
components are met.
1) Supervisory PLC: Provide I/O chassis with the number of slots as
required to house all YO and communication modules as required.
No PLC chassis shall have less than 8 slots. Module placement shall
be per the I/O Listing to be provided by the MFEM. All I/O,
including future and spare, shall be wired to terminal blocks. A
minimum of eight spare dry contact relays shall be provided for
interfacing with ancillary equipment.
2) Unit Mounted PLCs: Provide local and remote I/O chassis with the
. number of slots as required to house all I/O and communication
modules as required.
b. Provide all required signal and power cables between PLC processors , I/O
racks and power supplies, as required.
7. The PLC's shall be capable of being programmed in both an off-line (program)
mode and an on-line (run) mode from any of the Operator Interface Terminal
Stations across the ethernet highway and by means of a portable DM compatible
lap-top programmer connected to the PLC processor installed in the system YO
chassis. On-line data and program logic changes shall not necessitate halting the
processor.
2.03 EQUIPMENT AND COMPONENTS
A. PLC Processors
1.
2.
3.
4.
5.
6.
Memory Size: 64K words.
Memory Type: Battery-backed CMOS RAM with EEPROM back-up. The
lithium battery shall maintain memory for a minimum of one (1) year with no
power applied to the processor.
I/O Capacity: 2048 minimum, any mix of inputs and outputs.
Scan Time: 2 msik typical.
Installation Location: Left most slot of the I/O chassis.
Diagnostics:
a. Standard, self-diagnostic routines shall be provided to determine proper
hardware and software operation.
13335.PROORA"ABLEUXiICCONIROL(PLC)SYST.EM.DOC13335-5 APRIL 27,2001
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b. Diagnostic LED's shall be provided on the processor front panel to indicate
the following:
1) Processor running.
2) Processor fault.
3) Battery low.
4) Forced I/O.
5) Communications active.
6) Communications error.
7. Communications: The PLC shall be equipped with communications ports for two
Ethernet plus the following:
a. Remote I/O communications (to I/O racks and Operator Interface
Terminals).
b. Programming terminal connection.
c. Ethernet communications to other processors and to the Operator Interface
Computer Stations.
8. Instruction Set:
a. The PLC shall be equipped with the following instructions as a minimum:
Relay-type logic functions including normally open contacts,
normally closed contacts, and output coils.
Timers: On delay, off delay, and retentive.
Counters: Up, down.
Math functions including integer and floating point, add, subtract,
multiply, divide, and square root.
Data transfer instructions.
Logical AND, NOT, OR, XOR instructions.
Compare Instructions: Equal to, greater than, less than.
Proportional - Integral - Derivative control instruction.
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b. The PLC shall support branching functions to allow any combination of
series or parallel instructions.
c. The PLC shall support the use of subroutines.
9. Clock: Battery-backed clock with a typical variation off 20 seconds per month.
10. Manufacturer and Model:
a. Allen Bradley SLC-5/05,
B. Power Supply
1. Output Current: 5 A at 5 VDC
2. Input Voltage: 120 VAC, 60 Hz.
3. Output Cument: 16 A at 5 VDC.
4. Provide all cabling as required.
5. Manufacturer and Model:
a. Allen Bradley 1746-P2
C. I/O Chassis (Backplane)
1. Type: UO chassis designed to house the PLC processor, remote I/O
communication module, NO fiber optic converter modules, and the I/O modules.
The chassis shall be subpanel mounted.
2. Manufacturer and Model:
a. Allen Bradley 1746-A2, A4, A7, A10, A13.
D. PLC System YO Modules
1. Available Types: The types of I/O modules available for use with the PLC
system shall be the responsibility of the MFEM. The following types of
manufacturer standard UO modules shall be available:
a. Sixteen point individually isolated discrete input modules which accept an
input of 115 VAC, 60 Hz. The discrete input modules shall be Allen
Bradley Model 1746-lA16.
b. Sixteen point common relay output modules with an output capability of
1.5A at 115 VAC per pint and eight outputs per common. These shall
I3335.PRffiRA"ABLELOGIC CONTROL (F'LC) SYSTEM.Doc13335-7 APRIL 27,2001
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typically be utilized for process status indicator lights. The isolated
common relay output modules shall be Allen Bradley Model. 1746-OW 16.
c. Eight point isolated realy output modules witha na output current capability
of 3A at 115 VAC per point. These shall typically be tuilized for high
current application. The relay output modules shall be Allen Bradley Model
1746-0x8.
d. Eight point isolated analog input modules (12 bit minimum resolution)
which accept an input of 4-20 mA DC. The analog input modules shall be
Allen Bradley Model 1746-NI4.
e. Four point isolated analog output modules (12 bit minimum resolution) that
produce an output of 4-20 mA DC. Analog output modules shall allow
selectable output response to faults of minimum, maximum, or last output
value. The analog output modules shall be Allen Bradley Model. 1746-
N04I.
2. Required Features: The I/O modules and system hardware supplied shall
incorporate the following design and construction features and comply with the
following requirements:
a. Noise immunity and filtering
b. IEEE surge-withstand rating to IEEE 472
c. Optical isolation for all inputs and outputs to provide controller logic
protection
d. Any card, any slot, plug-in packaging, with locking bars andor screws to
hold YO modules in place
e. 600 volt, screw type, UO wiring terminal arms sized to accommodate a
minimum of two #14 AWG wires per terminal. Wiring design shall allow
UO module removal and replacement without disturbing UO wiring
connections,
f. Front-of-module LED Status indicators for each individual input and output
point that indicate when power is applied at I/O terminals
g. Fused output circuits for all output modules. Front panel indication shall be
provided for blown fuse status
h. Where required and recommended by the manufacturer, external transient
suppressors shall be provided for installation across the output loads
I333S.PRMjRA”ABLELOGICCO~OL(PLC)SYSTEM.DOC~3335-8 APRIL 27,2001
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i. Scaling to engineering units for analog modules
j. Provide required connectors with each I/O module
E. Software
1. PLC System Software:
a. All PLC programming required to perform the functions shown on the
Drawings and specified shall be provided by the MFEM. The system shall
be provided complete, programmed, tested and fully operational.
b. Provide and install programming software on OIT-MF.
2.04 CONTROLS AND INSTRUMENTATION - NOT USED
2.05 SPARE REPLACEMENT UNITS AND PARTS
A. MFEM shall supply 1 spare processor, power supply and I/O module of each type that
is used in the PLC control system.
PART 3 - EXECUTION
3.01 MSTALLATION REQUIREMENTS
A. General
1. Install all equipment and components in accordance with the Contract Drawings,
approved Shop Drawings, and installation instructions furnished by the
manufacturer. The MFEM shall responsible for coordination of all items listed in
Division 13 specifications with the Installation Contractor.
2. Do not begin installation of field instruments, system hardware, and panel until
building construction is completed and major equipment has been installed.
3. Maintain areas where instruments, control panels and enclosures are being or have
been installed, dust free and within the environmental conditions specified for the
equipment. Make provisions for or coordinate all panel penetrations that will be
required by the Installation Contractor.
4. Inspect each instrument, panel and other items for damage and defects before
installation. Replace deficient items.
5. The PLC and I/O racks shall be installed such that all LED indicators and
switches are readily visible with the panel door open and such that repair andor
1333S.PROOR*"ABLELOGlCCO~ROL(PLC)SYSTUI.DOC13335-9 APRIL 27,2001
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replacement of any PLC component can be accomplished without disconnecting
any wiring or removing any other components.
6. Comply with the other specific installation, start-up, and testing requirements as
specified in Section 13320. Coordinate the delivery of all PLC equipment with
the Installation Contractor.
+ +END OF SECTION + +
APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
SECTION 13340
SWERVISORY CONTROL SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. MFEM shall furnish all labor, materials, and components, and shall provide all
design, assembly, programming, configuration, testing, start-up services, and
training required to provide a complete and operational operator interface as
specified and shown on the Drawings for the Membrane System. The system
includes, but is not necessarily limited to the following:
a. PLC communications systems to remote VO racks, between processors, and
to the Operator Interface Terminal station (OIT).
b. One Operator Interface Terminal Station, one printer, ethemet switches and
peripherals.
c. The operator interface computer station shall be configured as substantially
indicated on the Drawings and as specified herein. The PLC system and
OIT shall be programmedconfigured by the MFEM to perform the
functions specified in .the detailed system specification sections following
Section 11300 as well as general functional requirements specified in
Section 13350.
2. Communication from the supervisory PLC upward to the OIT shall be ethemet as
shown on the Contract Drawings. The MFEM shall submit a PLC Architecture
scheme noting all communication protocols with his bid. Some variations in the
configuration will be considered provided the physical and functional constraints
as intended for the various system components are met.
B. Coordination
1. The Process and Instrumentation Diagrams (P&ID's), Division 11, and the
specifications of this Division illustrate and describe the overall instrumentation
and control system functional and operational requirements.
2. All computer station equipment shall be constructed specifically for the
demanding requirements of real-time process management and control on a
continuous basis for use in a municipal water treatment plant.
I334O.SUPERVISORY CONTROLSYSTEM.WC 13340-1 APRIL 21,2001
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1.02 QUALITY ASSURANCE / QUALITY CONTROL
A. Refer to Section 13320, Instrumentation and Control System, General.
1.03 SUBMITTALS
A. General
1. Provide submittals in accordance with Section 01340 and 13320.
B. Shop Drawings
1. Hardware Submittals
a. Provide a complete bill of materials including relative device catalog
numbers and quantities for hardware components of the supervisory control
system.
b. Provide manufacturer’s standard catalog information for each hardware
device, showing all pertinent dimensions, functions, technical specifications,
and options provided.
c. Include a site specific arrangement drawing for all equipment cabinets and
enclosures, including dimensions, component identification, spatial
arrangements, and clearance requirements.
2. Software Submittals
a. Provide a complete description and manufacturer’s standard documentation
of the application software program, including any modifications.
b. Furnish all original program disks supplied with the standard software
packages, including any program revisions or updates issued during the
construction or installation period.
c. Provide one copy of the PLC and workstation configuration files stored in
electronic format on CD-ROM, updated to final “As-Built” condition at
project completion.
d. Provide one complete set of all workstation accessible displays in full color
graphic format organized by program hierarchy.
e. Provide one complete set of all system and unit reports.
13340.SWERVISORY CONTROL SYSTEM.DOC 13340-2 APRIL 27,2001
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f. Provide a change of ownership registration form for each standard software
package provided on the OIT to allow the District to register the software
with the manufacturer.
1.04 EQUIPMENT DELIVERY, HANDLING, AND STORAGE
A. Comply with the requirements of Sections 01610 and 13320.
PART 2 - PRODUCTS
2.01 PROCESS DESIGN REQUIREMENTS
A. General
1. Components of the supervisory control system shall be suitable for use under the
following environmental conditions:
a. Operating Temperature: 32 OF to 110 "F.
b. Relative Humidity: 5 % to 95%, non-condensing
2.02 EQUIPMENT DESIGN AND FABRICATION REQUIREMENTS
A. General:
1. Provide the OIT (MF System Work Station) as shown on the drawings and as
specified herein. Provide and install all software per the requirements below.
a. Pentium III - based, lBM compatible mini-tower computer with CRTs,
keyboards, and pointing devices. The processor speed shall be the fastest
allowed by the PLC and graphical software version used, and specified
herein.
b. Ethernet system printers for printing alarms, logs, displays, reports,
programs, displayed graphics, applications help and program
documentation:
1) One color laser printer Hewlett Packard latest model.
2) One Impact Alarm printers Epson latest model.
c. Ethernet network modules for communications between the OIT and the
PLCS.
1) Configuration: The basic configuration of the network shall have a
Ethernet switch or switches mounted in a 19" rack suitable for wall
1334O.SuPERVISORY CONTROL SV.STEM.DOC 13340-3 APRIL 27,2001
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mounting. The Ethernet Switch shall support all OIT and PLCs as
shown on the Drawings. Some variations in the configuration will be
considered provided the physical and functional constraints as
intended are met. The switches shall be suitable for stacking to
accommodate the total number of ports plus 50% spare ports.
2) Network equipment supplied shall be compatible with the network
cards and the software specified elsewhere in this section.
d. All software and software drivers as necessary to perform the reporting,
alarming, monitoring, archiving, and operator entry functions as specified
herein.
2. The graphical software shall be the latest version of InTouch, by Wonderware.
and shall allow for the maximum point count available. The Wonderware
software provided under this contract shall be licensed to the District.
a. Provide front end interface software system with complete Development and
Runtime packages. Software shall be completely installed on all computers
and configured as shown and specified to provide color graphic display
monitoring, reporting, alarming, communications, system control, trending
data logging and manipulation functions.
b. MFEM shall provide one complete Professional Developer Kit (to be
installed on OIT-MF) and one Runtime system to be installed on OIT-MF.
3. The OIT computer shall be running latest version of Windows NT workstation
version operating system. Windows NT operating system shall be installed with
active NTFS (NT File System), no FAT (file allocation table) required.
4. The software shall support communication with the PLC device interface driver
using FAST-DDE. Software shall employ a Status bit to indicate communication
status with the field device. Software shall employ a DDE Status bit to indicate
status of the DDE conversation.
5. All licensed software shall be supplied on CD-ROM and shall .become the
property of the District. All commercial software provided under this contract
shall be licensed to District.
6. In addition to The Windows NT operating systems and the front end application
software packages, MFEM shall furnish, install and configure one licensed copy
of Microsoft Office 2000, latest version as well as the PLC software configuration
program. These shall be installed on OIT-MF.
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7. MFEM shall develop interface graphics screens to monitor and control the
processes as shown on the P&IDs and specified herein in accordance with the
general hctional requirements specified below. Suggested display layouts shall
be submitted for review and approval. Proposed graphic screens will be reviewed
with the District at a coordination meeting as specified in Section 13320. The
following screens are suggested for the operator interface:
a.
b.
C.
d.
e.
f.
g.
h.
i.
j.
Plant Overview.
UNIT Overview (1 per UNIT).
UNIT Status (1 per UNIT).
cIP Overview.
Plant Setpoints.
Historical Trends.
Plant Realtime Trends.
UNIT Realtime Trends (1 per UNIT).
System Setpoints
Alarm Configuration and Handling
8. Graphics screens shall not be crowded with information and shall be logically laid
out for easy view and operator control via use of the mouse.
9. MFEM shall develop one Plant Performance Overview monitoring screen for the
process and one for the PLC network with all Nodes and printers.
10. The system shall include a library of symbols from which custom graphic display
to be generated. The operator (District’s personnel) shall be able to modify
existing symbols or create new symbols and insert them into the library. Graphic
displays shall include both static and dynamic symbols. Dynamic syinbols shall
change color and/or shape depending on actual process conditions. Text windows
and analog values shall also dynamically update to reflect changing process
conditions. The graphic displays shall be configured by the control system
supplier as described herein and in the control descriptions in Section 13350.
Suggested display layouts shall be submitted for review and approval in
accordance with the requirements herein.
11. Reports shall be created to provide a record of plant process conditions. The
reports shall access the real time I/O and historical data bases and shall include
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such calculated values as run times, totals, averages, minimums, and maximums
over hourly, daily, weekly, and monthly time intervals, in addition to current
(snapshot) data values. Reports shall be created in an appealing and..useful
format, Suggested report layouts shall be submitted for review and approval as
specified herein.
12. Alarm processing and reporting shall be coordinated by the operator interface
software supplier. All alarms shall be logged and printed along with the data and
time when they first occur, when they are acknowledged, and when they return to
normal. The alarms shall be displayed on a common alarm summary screen and
on the graphic display associated with the alarmed process.
13. All data displayed or reported at the OIT shall be stored in historical data files.
The system shall maintain historical data on the hard disk for a period of 45 days
minimum up to 90 days maximum before being archived. System shall archive
collected data on a monthly basis (30 or 31 day's worth of data) to the Optical
Drive Cartridge. The archived data shall be readily available for import and
subsequent reporting at any time. Historical data shall be available for use in
reports and trends. The MFEM shall supply historical trend screens for the
following:
a. Plant Influent Data (1 point unless stated otherwise).
1) Feed VFD Speed (1 for each VFD Drive).
2) Feed Flow
3) Feed Temperature
4) Feed Manifold Pressure
5) Feed Turbidity
6) Receiver Air Pressure.
b. Plant Effluent Data (1 point unless stated otherwise)
1) Filtrate Flow
2) Filtrate Manifold Pressure
3) Filtrate Clearwell Level
4) Filtrate Turbidity
5) Filtrate Chlorine Residual
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c. UNIT operational performance data (1 per UNIT).
Trans-membrane Pressure
Flow Control Valve Position or Extraction Pump Speed, as
applicable.
Feed Pressure.
Filtrate Pressure.
Filtrate Setpoint.
Filtrate Flow
Any other Pressure or Flow Value measured at the unit.
Membrane Resistivity or Permeability (Temperature Compensated).
d. Historical Data Logging shall provide historical data logging to the hard
drive all trend points. Data logging shall occur once per hour. Data shall be
saved in a format that can be easily retrieved and manipulated in Microsoft
Excel (.xls) format.
e. MFEM shall calculate the daily totalized, display and log the totalized flow
for all installed flow meters including:
1) Feed Water Flow.
2) Filtered Water Flow (Plant).
3) UNIT Filtered Water Flow.
f. The operating screen shall display the totalized flow passed through the flow
meter for the current day as well as previous day.
g. The MFEM shall create a set of custom graphics displays that properly
represents the process as depicted on the P&IDs and as described herein.
The graphics will be the operator's interface to the actual process of the
facility and the main operating medium. This interface shall include facility
equipment, dynamics, point values, product representation, valve positions,
status of motors, and any other information that can be obtained from the
implemented instrumentation or is pertinent to operations and maintenance.
h. MFEM shall be responsible for the development of several layers of custom
graphics, and shall prepare and submit a drafted sample of each layer to be
13340.SUPERVISORY CONTROL SYSTEM.DOC 13340-7 APRIL. 27,2001
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MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
approved by the District and Engineer before development of the entire
graphics package. The draft should be submitted in color and should be
representative of all of the graphics in the layers so that Owner preferences
can be incorporated into the initial graphics development. MFEM should
expect and provide for direct District participation in the conceptual
development of the custom graphics displays. Each custom display created
by the MFEM shall be approved and accepted by the District before being
considered complete. MFEM shall allow District to operationally review
each custom display once for markups and comments before MFEM issues
the displays as complete.
i. Alarm Display and Acknowledgment:
The software shall have the ability to acknowledge individual alarms,
groups of alarms, or all alarms via a single keystroke or pre-
configured automatic response.
The software shall be able to be configured to either require operator
ACK or alarm before clearing, or to imply ACK when the alarm
condition is no longer present.
The software shall be able to display alarm status via color change or
blink in line, text, or fill attributes.
The software shall have both alarm summary and alarm history
displays with configurable message text including: DATE, TIME,
TAGNAME, ALARM EVENT, ALARM TYPE, VALUE,
SETPOINT, COMMENT.
The alarm summary and alarm history displays shall be configurable
for color of alarm window, new alarms, ACK alarms, and RTN
alarms.
Alarms shall be able to be routed to screen, printer, and/or disk file.
14. Detail System Schematic Graphic Displays:
a. MFEM shall be responsible for the development of one or two custom
graphic displays for each P&ID, with suggested minimum breakdowns and
general information content as specified herein. The graphic displays will
incorporate all of the detail as shown on the P&ID along with all dynamics
and variables available from the supplied instrumentation. The MFEM shall
estimate, in the submittal, the total number of detail graphic display
schematics to be developed.
1334O.SWERVISORY CONTROL SYSTEM.WC 13340-8 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
b. Detailed graphic display development shall incorporate, but not be limited to
the following features and functions:
All static equipment (no instrumentation) shall be white in color.
Running equipment shall be red; stopped equipment shall be green.
Only valves that can be operator or digital system controlled will be
represented on the graphics.
Two-position valves with positive feedback will be red when open,
green when closed, and yellow when in transition.
Analog control valves will be the color of the process line in which
they are installed and will have a percent open indication value next
to them. This value is actually the controller output if positive
feedback is not available. In cases in which analog control valves
have limit switches for position indication, the valve should turn
green when closed.
Alarms shall be indicated within the graphics by changing devices or
points to colors dependent on the type and severity of the event. The
MFEM shall submit proposed alarm annunciation scheme to the
District for approval.
The operator shall be able to acknowledge active alarms from the
custom display.
Schematic displays shall be logically arranged and connected so that
the operator can move from display to display by using targets, or
selectable points, on the graphics.
The operator shall be able to access the control graphic displays
related to the detail graphic system schematic directly from the
graphics display.
If the equipment is involved in batch production, appropriate
information that details the status of the batch recipe shall be
incorporated into the display. In addition, operator control functions
with respect to the execution of the batch procedure shall also be
available on the graphics display.
15. Control Schematics Displays:
a. The MFEM shall develop a set of custom displays that incorporate the
primary control and monitoring data necessary for the operation of facility
1334o.SuPuIVlSORY CONTROLSYSTEM.DOC 13340-9 APRIL 27,2001
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MF EQUIPMENT PROWMEN'I
Carlsbad Recycling Facility
units. These displays, or overviews, will be used to operate a process that
would normally appear spread out over several detail control schematic
displays. The MFEM shall estimate, in the submittal, the total number of
control schematic displays to be developed.
b. Control schematic displays shall incorporate, but not be limited to, the
following features and functions:
1) The operator shall be able to access the related detail control
schematics directly from the associated graphics display.
2) If alarms are present on a detail system schematic, this should be
reflected to the operator on the control schematic display.
3) An overall batch execution display for chemical batching and
Membrane Filter units rotation and cleaning shall be developed that
allows the operator to view a summary of all of the executing batch
recipes in the facility, along with the status of each.
16. Overview Display:
a. The MFEM shall be responsible for the development of one overview
graphics display for the entire system. The display shall summarize the
entire facility in a fashion that allows the operator to access any control
display in the system by selecting an area or unit from the graphics. The
MFEM shall use graphics symbols along with appropriate text to create the
display. *
b. The MFEM shall be responsible for the development of one or two
overview graphics displays that will represent the PLC system in a dynamic
format for all PLCs, OIT, printers, data highway status.
17. Maintenance and Help Screens:
a. The MFEM shall be responsible for the development of at least one-
maintenance or help screen for each custom graphic display schematic in the
system. These displays shall incorporate the,se use of hypertext to assist the
operation and maintenance personnel in use of the control system, and in
monitoring, operation and troubleshooting of the plant operating systems
and equipment. They will include operational procedures, equipment lists,
control descriptions, and similar informative data. The District will work in
conjunction with the "EM on the definition and format of these displays.
18. Graphic Standards:
13340.SUPERVISORY CONTROL SYSTEM.DOC 13340-10 APRIL 27.2001
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MF EQUIPMENT PROCUREMENT
a. All custom graphics shall incorporate, but not be limited to, the following
features and functions:
Each display will have a description in one of the four comers of the
graphics layout.
All equipment will be identified by the equipment numbers as they
are assigned on the P&IDs.
All process lines and equipment will be color-coded. MFEM shall
propose a color scheme to the District for approval.
All process lines will have directional flow arrows and will enter and
leave the related graphics displays at approximately the same screen
location @om display to display).
All process lines will have a description depicting line origin and
destination.
All process lines will be "targeted" where they enter and leave the
graphics page so that the operator can select the target and call up the
related graphics display, giving the effect of flowing between
displays.
The operator shall have full control and functionality, from the
custom graphics display, of any point appearing within the display.
This includes, but is not limited to, set point changes, mode changes,
controller tuning, alarm set point adjustment and similar point
features.
19. Documentation Standards:
a. File Naming Conventions: After release of purchase order, the MFEM shall
submit a standard file naming convention to the District, for approval, for all
programs and data developed during the system configuration. This
includes, but is not limited to, custom code, data base files, and graphics
displays. The MFEM shall utilize the naming convention for all files
developed within the scope of this specification.
b. Program Documentation: All programs and custom code written by the
h4FEM shall be submitted to the District for approval. The MFEM is
responsible for properly documenting the code in a manner that expedites
future modifications or additions to the program or application.
c. Software Rights: Any applicable source code which was developed in order
to accomplish specific tasks shall become property of the District. The
13340,SWERVISORY CONTROL SYSTfM.WC 13340- 1 1 APRIL 27,2001
City of Carlsbad
Cadsbad Recycling Facility MF EQUIPMENT PROCUREMENT
compiler used to compile the above mentioned source code shall be turned
over to the District before acceptance testing.
d. Updated Design Documents: The MFEM shall update, or provide as-built,
one complete set of the supplied design documents within four weeks after
completion of start-up of the facility. The documents shall be marked in a
manner that is legible to the District so that the District can make the
necessary changes to the original copies. The design documents include the
flow charts, system block diagrams, and cause and effect drawings.
e. Hard Copy Requirements: The MFEM shall be responsible for producing
hard copy printouts of all configuration data developed, including color
graphics displays. These printouts shall be submitted to the District within
two weeks after completion of the facility start-up. If color graphics
displays cannot be color printed, reproducible color photographs shall be
supplied as an alternative.
f. Custom Report Development
1) MFEM shall create a set of custom reports that provide process
information as shown on the Drawings and as specified herein.
2) MFEM shall prepare 'and submit a draft sample of each type of report
to be approved by District and Engineer before the development of
the entire report package. MFEM should expect and provide for
direct District participation on the conceptual development of custom
process reports. Each report created by MFEM shall be approved and
accepted by the District before being considered complete. MFEM
shall allow District to operationally review each report for comments
before MFEM issues reports as complete.
3) All programs and custom code written by MFEM for process reports
shall be submitted to the District for approval. MFEM is responsible
for properly documenting the code in a manner that expedites future
modifications or additions to the program or application. For this
contract, two compete iterations of comment and/or review will be
provided. Additional custom code will be provided by the MFEM at
additional cost.
4) Any applicable source code which was developed in order to
accomplish specific tasks shall become property of the District. The
compiler used to compile the above mentioned source code shall be
turned over to the District before acceptance testing.
13340.SUPERVISORY CONTR0LSYSTEM.DOC 13340-12 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
5) MFEM shall be responsible for producing hard copy printouts of all
configuration data developed, including custom reports. These
printouts shall be submitted to the District within two weeks after
completion of the facility start-up.
2.03 EQUIPMENT AND COMPONENTS
A. Computers: All of the computer components shall be listed on the latest Microsoft
Windows NT Version Compatibility list, and shall meet the following requirements:
1. Main Board:
a. Intel Pentium III based CPU - 1.0 GHZ or greater. (PLC and Graphical
software dependent)
b. Memory Architecture: Main board and be expandable up to 512 MB
SDRAM utilizing the same type of memory chips. 256 MB of RAM shall
be installed initially.
c. Bus Interface: supporting up to six (6) EISA Bus Master adapter cards,
d. Cache: Integrated 256 KB direct mapped write back.
e. Manufactured by
1) Dell Computer Corporation
2) Gateway
3) IBM
4) Sony
2. Video Adapter: 32 Mb (Minimum) NVDIA TNT2 M64 4X AGP Graphics
3. Magnetic Storage (All OIT Internal Hard Disk Drive):
a. Interface: Fast SCSI-3 1 & Fast Wide SCSI-3.1.
b. Formatted Capacity: 60 GB or greater.
c. Projected Field MTBF: 500,000 hours.
d. Data Transfer rate: 20 mb/sec (Fast Wide SCSI).
e. Manufactured by Quantum or equal.
13340.SWERVISORY CONTROL SYSTEM.DOC 13340-13 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
4. Storage Interface Controller.
a. Interface: SCSI-2 and SCSI-3.
b. Protocol support: Fast and Wide SCSI peripherals.
c. Data Transfer rate: 33 MB / Sec. on EISA Bus.
d. Provide complete KIT for each system with all available software drivers to
support Erasable optical disk, CD-ROM and any externally connected SCSI
devices. In case of PC1 bus selection, the interface controller shall be 100
percent tested for compatibility with PCI-2.0 Specifications. In case of
EISA bus selection the interface controller shall also support two internal
floppy disk drives. This controller shall support all drives.
e. Manufactured by Adaptec, STB, Future Domain or equal.
5. Audio Synthesizer Board: Audio Synthesizer Board shall provide audio output to
internally installed in auxiliary chassis amplified loud speakers. The board shall
be capable of digitizing sounds using Text-To-Speech syntheses and storing files
in "Wav" format. Wav files shall be stored in the directory "SOUND" of the
Microcomputer and be used by the OIT front-end application as an alarm and
status annunciation, i.e. the system shall play a voice alarm message via speaker
until the alarm is acknowledged. MFEM shall create the most common sound
files, like Open, Close, Pump, Run, On, Off, High, Low, Failure, Malfunction,
etc., and shall provide any additional sound files as needed during start-up and
final acceptance test. Manufactured by:
a. Creative Lab
b. AT1
c. Turtle Beach.
6. Network Adapter: Ethernet adapter shall comply with the IEEE 802.3 Ethernet
standard and shall be fully compatible with Windows NT operating system.
Adapter shall be provided with standard diagnostics and network drivers.
Adapter shall have the following characteristics:
a. Support direct connection to 100 MB ethernet cabling for computers and
network switch and 10 Base-T for PLC communication.
b. EISA-bus master interface and support the EISA 33mb/second burst mode
for data transfer at maximum speed.
c. Memory: 48Kb SRAM minimum.
13340.SUPERVISORY CONTROLSYSTEM.WC 13340-14 APRIL 27,2001
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Carlsbad Recycling Facility
d. Manufactured by Intel, Model EtherExpress32, or equal.
7. CD-ROM Drives: Provide internal CD-ROM and CD-RW drives for the
computer.
a. 48X CD-ROM Drive
b. 12X CD RW Drive
8. External 3.5" floppy drive: (one)
B. Input Devices
1. Keyboard: Provide 101- Key small footprint construction.
2. Mouse Resolution: 400 points per inch, Two-button control with scroll USB
interface.
C. Output Devices
1. Printers: One Ethernet alarm printer and one ethemet color/report printer each
shall be located in the control room. The alarm Printer shall be configured to
print all alarm events in the order as they appear in the system. MFEM shall
provide 3 boxes of paper and 3 printer heads /cartridges.
2. Printer characteristics:
a. Manufacturer
1) Epson
2) Hewlett Packard
3) Cannon
3. One Network Color GraphicsReport Printer:
a. Printer shall utilize ink-jet technology with resolution up to 720 x 300 dpi;
b. Printer output shall be up to 10 ppm in color, and 12 ppm in black and
white.
c. Provide upper and lower paper tray assemblies. Printer shall use plain paper
and / or transparencies. No special papers should required.
d. Memory: 48 MB installed.
I3340,SUPERVISORY MN'IROL SYSTEM.DoC 13340-15 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
e.
f.
g.
h.
i.
j.
k.
1.
m
Description Language (PDL): Adobe PostScript Level 2, PCLS emulation
Resident Typefaces: 35 Adobe Type 1; 13 intellifonts; 7 bitmapped fonts; all
typefaces shall have multilingual character sets.
Software Compatibility: Printer drivers for Windows NT.
Extended Features: 69 Resident fonts, with full set of supplies.
Resolution: 720 x 300 dpi in color.
Maximum Duty Cycle: 5,000 prints/month.
Paper Handling:
1) Media Sizes: Letter, legal, A4, and executive.
2) Weight: 16-28 Ibs. (60-105 g/m2).
3) Media Input: One universal paper tray, holding up to 250 sheets of
paper and standard singlekheet manual bypass tray.
Automatic Jam Recovery-Automatically reprints jammed pages.
Manufacturer
1) Hewlett Packard
2) Epson
3) Cannon.
4. Computer Monitor (CRT)
a. Size: 21-inch (OICS 1-2) 17 inch OICS 3 & 4.
b. Dot Pitch: 0.28 111111.
c. Tube Type: Flat square.
d. Resolution (max): 1600 x 1280.
e. Power Supply: 180 - 264 VAC, 47 - 76 Hz.
f. Manufacturer
1) Sony
13340.SWERVISORY CONTROL SYSTEM.DOC 13340-1 6 APRIL 27,2001
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Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2) NEC
3) Mitsubishi.
5. Speakers: Speakers shall be securely mounted in the computer console. The
console shall be provided by others under a future contract. Speakers shall meet
the following characteristics:
a. Driver (satellites): 4 inch shielded woofers, 2" dome tweeters with
ferrofluid cooling.
b. Drivers (subwoofer): Two 4 inch long woofers.
c. Manufacturer
1) Polk
2) Creative Lab
3) JBL
D. Network Equipment
1. Ethernet Switches:
a. Compliant with IEEE 802.3 standard.
b. One Coax (thinnet) port, minimum per switch.
c. 10/100 Base-TX and two 10 Base-T ports, minimum per switch.
d. Provide all Ethernet switch software required and provide switch
configuring to provide a working network.
e. Manufacturer:
1) Cisco.
2) 3Com.
3) Or equal.
2. 4 Port Repeaterrnub:
a. Compliant with IEEE 802.3 standard.
13340SUPERVlSORY CONTROL SYsTEM.wC 13340-17 APRIL 27,2001
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MF EQUIPMENT PROCUREMEM
b. Unit shall use a modular approach that allows ports of different types to be
installed in the repeater.
c. Unit shall provide for installation of a minimum of four ports.
d. Provide total number required by MFEM design.
e. Product and Manufacturer:
1) Anyway repeater by IMC Networks,
2) Or equal.
E. Software
1. Provide and install a virus protection software on the OIT, Norton Antivirus for
Windows NT, or equal.
2. The graphical software shall be the latest version of InTouch, by Wonderware
and shall allow for the maximum point count available. Graphic Software
Requirements are as follows:
a.
b.
C.
d.
e.
f.
g.
h.
The software shall allow definition of the following variable types
[Tagnames] for communication with the I/O device (programmable
controller) and/or other programs:
The software shall allow definition of the following variable types
[Tagnames] for internal computation and communication with other
programs:
The software shall allow definition of up to at least 32000 Tagnames total.
The software shall allow creation and modification of Tagnames on-line.
The software shall prevent deletion of Tagnames used by the application.
The software shall allow readwrite (i.e. operate as a DDE Client or Server)
access to Tagnames by other programs via Microsoft Dynamic Data
Exchange (DDE).
The software shall have an embedded logic engine which allows
manipulation of Tagnames via logical, relational, conditional and arithmetic
operators.
The embedded logic engine shall allow automatic actions (i.e.: no user
intervention) Alarms:
13340.SWERVISORY CONTROL SYSTEM.= 13340-18 AF'IUL 27,2001
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MF EQUIPMENT PROCUREMENT
The software shall have the ability to detect HIHI, HI, LO, LOLO,
Rate-Of-Change, and Deviation alarms for all analog variables.
Alarm limits for analog alarms shall be able to be modified during
operation by either operator selection or via pre-configured automatic
response.
The software shall have the ability to process Change-Of- State
alarms for discrete variables.
The system shall allow configuration for automatic response to alarm
conditions (change set point, shutdown, call up new screen,
opedclose discrete points, etc).
Alarm detection shall employ a user-configured dead band per
Tagname.
Software shall support up to 999 alarm priority levels.
Alarm priority levels shall be individually assignable per alarm.
3. Realtime Trending:
a.
b.
C.
d.
e.
f.
g.
h.
Software shall allow the configuration of realtime trend displays which
update continuously as new values are acquired.
Realtime trend display shall be in Variable versus Time format.
Realtime trend display shall support scaling of both variable and time axes.
Realtime trend display shall support 4 variables per graph.
Software shall allow any number of realtime trend graphs per screen.
Software shall allow configuration of Realtime trends and Historical trends
on same screen.
Software shall allow configuration of trend graphs and other animation (bar-
charts, pushbuttons, etc) on the same screen.
Realtime trend shall support trending result of arithmetic and/or logical
expressions involving Tagnames by typing in the expression in the desired
pen field.
4. Historical TrendindArchiving and Playback:
13340.SWERVISORY COMOLSYSTEM.WC 13340-19 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
a.
b.
C.
d.
e.
f.
g.
h.
i.
j.
k.
Software shall support Historical Trending by which variable data is
continually stored on hard disk and provides trend display to call up stored
trend data.
Historical trend display shall be in Variable versus Time format.
Historical trend display shall support scaling of both variable and time axes.
Historical trend display shall support 4 variables per graph.
Software shall allow any number of historical trend graphs per screen.
Software shall allow configuration of Realtime, and Historical trend on
same screen.
Software shall allow configuration of trend graphs and other animation (bar-
charts, pushbuttons, etc) on the same screen.
Software shall allow "zooming" on either time or variable axis from a single
keystroke/touch/click.
Software shall allow automatic manipulation of historical trend chart's
variables, variable scaling, and time scale without user intervention.
Software shall allow the export of Historical trend data in comma-separated-
variable (CSV) format.
Historical trend data storage shall be exception-based, and employ a user-
configured deadband (deviation from previous value) per Tagname.
5. Reports:
a. Software shall support printing of any screen created by the system
designer, whether or not it is the current active screen used by the operator.
b. Software shall allow screen prints based on demand (i.e. pushbutton), event,
time, or combination thereof.
c. Software shall allow other programs to access Realtime and Historical
Tagname data using DDE.
F. Graphical User Interface:
1. The software shall employ object-oriented graphics.
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MF EQUIPMENT PROCUREMENT Carlsbad Recycling Facility
2.
3.
4.
5.
6.
7.
The software shall provide basic drawing tools including scalable circles, squares,
rectangles, filled polygon, connected lines, and orthogonal lines.
The software shall allow the designer to select a line color, fill color (where
appropriate), and text color (where appropriate) for any object.
The software shall allow the designer to create new scalable objects by grouping
objects together.
The sohare shall allow the designer to import bitmapped graphics from other
programs and scanners and to create new scalable objects with the imported
images.
The software shall allow the designer to animate the objects using any of the
following animation tools:
a.
b.
C.
d.
e.
f.
g.
h.
1.
j.
k.
1.
m.
Change Object's Line Color Discrete ON/OFF Status.
Discrete ALARM Status Analog Level.
Analog Alarm Status, or combination thereof evaluated as a logical,
relational, or arithmetic expression.
Change Object's Fill Color See above.
Change Object's Text Color See above.
Change Object's Width See above.
Change Object's Height See above.
Change Object's Horizontal Location on Screen See above.
Change Object's Vertical Location on Screen See above.
Change Object's %FILL in Horizontal Direction (R-L or L-R) See above.
Change Object's %FILL in Vertical Direction (T-B or B-T) See above.
Change Object's Orientation (through 360 degrees) See above.
Cause Object to Blink
The software shall allow the designer to display Tagname values in Text format
using any size and font supported by Windows operating system.
13340SWERVISORY CONTROL SYSTEM.DOC 13340-21 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
8. The software shall allow user actions to be executed fiom keyboard, function
buttons, or mouse with equal facility.
9. The software shall allow the designer to create objects to be used as
"pushbuttons" to allow the following user actions:
a. Change state of Discrete Tagname using single keystroke/ touch/click.
b. Change state of Discrete Tagname using a select and confirm operation.
c. Change Analog Tagname by typing in the new value using keyboard.
d. Change Analog Tagname by typing in the new value using a mouse and a
numeric keypad.
e. Change Analog Tagname by typing in the new value.
f. Change Analog Tagname by typing in the new value using an object as a
"slider".
g. Call up new screen.
h. Call up a new screen in a particular X,Y location.
i. Change group of Tagname values from a single keystroke/ touch/click.
j. Download a predefined recipe from a single keystroke/ touch/click.
k. Invoke another program and send commands to it fiom a single
keystroke/touch/click.
10. The software shall allow Export and Import of screens created with the software
for other applications.
11. The software shall allow export of the Tagname dictionary to CSV format, and
allow the import of Tagnames from a CSV file.
12. The software shall support copy, paste, and substitute Tags function.
13. The software shall support multimedia so that Windows sound files (.way) may
be employed in the animation scheme.
14. The software shall support development of screens with pixel resolution up to
1280 x 1024. Development shall be done for resolution 800 by 600.
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15. The software shall support execution on any Windows supported PC with any
Windows-supported peripherals (i.e. printer, graphics card, mouse, keyboard,
etc).
G. Security
1. Software shall allow system designer to individually disable Windows-standard
elements, including: Size Controls, Control Bar, Title Bar, Pull-Down Menu Bar,
Maximize Button, Minimize Button, Restore Button, ALT Key, and CTL-ESC
Key.
2. Software shall support up to 500 user names, each with unique Operator Name
and Password.
3. Software shall support up to 9999 Access Levels.
4. Software shall allow system designer to restrict access to screens, function
buttons, data entry fields, setpoint changes, recipe downloading, other programs,
exiting the software, etc through use of Access Levels, Operator Name, or
combination thereof.
5. MFEM shall configure the security system for District's operations and
maintenance personnel. Security levels and access capabilities shall be selected
by District.
H. Additional Required Capabilities of the Supplied Applications Software
1. Software shall support a Recipe Option to allow creation, review edit, upload
from field device, download to field device, and saving of recipes from the
Software to CSV files.
2. Software shall support a SPC Option to allow the collection, presentation,
alarming, and export of SPC data; Creation of dynamic XBAR, XBAR-R,
Histograms, and Pareto Charts; and ability to automatically adjust process
parameters based on SPC analysis.
3. Software shall support and provide a Network Option to allow any Tagname to be
read from any other computer via NETDDE. Supported networks shall be Serial,
NETBIOS, and Decnet.
4. Software shall support a SQL Access Option to allow realtime data to be inserted
to a SQL database, and allow records to be extracted from a SQL database.
Supported SQL databases to include Oracle, Microsoft and Sybase SQL Server,
IBM OS/2 Database Manager, and Gupta SQLBase.
I. PLC System Software/Hardware
13340.SWERVISORY CONTROL SYSTEM.WC 13340-23 APRIL 27.2001
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Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
1. Provide one set of programming cables and hardware keys or module cards and
installed in OIT-MF.
PART 3 - EXECUTION - NOT USED
+ + END OF SECTION +t
I3340SWERVISORY CONTROL SYSIEM.M?€ 13340-24 APRIL 27,2001
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MF EQUIPMENT PROCUREMENT
SECTION 13350
CONTROL LOOP FUNCTIONAL DESCRIPTIONS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. MFEM shall furnish all labor, materials, and components, and shall provide all
design, assembly, programming, configuration, testing, start-up services, and
training required to configure the system PLCs and OIT to accomplish the control
system functional requirements shown on the Drawings and specified herein.
B. Coordination
1. This section defines general functional requirements for the control system and
overall control architecture. For detailed functional requirements, see the loop
function data sheets attached as supplements to the detailed system specification
sections following Section 11300.
PART 2 - PRODUCTS
2.01 PROCESS DESIGN REQUIREMENTS
A. Control System Architecture
1.
2.
3.
4.
5.
6.
All analog and discrete inputs to the PLC shall be displayed at the OIT.
Trending for all analog inputs to the PLC shall be performed.
All analog inputs shall be scaled into specified engineering units at the PLC.
All flow inputs shall be totalized at the PLC and displayed at the OIT.
All pump run status inputs shall be used to establish RUN time meters at the PLC
and displayed at the OIT.
Displays shall be arranged using a hierarchy level, where the first level of a
process area shall show only information that needs to be immediately available
for operations and shall be a system overview. The second level shall be poke
points for more details on a particular process or piece of equipment. The thrd
1335O.CONTROL LOOP FUNCTIONAL DESCRIPTIONS.WC 13350-1 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT Carlsbad Recycling Facility
level shall also be poke points for control stations for devices such as pumps and
valves, etc.
7. For all equipment controlled by the PLC, receive and display specified status and
alarm signals, such as operating mode (LOCAL, REMOTE, etc.), operating status
(ON, OPEN, CLOSED, etc.) and alarm status (FAIL, LOCKED-OUT, etc.). For
multistate devices where an actual digital input is not shown on the P&IDs,
provide PLC logic based on the status of the other inputs to develop the remaining
status. For example, for LOR switches, use the status of the LOCAL and
REMOTE inputs to develop and display the status of the OFF position.
8. For all equipment controlled by the PLC, provide separate displays and poke
points for selection of AUTOMANUAL operating modes. In AUTO mode, the
device shall be controlled by the PLC. In MANUAL mode, the device shall be
operated by START/STOP, OPENELOSE poke points, as appropriate. The OIT
shall display the current operating status of each device and an alarm if the
equipment fails to respond to a command signal after an operator adjustable time
period.
9. All proportional plus integral plus derivative (PID) control functions shall be
performed at the PLC with controller faceplate displays at the OIT. All standard
PID control operator interface shall be provided, including AUTOMANUAL
mode selection. In AUTO, the controller output shall be based on the PID control
function at the PLC. In MANUAL, the output of the controller shall be based on
an operator set value. Transfer between MANUAL and AUTO shall be
bumpless. At the OIT, provide AUTOMANUAL selection poke points for PID
controlled equipment, with graphic loading displays for manual control.
10. All alarm functions shall be canied out at the PLC level. Equipment safety
interlocks specified to shutdown equipment “independent of control mode” or
other like description shall be active regardless of PLC (MANUAL/AUTO) or
field control station (ON, LOCALJREMOTE) operating status. Other software
generated alarms shall remain active independent of operating mode, but only
effect specified control actions in AUTO (PLC) and REMOTE (field) operating
modes.
B. Level of Automation
1. Manual:
a. In the Manual mode of control, control shall be either at the MCC or at the
device’s local control panel or control station.
IJ35O.CONTiOL LOOP FUNCTIONAL DESCRIFTIONS.DOC 13350-2 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
b. The LOCAL/OFF/REMOTE selector switch shall be in LOCAL position, or
the HAND/OFF/AUTO selector switch shall be in the HAND position for
the Manual mode to be functional.
c. Control of a device in the Manual mode shall be by the local operator with
equipment safety interlocks active through the PLC.
2. Automatic:
a. In the Automatic mode, control shall be by the PLC.
b. The LOCAL/OFF/REMOTE selector switch shall be in the REMOTE
position, or the HAND/OFF/AUTO shall be in the AUTO position for the
Automatic mode to be functional.
2.02 EQUIPMENT DESIGN AND FABRICATION REQUIREMENTS
A. Loop Function Data Sheets
1. General:
a. Required control functionality associated with each discrete control loop
enumerated on the P&IDs is further described in the loop function data
sheets attached as supplements to the detailed system specification sections
following Section 11300.
2. The following terms are used in the descriptions of loop functions:
a. Operator Entered Setpoints: Process values that are entered by the operator
at the OIT operator station which are required to operate the treatment
system. Some examples of operator entered setpoints are flow, chemical
dose, or pressure setpoints for process control purposes.
b. Operator Adjustable Setpoints: Values that are entered at the OIT to modify
or change PLC control parameters. These values shall be adjustable from
operator displays at a higher level of password protection. Some examples
of operator adjustable setpoints are PID parameters, time settings, and alarm
setpoints.
3. Fields:
a. Component Summary
1) Tag Number(s): Lists the tag number of devices residing in the loop.
13350.CONTROL LOOP FUNCTIONAL DESCPlPTIONS.DOC 13350-3 APRIL 27,2001
city of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
Component Code: Lists the applicable component code for each
device as cross-reference to specification requirements.
Component Name/Type: Provides a narrative descriptor of each
device.
Process Rangektpoint: Lists the device normal measuring range or
process setpoint.
Full Scale Range: Lists the device full scale measuring range or
range of setpoint adjustment.
Process Fluid: Identifies the process fluid to which wetted
components of the listed device are exposed.
Process Connection(s): Identifies the configuration of the device
process interface.
b. Summary of Loop Functions External to the PLC: Provides a narrative
description of loop functions which are carried out external to PLC software
controls.
c. Summary of PLC Loop Functions: Provides a narrative description of loop
functions which are carried out at the PLC level.
PART 3 - EXECUTION - NOT USED
+ + END OF SECTION ++
I33SO.CO~ROLux)P FUNCTIONAL DESCRIPTIONS.WC 13350-4 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 15062
STAINLESS STEEL PIPING SYSTEMS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide stainless steel piping systems where shown and where
specified, or where required by the MFEM for his system.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
A. Manufacturers’ Qualifications
1. Manufacturer(s) of the piping furnished under this Section shall have experience
in providing similar type of piping and shall show evidence with his submittal of
at least five (5) installations where the piping of the same material and same
application of the type specified herein have been in satisfactory operation for at
least five (5) years.
2. All piping of the same type shall each be the product of one manufacturer.
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a.
b.
C.
d.
e.
f.
g.
h.
Standards of American Water Works Association, AWWA.
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 US. 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.
IS062.STAMLESS STEELPIPING SYSTEMS.DOC 15062-1 APRIL 27.2001
city of Carlsbad
MF EQUIPMENT PROCUREMEN?
Carlsbad Recycling Facility
C.
1.03
A.
B.
C.
1.04
A.
Manufacturers Quality Assurance / Quality Control Program
1. Stainless steel piping shall be obtained from a manufacturer who has a continuous
quality control program. All stainless steel materials used to manufacture pipe
and fittings under this Section shall be tested for conformance to the requirements
of the referenced ASTM standard. Submit results of the tests.
SUBMITTALS
Shop Drawings
1. Submit detailed drawings and data for piping.
Installation Instructions
1. Complete operation and maintenance instruction, lubrication schedules and
troubleshooting guides shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340.
Certificates Warranties and Guarantees
1. Submit certificates of compliance with applicable referenced standards.
PRODUCT DELIVERY STORAGE AND HANDLING
General
1. Refer to Sections 01610 and 01611.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Pipe Material
1. Stainless steel pipe shall be made from all new material and shall be welded
process, Grade TP316L, Schedule 10s in accordance with ASTM A 312 Standard
Specification for Seamless and Welded Austenitic,Stainless Steel Pipes.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Branch Connections
1. Branch connections may include wrought tees or reducing tees, forged
commercial welding branch fittings, extruded reducing branches, or weld-o-lets.
I5062.STAMLESS STEELPIPING SYSTEMSSYX 1.5062-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Branch connections shall be tees or reducing tees in conformance with ASTM
A403 - Standard Specifications for Wrought Austenitic Stainless Steel Piping
Fittings, Grade WP3 16L, Class W with schedule to match the connected piping.
Tees shall have no welds in the throat area and the crotch shall be reinforced with
long radius design to eliminate sharp corners.
3. Forged commercial welding branch fittings with butt welded outlet shall be
stainless steel, in conformance with ASTM A182 - Standard Specification for
Forged or Rolled Alloy-Steel Pipe Flagnes, Forged Fittingd, and Valves and Parts
for High-Temperature Service, Grade F316L, with schedule to match connected
piping. No repair welding shall be performed on forged fittings without prior
approval of the Engineer. If permitted, the restrictions imposed by the referenced
standard under Section 14 shall apply.
4. Extruded reducing branches shall be pulled from the pipe. Not cutting of pipe
will be permitted.
5. Weld-0-lets may be used for connections up to 1R-inch maximum. Construction
shall be Type 316L stainless steel in sizes to match the connected pipe size and
schedule with FNPT outlet.
B. Pipe Joints
1. Butt Weld:
a. Butt weld joints shall be used for all permanent connections in stainless steel
piping systems.
b. All welding shall be performed in the shop in accordance with the latest
edition of Section IX of the ASME Boiler and Pressure Vessel Code and
ASME Code for Pressure Piping, ASME B31.3.
c. All welds shall have 100 percent penetration. The internal weld bead shall
be small, smooth and continuous with no crevices, pits or other voids. The
external weld bead shall be well rounded, smooth and continuous with no
anomalies.
d. All welded connections shall be parallel and perpendicular to the extent that
the piping appears to be correct to the naked eye.
e. Procedure:
1) Pipe edges shall be prepared by machine cutting or shaping using an
aluminum oxide blade. Beveled ends shall conform to the
requirements of ANSUASME B16.9 - Factory-Made Wrought Steel
Buttwelding Fittings.
15062.STAMLESS STEELPIPING SYSTEMS.DOC 15062-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2) Clean weld joints and weld joint areas both before and after welding
in accordance with ASTM A380 - Standard Practice for Cleaning,
Descaling, and Passivation of Stainless Steel Parts, Equipment, and
Systems, using stainless steel wire brushes or stainless steel wool.
3) Alignment:
a) Align ends to be joined within commercial tolerances on
diameter, wall thickness, and out-of-roundness.
b) When joining pipes of different wall schedule, taper bore the
interior of the larger schedule pipe to match the interior
diameter of the connecting pipe with a maximum 1 :3 slope.
c) Root opening at the joint shall be as stated in the procedure
specification.
4) Welding:
a) The direct current, straight polarity, gas tungsten-arc (GTAW)
process shall be used for all welding. Welding may be by
manual GTAW or automatic (orbital) GTAW processes.
b) The inside of the pipe shall be purged with Argon gas during
welding and while the weld is cooling to prevent oxidation of
the weld.
c) Tack Welds:
(1) All tack welds shall be made by a qualified welder.
(2) All tack welds shall be made with welding rod the same
(3) Tack welds shall be small enough to be readily fused into
(4) Thoroughly clean tack welds with a stainless steel wire
as that used for the succeeding root pass.
the bead of the root pass.
brush prior to the root pass to prevent pinholing or
excessive porosity.
(5) Tack welds which have cracked shall be completely
removed prior to making the root pass.
(6) Surface defects which will affect the soundness of the
weld shall be removed, visually inspected, and re-welded.
(7) Branch connections shall be fitted and groove-welded in
accordance with the details described and shown in
Chapter V of ASME B31.3.
IS062.STAlNLESS STEELPIPING SYSTEMS.DOC 15062-4 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
(8) Finished welds shall conform to requirements under
Chapter V of ASME B3 1.3, as applicable.
2. Screwed:
a. Screwed joints shall be used for connections to weld-0-let outlet for
instrument or sample taps only.
b. Screwed joints shall be made up with Teflon tape.
3. Flanged:
a. Flanged joints shall be used where necessary to match up to flanged fittings
or other inline components.
b. Flanged joints shall be forged stainless steel, ASTM A182 - Standard
Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged
Fittings, and Valves and Parts for High-Temperature Service, Grade F316,
lap joint flange with stainless steel stub end, ASTM A240 - Standard
Specification for Heat-Resisting Chromium and Chromium-Nickel Stainless
Steel Plate, Sheet, and Strip for Pressure Vessels, Type 316L, welded grade
conforming to MSS SP-43 - Wrought Stainless Steel Butt-welding Fittings;
schedule to match pipe.
c. Dimensions shall match connected piping, faced and drilled ANSI Class
150, 1116-inch raised face, unless otherwise shown or required for
connection to equipment.
d. Gaskets shall be ANSI 150 lb. full face, 1/8-inch thick EPDM.
4. Grooved:
a. Grooved joints may be used in stainless steel piping systems in sizes up to
6-inches diameter provided Schedule 40s nipples are used. Cut or rolled
grooves in Schedule 10s piping are not allowed.
b. Housing shall be ductile iron conforming to ASTM A536 - Standard
Specification for Ductile Iron Castings.
c. Housings shall be electroless nickel plated in accordance with MIL-C-26074
- Requirements for Electrical Nickel Coatings, Class 1, Grade C (0.0015-
inch minimum thickness).
d. Gaskets shall be EPDM.
C. Fittings
I5062.STAMLESS STEEL PIPING SYSTEMS.DC€ 15062-5 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Butt Welding Type:
a. Butt weld fittings shall be stainless steel in conformance with ASTM A403 -
Standard Specifications for Wrought Austenitic Stainless Steel Piping
Fittings, Grade W316L, Class W with schedule match connected piping.
b. Dimensions shall be in accordance with MSS SP-43 - Wrought Stainless
Steel Butt-welding Fittings and ANSYASME B16.9 - Factory-Made
Wrought Steel Buttwelding Fittings.
2. Grooved End:
a. Grooves shall be machine cut into pipe in conformance with the fitting
manufacturer’s required tolerances.
b. Roll cutting of grooves into piping will not be permitted.
c. The interior pipe wall shall be smooth and free of crevices, gouges, or other
anomalies.
D. Finishing
1. Pickle all stainless steel pipe, fittings, and finished assemblies inside and out
following fabrication to remove all mill scale, weld inclusions, and color.
2. Passivate all assemblies inside and out in accordance with military plating
specification QQ-P-35 C - Passivation Treatments for Corrosion Resistant Steel,
Type VI.
2.03 EQUIPMENT AND COMPONENTS
A. Accessories
1. Thread lubricant:
a. Teflon tape.
2. Welding rod and bare electrode:
a. In accordance with AWS 5.9 - Specification for Bare Stainless Steel
Welding Electrodes and Rods, Type 316L.
3. Bolting:
a. Bolting for flanged joints shall be Type 316 stainless steel; ASTM A193 -
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials
15062.STAMLESS STEELPLPMG SYSTEMS.WC 15062-6 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
for High Temperature Service; Grade B8M hex head bolts and washers with
Grade B8M hex head nuts.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Pipe Preparation
1. Prior to installation, each pipe length shall be carefully inspected, flushed clean of
any debris or dust, and be straightened, if not true.
2. Ends of threaded pipes shall be reamed and filed smooth.
3. All pipe fittings shall be equally cleaned before assembly.
B. Pipe Joints
1. Threaded Joints:
a. Pipe threads shall conform to ANWASME B 1.20.1 - Pipe Threads,
General Purpose (inch), and shall be full and cleanly cut with sharp dies.
b. Not more than three threads shall remain exposed after installation.
c. All joints shall be made with Teflon tape.
2. Flange Joints:
a. Flanged joints shall be made with gaskets and Type 316 stainless steel bolts
and nuts.
b. Care shall be taken not to over-torque the bolts.
C. Installation
1. Supports and Anchors:
a. All piping shall be firmly supported with fabricated or commercial hangers
or supports.
b. Where necessary to avoid stress on equipment or structural members, the
pipes shall be anchored or harnessed.
2. . Valves and Unions:
I5062.STANLESS STEEL PIPING SYSTEMS.DOC 15062-7 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
a. Unless otherwise indicated, all connections to fixtures, groups of fixtures,
and equipment shall be provided with a shutoff valve and union, unless the
valve has flanged ends.
b. Unions shall be provided at threaded valves, equipment, and other devices
requiring occasional removal or disconnection.
3. Pipe Taps:
a. Field taps to stainless steel pipe assemblies are not allowed.
3.02 COMMISSIONING
A. General
1. All piping systems shall be pressure tested by the Installation Contractor during
system commissioning.
2. A representative of the MFEM shall be present to witness and coordinate the
testing.
+ + END OF SECTION + t
IS062.STAlNLESS STEEL PIPING SYSSEMS.DOC 15062-8 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 15063
COPPER PIPING SYSTEMS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide copper piping systems where shown and where
specified, or where required by the MFEM for his system.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
A. Manufacturers’ Qualifications
1. Manufacturer(s) of the piping furnished under this Section shall have experience
in providing similar type of piping and shall show evidence with his submittal of
at least five (5) installations where the piping of the same material and same
application of the type specified herein have been in satisfactory operation for at
least five (5) years.
2. All piping of the same type shall each be the product of one manufacturer.
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a.
b.
C.
d.
e.
f.
g.
h.
Standards of American Water Works Association, AWWA.
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 American Welding Society, AWS.
Standards of the US. Department of Defense, MIL
Standards of the Manufacturers Standardization Society of the Valve and
Fittings Industry, MSS.
National Sanitation Foundation, NSF.
IS063.COPPER PIPING SYSTEMS.% 15063-1 APRIL 27,2001
city of carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEN
C. Manufacturers Quality Assurance / Quality Control Program
1. Copper piping shall be obtained from a manufacturer who has a continuous
quality control program. All materials used to manufacture pipe and fittings
under this Section shall be tested for conformance to the requirements of the
referenced ASTM standard. Submit results of the tests.
1.03 SUBMITTALS
A. Shop Drawings
1. Submit detailed drawings and data for piping.
B. Installation Instructions
1. Complete operation and maintenance instruction, lubrication schedules and
troubleshooting guides shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340.
C. Certificates Warranties and Guarantees
1. Submit certificates of compliance with applicable referenced standards.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. General
1. RefertoSections01610and01611.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Pipe Material
1. Copper pipe shall be made from all new material and shall be seamless, Type L,
hard draw in accordance with ASTM B88 - Standard Specification for Seamless
Copper Water Tube.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Fittings
1. Fittings shall be commercially pure wrought copper, socket joint in conformance
with ASTM B75 - Standard Specification for Seamless Copper Tube with
15063.COPPKR PIPING SYSTEMS.WC 15063-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMEN?
B.
C.
dimensions conforming to ANSYASME B16.22 - Wrought Copper and Copper
Alloy Solder Joint Pressure Fittings.
Solder
1. Solder shall be 95 percent tin, 5 percent antimony, Grade 95 TA in conformance
with ASTM B32 - Standard Specification for Solder Metal.
2. The use of cored solder is not permitted.
Flux
1. Soldering Flux:
a. Soldering flux shall be paste type, Type I, Form A in conformance with
military specification A-A-51 145C - Flux, Soldering, Non-Electronic, Paste
and Liquid.
2. Brazing Filler Metal:
a. Brazing filler metal shall meet the requirements of AWS A5.8 -
Specification for Brazing Filler Metals, Type BcuP-5.
b. Manufacturers:
1) Wolverine Joining Technologies, Silvaloy 15;
2) Stan Rubinstein Associates, Silverphos 15;
3) Handy & Harman, Sil-Fos.
D. Flanges
1. Flanges shall conform to ANSYASME B16.24 - Cast Copper Alloy Pipe Flanges
and Flanged Fittings, Class 150, cast bronze with brazed joint.
2. where connecting to dissimilar metal, use an insulating flange set:
a. Epco Sales Inc., Dielectric Flange Unions;
b. Central Plastics Co., Insulating Flange Unions.
3. Gaskets shall be EPDM, ring type, minimum 1/8-inch thick.
2.03 EQUIPMENT AND COMPONENTS
A. Accessories
I5063.COWUIPIPING SYSTEMS.DOC 15063-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Expansion Joints:
a. Expansion joints shall have an anti.
shall be of all bronze construction.
-torque device to protect the bellows and
b. Minimum design working pressure shall be 90 psig.
c. Manufacturers:
1) Senior Flexonics, Model HB;
2) Hyspan Precision Products Inc., Model 8501 or 8502.
2. Bolting:
a. Bolting for flanged joints shall be Type 316 stainless steel; ASTM A193 -
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials
for High Temperature Service; Grade B8M hex head bolts and washers with
Grade B8M hex head nuts.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Pipe Preparation
1. Prior to installation, each pipe length shall be carefully inspected, flushed clean of
any debris or dust, and be straightened, if not true.
2. Ends of threaded pipes shall be reamed and filed smooth
3. All pipe fittings shall be equally cleaned before assembly.
B. Pipe Joints
1. Threaded Joints:
a. Pipe threads shall conform to ANSYASME B 1.20.1 - Pipe Threads,
General Purpose (inch), and shall be full and cleanly cut with sharp dies.
b. Not more than three threads shall remain exposed after installation.
c. All joints shall be made with Teflon tape.
2. . Flange Joints:
I5063.COPPERPIPMG SYSTEMS.DOC 15063-4 APRIL 27,2001
city of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
a. Flanged joints shall be made with gaskets and Type 316 stainless steel bolts
and nuts.
b. Care shall be taken not to over-torque the bolts.
C. Installation
1. Supports and Anchors:
a. All piping shall be firmly supported with fabricated or commercial hangers
or supports.
b. Where necessary to avoid stress on equipment or structural members, the
pipes shall be anchored or harnessed.
2. Valves and Unions:
a. Unless otherwise indicated, all connections to fixtures, groups of fixtures,
and equipment shall be provided with a shutoff valve and union, unless the
valve has flanged ends.
b. Unions shall be provided at threaded valves, equipment, and other devices
requiring occasional removal or disconnection.
3.02 COMMISSIONING
A. General
1. All piping systems shall be pressure tested by the Installation Contractor during
system commissioning.
2. A representative of the MFEM shall be present to witness and coordinate the
testing.
+ + END OF SECTION + +
ISO63.COPPER PIPING SYSTEMS.DOC 15063-5 APRIL, 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
SECTION 15065
PVC PIPING SYSTEMS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide PVC piping systems where shown and where specified,
or where required by the MFEM for his system.
1.02 QUALITY CONTROL I QUALITY ASSURANCE (QNQC)
A. Manufacturers' Qualifications
1. Manufacturer(s) of the piping furnished under this Section shall have experience
in providing similar type of piping and shall show evidence with his submittal of
at least five (5) installations where the piping of the same material and same
application of the type specified herein have been in satisfactory operation for at
least five (5) years.
2. All piping of the same type shall each be the product of one manufacturer,
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a. Standards of American Water Works Association, AWWA.
b. Standards of American Society for Testing and Materials, ASTM.
c. Standards of American National Standards Institute, ANSI.
d. National Sanitation Foundation, NSF.
C. Manufacturers Quality Assurance / Quality Control Program
1. Plastic piping shall be obtained from a manufacturer who has a continuous quality
control program. All PVC plastic molding materials used to manufacture pipe
and fittings under this Section shall be tested for conformance to the requirements
of ASTM D 1784 and ASTM D 1785. Submit results of the tests.
1.03 SUBMITTALS
lS065.PVCPIPMG SYSTEMS.WC 15065-1 APRIL 27,2001
A. Shop Drawings
1. Submit detailed drawings and data for piping.
B. Installation Instructions
1. Complete operation and maintenance instruction, lubrication schedules and
troubleshooting guides shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340.
C. Certificates Warranties and Guarantees
1. Submit certificates of compliance with applicable referenced standards.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. General
1. Refer to Sections 01610 and 01611.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Pipe Material
1. PVC pipe shall be made from all new rigid unplasticized polyvinyl chloride and
shall be normal impact class 12454-B, Schedule 80 in accordance with ASTM D
1785 Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Pipe Joints
1. Solvent Weld:
a. Solvent weld joints shall be used for all permanent connections in PVC
piping systems.
b. Joints shall be solvent-welded with solvent cement in accordance with
ASTM D 2564 - Specification for Solvent Cements for Poly (Vinyl
Chloride) (PVC) Plastic Piping Systems, and with primer in accordance
with ASTM F 656 - Specification for Primers for use in Solvent Cement
Joints of Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings.
2. Screwed:
1SMS.PVC PIPING SYSTEMS.DOC 15065-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Screwed joints shall be used where necessary to match up to threaded valves
or fittings on pipe sizes up to 1-112 inches in diameter.
b. Screwed joints shall be made up with Teflon tape only.
3. Flanged:
a. Flanged joints shall be used where necessary to match up to flanged fittings
or other inline components.
b. Flanged joints shall be made with two-piece molded hub PVC raised face
flanges, drilled to ANSYASME B 16.5 - Pipe Flanges and Flanged Fittings,
Class 150, unless otherwise indicated.
c. Gaskets shall be ANSI 150 lb. full face, 1/8-inch thick EPDM.
d. Provide a filler gasket between flanges with a raise face to protect the PVC
flange from the bolting moment.
4. Grooved:
a. The use of grooved joints in PVC piping systems is not allowed,
B. Fittings
1. Solvent Weld Fittings:
a. Solvent-welded fittings shall be Schedule 80 PVC fittings in accordance
with ASTM D 2467 - Specification for Socket-Type Poly (Vinyl Chloride)
(PVC) Plastic Pipe Fittings, Schedule 80.
2. Threaded Fittings:
a. Threaded fittings shall be Schedule 80 PVC fittings in accordance with
ASTM D 2464 - Specification for Threaded Poly (Vinyl Chloride) (PVC)
Plastic Pipe Fittings, Schedule 80.
3. Flanged Fittings:
a. Flanged fittings shall be Schedule 80 fabricated PVC fittings with 150 lb.
flanges to ANWASME B 16.5.
2.03 EQUIPMENT AND COMPONENTS
A. Accessories
1. Service Saddles:
IS06S.PVC PIPING SYSTEMS.lXK 15065-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
a. Saddles for piping up through 8-inches diameter shall have solid PVC
bodies conforming to ASTM D 1784 (cell classification 12454-B) with
EPDM seals and 1-1/2 inch NPT threaded taps. Saddles shall be designed to
conform to appropriate performance criteria for 200 psig rated systems,
including ASTM D3139 and ASTM D 1599 for dimensions and testing
performance. Saddles shall be Clamp It Style II; or equal.
b. Saddles for piping larger than 8-inches diameter shall have Type 304
stainless passivated steel bodies, tie bolts, nuts and washers with EPDM
seals and 1-1/2 inch NPT threaded taps. Saddles shall be Romac Industries,
Inc. Style 306; or equal.
2. Flexible Couplings:
a. Couplings shall be single or multiple arch bellows type as required to suit
specific installation requirements. Bodies shall fabridmetal reinforced
chlorobutyVpolyester with and EPDM liner extending to the flange faces.
Backing rings and gusset plates shall be Type 316 stainless steel. Minimum
design pressure rating shall be 150 psig at 250 OF. Flanges shall be drilled
ANSI Class 150 standard.
b. Couplings shall be provided with Type 316 stainless steel control rod
assemblies to prevent excessive deflection or elongation. Rubber washers
shall be provided for vibration dampening.
c. Couplings shall be Garlock Style 204 HP; or equal.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Pipe Preparation
1. Prior to installation, each pipe length shall be carehlly inspected, flushed clean of
any debris or dust, and be straightened, if not true.
2. Ends of threaded pipes shall be reamed and filed smooth.
3. All pipe fittings shall be equally cleaned before assembly.
B. Pipe Joints
1. Threaded Joints:
a. Pipe threads shall conform to ANWASME B 1.20.1 - Pipe Threads,
General Purpose (inch), and shall be full and cleanly cut with sharp dies.
ISO65.PVC PIPING SYSTEMS.DOC 15065-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility MF EQUIPMENT PROCUREMENT
b. Not more than three threads shall remain exposed after installation.
c. All joints shall be made with Teflon tape.
2. Solvent-Welded Joints:
a. Solvent-welded joints shall be made with fresh primer and solvent cement
on clean, dry pipe ends.
b. The primer and cement cans shall be kept closed at all times and the joints
shall be made up at the recommended ambient temperatures, to the pipe
Manufacturer's written recommendations.
c. All pipe ends shall be inserted to the full depth of the socket.
3. Flange Joints:
a. Flanged joints shall be made with gaskets and Type 316 stainless steel bolts
and nuts.
b. Care shall be taken not to over-torque the bolts.
C. Installation
1. Supports and Anchors:
a. All piping shall be firmly supported with fabricated or commercial hangers
or supports.
b. Where necessary to avoid stress on equipment or structural members, the
pipes shall be anchored or harnessed.
c. Expansion joints and guides shall compensate for pipe expansion due to
temperature differences.
2. Valves and Unions:
a. Unless otherwise indicated, all connections to fixtures, groups of fixtures,
and equipment shall be provided with a shutoff valve and union, unless the
valve has flanged ends.
b. Unions shall be provided at threaded valves, equipment, and other devices
requiring occasional removal or disconnection.
3. Pipe Taps:
ISO6S.PVC PlPMG SYS7EMS.DOC 15065-5 APRIL. 27,2001
City of carlsbad Carlsbad Recycling Facility
MF EQUPMENT PROCUREMENT
a. Pipe taps to the PVC pipe barrel are not allowed. All taps shall be made
using standard fittings or a service saddle.
b. The exception shall be that 1M-inch taps for instruments may be used in
pipes over 4-inches diameter when the tap is made at a fitting, such that the
tapped wall includes both pipe and fitting.
3.02 COMMISSIONING
A. General
1. All piping systems shall be pressure tested by the Installation Contractor during
system commissioning.
2. A representative of the MFEM shall be present to witness and coordinate the
testing.
+ + END OF SECTION + +
1506S.PVC PlPlNG SYSTEMS.DOC 15065-6 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROWMENT
SECTION 15070
CPVC PIPING SYSTEMS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide CPVC piping systems where shown and where
specified, or where required by the MFEM for his system.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
A. Manufacturers' Qualifications
1. Manufacturer(s) of the piping furnished under this Section shall have experience
in providing similar type of piping and shall show evidence with his submittal of
at least five (5) installations where the piping of the same material and same
application of the type specified herein have been in satisfactory operation for at
least five (5) years.
2. All piping of the same type shall each be the product of one manufacturer.
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a. Standards of American Water Works Association, AWWA.
b. Standards of American Society for Testing and Materials, ASTM,
c. Standards of American National Standards Institute, ANSI.
d. National Sanitation Foundation, NSF.
C. Manufacturers Quality Assurance / Quality Control Program
1. Plastic piping shall be obtained from a manufacturer who has a continuous quality
control program. All CPVC plastic molding materials used to manufacture pipe
and fittings under this Section shall be tested for conformance to the requirements
of ASTM D 1784 and ASTM F 441. Submit results of the tests.
1.03 SUBMITTALS
1307O.CPVC PIPING SYSTEMS.Doc 15070-1 APRIL 27,2001
City of carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Shop Drawings
1, Submit detailed drawings and data for piping.
B. Installation Instructions
1. Complete operation and maintenance instruction, lubrication schedules and
troubleshooting guides shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340.
C. Certificates Wmanties and Guarantees
1. Submit certificates of compliance with applicable referenced standards.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. General
1. Refer to Sections 01610 and 01611.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Pipe Material
1. CPVC pipe shall be made from all new rigid unplasticized chlorinated polyvinyl
chloride and shall be normal impact class 23477-B, Type lV, Grade 1, Schedule
80 in accordance with ASTM D 1784 Standard Specification for Rigid
Poly(Viny1 Chloride) (PVC) Compounds and Chlorinated Poly(Viny1
Chloride)(CPVC) Compounds and ASTM F 441 Standard Specification for
Chlorinated Poly(Viny1 Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Pipe Joints
1. Solvent Weld:
a. Solvent weld joints shall be used for all permanent connections in CPVC
piping systems.
b. Joints shall be solvent-welded with solvent cement in accordance with
ASTM F 493 - Standard Specification for Solvent Cements for Chlorinated
Poly(Viny1 Chloride) (CPVC) Plastic Pipe and Fittings.
ISO7O.CPVC PIPING SYSTEMS.WC 15070-2 APRIL 27,2001
City of Carlsbad Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Screwed:
a. Screwed joints shall be used where necessary to match up to threaded valves
or fittings on pipe sizes up to 1-112 inches in diameter.
b. Screwed joints shall be made up with Teflon tape only.
3. Flanged:
a. Flanged joints shall be used where necessary to match up to flanged fittings
or other inline components.
b. Flanged joints shall be made with two-piece molded hub CPVC raised face
flanges, drilled to ANSVASME B 16.5 - Pipe Flanges and Flanged Fittings,
Class 150, unless otherwise indicated.
c. Gaskets shall be ANSI 150 Ib. full face, 1/8-inch thick EPDM.
d. Provide a filler gasket between flanges with a raise face to protect the CPVC
flange from the bolting moment.
4. Grooved:
a. The use of grooved joints in CPVC piping systems is not allowed.
B. Fittings
1. Solvent Weld Fittings:
a. Solvent-welded fittings shall be Schedule 80 CPVC fittings in accordance
with ASTM F 439 - Standard Specification for Socket-Type Chlorinated
Poly(Viny1 Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80.
2. Threaded Fittings:
a. Threaded fittings shall be Schedule 80 PVC fittings in accordance with
ASTM D 2464 - Standard Specification for Threaded Chlorinated
Poly(Viny1 Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80.
3. Flanged Fittings:
a. Flanged fittings shall be Schedule 80 fabricated CPVC fittings with 150 Ib.
flanges to ANSUASME B 16.5.
2.03 EQUIPMENT AND COMPONENTS
IS070.CPVC PIPING SYSTEMS.MX3 15070-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Accessories
1. Service Saddles:
a. Saddles for piping up through 8-inches diameter shall have solid CPVC
bodies conforming to ASTM D 1784 with EPDM seals and 1-1/2 inch NF'T
threaded taps. Saddles shall be designed to conform to appropriate
performance criteria for 200 psig rated systems, including ASTM D3139
and ASTM D 1599 for dimensions and testing performance. Saddles shall
be Clamp It Style 11; or equal.
b. Saddles for piping larger than 8-inches diameter shall have Type 304
stainless passivated steel bodies, tie bolts, nuts and washers with EPDM
seals and 1-1/2 inch NF'T threaded taps. Saddles shall be Romac Industries,
Inc. Style 306; or equal.
2. Flexible Couplings:
a. Couplings shall be single or multiple arch bellows type as required to suit
specific installation requirements. Bodies shall fabridmetal reinforced
chlorobutylipolyester with and EPDM liner extending to the flange faces.
Backing rings and gusset plates shall be Type 316 stainless steel. Minimum
design pressure rating shall be 150 psig at 250 OF. Flanges shall be drilled
ANSI Class 150 standard.
b. Couplings shall be provided with Type 316 stainless steel control rod
assemblies to prevent excessive deflection or elongation. Rubber washers
shall be provided for vibration dampening.
c. Couplings shall be Garlock Style 204 HP; or equal.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Pipe Preparation
1. Prior to installation, each pipe length shall be carehlly inspected, flushed clean of
any debris or dust, and be straightened, if not true.
2. Ends of threaded pipes shall be reamed and filed smooth.
3. All pipe fittings shall be equally cleaned before assembly.
B. Pipe Joints
Is070.cPvc PIPING SYSTEMS.0OC 15070-4 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
1. Threaded Joints:
a. Pipe threads shall conform to ANWASME B 1.20.1 - Pipe Threads,
General Purpose (inch), and shall be full and cleanly cut with sharp dies.
b. Not more than three threads shall remain exposed after installation.
c. All joints shall be made with Teflon tape.
2. Solvent-Welded Joints:
a. Solvent-welded joints shall be made with fresh primer and solvent cement
on clean, dry pipe ends.
b. The primer and cement cans shall be kept closed at all times and the joints
shall be made up at the recommended ambient temperatures, to the pipe
Manufacturer's written recommendations.
c. All pipe ends shall be inserted to the full depth of the socket.
3. Flange Joints:
a. Flanged joints shall he made with gaskets and Type 316 stainless steel bolts
and nuts.
b. Care shall be taken not to over-torque the bolts.
C. Installation
1. Supports and Anchors:
a. All piping shall be firmly supported with fabricated or commercial hangers
or supports.
b. Where necessary to avoid stress on equipment or structural members, the
pipes shall be anchored or harnessed.
c. Expansion joints and guides shall compensate for pipe expansion due to
temperature differences.
2. Valves and Unions:
a. Unless otherwise indicated, all connections to fixtures, groups of fixtures,
and equipment shall be provided with a shutoff valve and union, unless the
valve has flanged ends.
ISO7O.cPVC PIPING SYsTEMS.Doc 15070-5 APRIL 27,2001
City of Carlsbad
MF EQUWMENT PROCUREMENT Carlsbad Recycling Facility
b. Unions shall be provided at threaded valves, equipment, and other devices
requiring occasional removal or disconnection.
3. Pipe Taps:
a. Pipe taps to the CPVC pipe barrel are not allowed. All taps shall be made
using standard fittings or a service saddle.
b. The exception shall be that 1M-inch taps for instruments may be used in
pipes over 4-inches diameter when the tap is made at a fitting, such that the
tapped wall includes both pipe and fitting.
3.02 COMMISSIONING
A. General
1. All piping systems shall be pressure tested by the Installation Contractor during
system commissioning.
2. A representative of the MFEM shall be present to witness and coordinate the
testing.
+ + END OF SECTION + +
IS070.CPVC PIPING SYSTEMS.Doc 15070-6 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
SECTION 15071
HDPE PIPING SYSTEMS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide HDPE piping systems where shown and where
specified, or where required by the MFEM for his system.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QA/QC)
A. Manufacturers' Qualifications
1. Manufacturer(s) of the piping furnished under this Section shall have experience
in providing similar type of piping and shall show evidence with his submittal of
at least five (5) installations where the piping of the same material and same
application of the type specified herein have been in satisfactory operation for at
least five (5) years.
2. All piping of the same type shall each be the product of one manufacturer.
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a. Standards of American Water Works Association, AWWA
b. Standards of American Society for Testing and Materials, ASTM.
c. Standards of American National Standards Institute, ANSI.
d. National Sanitation Foundation, NSF.
C. Manufacturers Quality Assurance / Quality Control Program
1. High density polyethylene (HDPE) piping shall be obtained from a manufacturer
who has a continuous quality control program. All materials used to manufacture
pipe and fittings under this Section shall be tested for conformance to the
requirements of ASTM D3350 - Standard Specification for Polyethylene Plastics
Pipe and Fittings Materials, for PE 3408 material with a cell classification of
335434C or better. Submit results of the tests.
15071.HDPE PIPING SYSTEMSDX 15071-1 APRIL, 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. The pipe manufacturer shall be listed with the Plastic Pipe Institute as meeting the
recipe and mixing requirements of the resin manufacturer for the resin used to
manufacture the pipe for this project. ..
1.03 SUBMITTALS
A. Shop Drawings
1. Submit detailed drawings and data for piping.
B. Installation Instructions
1. Complete operation and maintenance instruction, lubrication schedules and
troubleshooting guides shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340.
C. Certificates Warranties and Guarantees
1. Submit certificates of compliance with applicable referenced standards.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. General
1. Refer to Sections 01610 and 01611.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Pipe Material
1. HDPE pipe shall be made from all new polyethylene material as specified herein.
2. The HDPE material shall be suitably protected against degradation by ultraviolet
light by means of carbon black, well dispersed by pre-compounding in a
concentration of not less than 2 percent.
3. The maximum allowable hoop stress shall be 800 psi at 73.4 degrees F.
4. Pipe sizes shall conform to ASTM F714 - Standard Specification for Polyethylene
(PE) Plastic Pipe (SDR-PR) Based on Outside Diameter.
5. The pipe and fittings shall have a pressure rating of 150 psi (nominal SDR 11).
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Pipe Joints
ISO7I.HDPEPIPlNG SYSTuIS.Doc 15071-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
1. Thermal Butt Fusion:
a. Butt fusion joints shall be used for all permanent joints not requiring future
disassembly for maintenance and component replacement.
b. Joints shall be made using commercial equipment according to the
recommendations of the pipe manufacturer.
2. Flanged:
a. Flanged joints shall be used where necessary to match up to flanged fittings
or other inline components.
b. Flanged joints shall be made with one-piece molded polyethylene stub end
and stainless steel backing flange, drilled to ANSUASME B 16.5 - Pipe
Flanges and Flanged Fittings, Class 150, unless otherwise indicated.
c. Backing flanges shall be Type 316 stainless steel in accordance with ASTM
A240 - Standard Specification for Heat-Resisting Chromium and
Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels.
d. Flanged connections shall have the same pressure rating as the pipe or
greater.
e. Gaskets shall be ANSI 150 Ib, flat ring type, US-inch thick EPDM.
B. Fittings
1. HDPE fittings shall be molded butt fusion joined.
2. HDPE material in fittings for sizes 6-inches and smaller and shall conform to
ASTM Dl248 - Standard Specification for Polyethylene Plastics Extrusion
Materials For Wire and Cable.
3. For sizes 8-inch and larger, fittings shall be the same as the pipe, butt fusion
joined, conforming to ASTM D3350 - Standard Specification for Polyethylene
Plastics Pipe and Fittings Materials.
4. The ends of the fabricated fittings shall not be trimmed to match the pipe section
to which they are going to be joined.
5. All polyethylene fittings shall have the same or higher pressure rating as the pipe
when installed in accordance with the latest technical specifications.
2.03 EQUIPMENT AND COMPONENTS
ISO7I.HDPEPIPMG SYSTFMS.DOC 15071-3 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
A. Accessories
1. Flexible Couplings:
a. Couplings shall be single or multiple arch bellows type as required to suit
specific installation requirements. Bodies shall fabriclmetal reinforced
chlorobutyVpolyester with and EPDM liner extending to the flange faces.
Backing rings and gusset plates shall be Type 316 stainless steel. Minimum
design pressure rating shall be 150 psig at 250 OF. Flanges shall be drilled
ANSI Class 150 standard.
b. Couplings shall be provided with Type 316 stainless steel’ control rod
assemblies to prevent excessive deflection or elongation. Rubber washers
shall be provided for vibration dampening.
c. Couplings shall be Garlock Style 204 HP; or equal.
2. Service Saddles
a. Service saddles shall have hsion bonded epoxy coated metal bodies with all
Type 3 16 stainless steel hardware.
b. Seals shall be EPDM.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Pipe Preparation
1. Prior to installation, each pipe length shall be carehlly inspected, flushed clean of
any debris or dust, and be straightened, if not true.
2. Ends of threaded pipes shall be reamed and filed smooth.
3. All pipe fittings shall be equally cleaned before assembly.
B. Pipe Joints
1. Butt Fusion Joints:
a. Follow manufacturer’s written procedures.
2. Flanged Joints:
a. Flanged joints shall be made with gaskets and Type 316 stainless steel bolts
and nuts.
ISOl1.HDPEPIPlNGSYSTEMS.DM: 15071-4 APRlL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
b. Care shall be taken not to over-torque the bolts.
C. Installation
1. Supports and Anchors:
a. All piping shall be firmly supported with fabricated or commercial hangers
or supports.
' b. Where necessary to avoid stress on equipment or structural members, the
pipes shall be anchored or harnessed.
c. Expansion joints and guides shall compensate for pipe expansion due to
temperature differences.
2. Pipe Taps:
a. Pipe taps to the HDPE pipe barrel are not allowed. All taps shall be made
using standard fittings or a service saddle.
3.02 COMMISSIONING
A. General
1, All piping systems shall be pressure tested by the Installation Contractor during
system commissioning,
2. A representative of the MFEM shall be present to witness and coordinate the
testing.
+ + END OF SECTION + +
ISO7I.HDPEPIPlNG SYSTEMS.DOC 15071-5 APRIL 27,2001
City of Carkbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
SECTION 15072
ABS PIPING SYSTEMS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. The MFEM shall provide ABS piping systems where shown and where specified,
or where required by the MFEM for his system.
1.02 QUALITY CONTROL / QUALITY ASSURANCE (QNQC)
A. Manufacturers’ Qualifications
1. Manufacturer(s) of the piping furnished under this Section shall have experience
in providing similar type of piping and shall show evidence with his submittal of
at least five (5) installations where the piping of the same material and same
application of the type specified herein have been in satisfactory operation for at
least five (5) years.
2. All piping of the same type shall each be the product of one manufacturer.
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a. Standards of American Water Works Association, AWWA.
b. Standards of American Society for Testing and Materials, ASTM.
c. Standards of American National Standards Institute, ANSI.
d. National Sanitation Foundation, NSF.
C. Manufacturers Quality Assurance / Quality Control Program
1. Acrylonitrile Butadiene Styrene (ABS) piping shall be obtained from a
manufacturer who has a continuous quality control program. All materials used
to manufacture pipe and fittings under this Section shall be tested for
conformance to the requirements of ASTM D3965 - Standard Specification for
Rigid Acrylonitrile-Butadiene-Styrene (ABS) Compounds for Pipe and Fittings.
Submit results of the tests.
I5072.ABSPIPMG SYSTEMS.DOC 15072-1 APRIL 27,2001
City of Carlsbad
C&lsbad Recycling Facility
IvlF EQUIPMENT PROCUREMENT
2. The pipe manufacturer shall be listed with the Plastic Pipe Institute as meeting the
recipe and mixing requirements of the resin manufacturer for the resin used to
manufacture the pipe for this project.
1.03 SUBMITTALS
A. Shop Drawings
1. Submit detailed drawings and data for piping.
B. Installation Instructions
1. Complete operation and maintenance instruction, lubrication schedules and
troubleshooting guides shall be submitted for review in accordance with the
procedures and requirements set forth in Section 01340.
C. Certificates Warranties and Guarantees
1. Submit certificates of compliance with applicable referenced standards.
1.04 PRODUCT DELIVERY STORAGE AND HANDLING
A. General
1. Refer to Sections 01610 and 01611.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. Pipe Material
1. ABS pipe shall be made from all new material as specified herein.
2. The pipe and fittings shall have a pressure rating of 150 psi.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Pipe Joints
1. Socket Weld:
a. Socket weld joints shall be used for all permanent joints not requiring future
disassembly for maintenance and component replacement.
b. Joints shall be made using an appropriate primer and solvent cement
according to the recommendations of the pipe manufacturer.
IS072.ABSPlPMG SYSTEMS.DOC 15072-2 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
2. Flanged:
a. Flanged joints shall be used where necessary to match up to flanged fittings
or other inline components.
b. Flanged joints shall be made with two-piece molded ABS stub end and ABS
backing flange, drilled to ANWASME B 16.5 - Pipe Flanges and Flanged
Fittings, Class 150, unless otherwise indicated.
c. Flanged connections shall have the same pressure rating as the pipe or
greater.
d. Gaskets shall be ANSI 150 lb, flat ring type, l/S-inch thick EPDM.
B. Fittings
1. ABS fittings shall be molded socket weld type.
2. ABS material in fittings shall conform to the requirements of the pipe
hereinbefore.
3. All ABS fittings shall have the same or higher pressure rating as the pipe when
installed in accordance with the latest technical specifications.
2.03 EQUIPMENT AND COMPONENTS
A. Accessories
1. Flexible Couplings:
a. Couplings shall be single or multiple arch bellows type as required to suit
specific installation requirements. Bodies shall fabridmetal reinforced
chlorobutyVpolyester with and EPDM liner extending to the flange faces.
Backing rings and gusset plates shall be Type 316 stainless steel. Minimum
design pressure rating shall be 150 psig at 250 OF. Flanges shall be drilled
ANSI Class 150 standard.
b. Couplings shall be provided with Type 316 stainless steel control rod
assemblies to prevent excessive deflection or elongation. Rubber washers
shall be provided for vibration dampening.
c. Couplings shall be Garlock Style 204 HP; or equal.
2. Service Saddles
a. Service saddles shall have fusion bonded epoxy coated metal bodies with all
Type 3 16 stainless steel hardware.
15072.ABS PIPING SYSTEMS.DOC 15072-3 APRIL 27,2001
city of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
b. Seals shall be EPDM.
PART 3 - EXECUTION
3.01 DELIVERY AND INSTALLATION
A. Pipe Preparation
1. Prior to installation, each pipe length shall be carefully inspected, flushed clean of
any debris or dust, and be straightened, if not true.
2. Ends of threaded pipes shall be reamed and filed smooth.
3. All pipe fittings shall be equally cleaned before assembly.
B. Pipe Joints
1. Socket Weld Joints:
a. Follow manufacturer’s written procedures.
2. Flanged Joints:
a. Flanged joints shall be made with gaskets and Type 316 stainless steel bolts
and nuts.
b. Care shall be taken not to over-torque the bolts.
C. Installation
1. Supports and Anchors:
a. All piping shall be firmly supported with fabricated or commercial hangers
or supports.
b. Where necessary to avoid stress on equipment or structural members, the
pipes shall be anchored or harnessed.
c. Expansion joints and guides shall compensate for pipe expansion due to
temperature differences.
2. Pipe Taps:
a. Pipe taps to the ABS pipe barrel are not allowed. All taps shall be made
using standard fittings or a service saddle.
3.02 COMMISSIONING
15072.ABSPlPMGSYSTEMS.WC 15072-4 APRIL 27,2001
City of Carlsbad
MF EQUrPMENT PRCKURF,MENT
Carlsbad Recycling Facility
A. General
1. All piping systems shall be pressure tested by the Installation Contractor during
system commissioning.
2. A representative of the MFEM shall be present to witness and coordinate the
testing.
+ + END OF SECTION + +
15072.ABSPIPMG SYSTEMS.DOC 15072-5 APRIL 27,2001
city of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
SECTION 15 100
VALVES AND APPURTENANCES
PART 1 - GENERAL
1.01 DESCRIPTION
A. Description of Work
1. Furnish all labor, materials, equipment and incidentals required and install
complete and ready for operation and test all valves as shown on the Drawings
and as specified herein.
2. The equipment shall include, but not be limited to, the following:
a.
b.
C.
d.
e.
f.
g.
h.
i.
j.
k.
1.
m.
n.
0.
Valve Actuators - General
Valve Actuators - Manual
Valve Actuators - Pneumatic
Solenoid Valves
Butterfly Valves
Ball Valves
Check Valves
Diaphragm Valves
Plug Valves
Gate Valves
Air Relief Valves
Pressure Relief Valves
Pressure RegulatinglControl Valves
Automatic Drain Valves
Sample Valves
1SIW.Valvs~ and Appurtemncer.das 15100-1 APRIL. 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQuPMENT PROCUREMENT
B. Coordination
1. Valve Designations
a. All valves are shown on the Drawings by unique tag number and listed in
the Valve Schedules in or appended to the detailed system specification
sections following Section 11300. The valve schedules assign each tagged
valve and power actuator a code identifier. Each valve and actuator
identified by a given code identifier is bound to the requirements
corresponding to that identifier under Part 2.
b. The MFEM shall identify each valve by its assigned tag number on all shop
drawings and equipment submittals.
1.02 QUALITY CONTROUQUALITY ASSURANCE (QNQC)
A. Manufacturer’s Qualifications
1. Manufacturer(s) of the valves and appurtenances furnished under this Section
shall have experience in providing similar products and shall show evidence with
his submittal of at least five (5) installations where the components of the same
type in similar application to that specified herein have been in satisfactory
operation for at least five (5) years.
2. All valves and components of a similar type or class shall be the product of a
single manufacturer for consolidation of spare parts and manufacturer’s services.
B. Reference Standards
1. Comply with applicable provisions and recommendations of the following:
a. Standards of American Water Works Association, AWWA.
b. Standards of American Society for Testing and Materials, ASTM.
c. Standards of American National Standards Institute, ANSI.
d. Standards of the American Society of Mechanical Engineers, ASME.
e. Standards of the US. Department of Defense, MIL
f. Standards of the American Welding Society, AWS.
g. Standards of the Manufacturers Standardization Society of the Valve and
Fittings Industry, MSS.
l5lW.V~lvcs and Appuncmnccs.doc 15100-2 APRIL 27,2001
city OfCarlsbad Carlsbad Recycling Facility
MF EQUPMENT PROCUREMENT
h. National Sanitation Foundation, NSF.
1.03 SUBMITTALS
A. Shop Drawings
1. Submit materials required to establish compliance with these Specifications in
accordance with Section 01340. Submittals shall include the following:
a. Equipment tag number or name used in the Specifications.
b. The manufacturer or supplier.
c. The address at which equipment will be fabricated or assembled.
d. Certified drawings showing all important details of construction and
dimensions.
e. Descriptive literature, bulletins and/or catalogs of the equipment.
f. The total weight of each item.
g. A complete bill of materials.
h. Additional submittal data, where noted with individual pieces of equipment.
i. Individual electrical control schematics and wiring diagrams for each valve
operator with all external interfaces, identified. Standard catalogue cut
sheets that show typical wiring diagrams only are not acceptable. Valve
actuators shall be coordinated with electrical requirements shown on the
Drawings and valves as specified herein.
j. The MFEM shall submit a complete valve schedule including the following
items as a minimum:
1) Organized by valve type, list all valves identified by their assigned tag
number.
2) List all valves that are greater than 2-inches that are provided for
systems or sub-assemblies not shown on the P&ID drawings.
3) For each valve, list the following as applicable:
a) Size
b) Type
APRIL 27,2001
city of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
Body and end style
Body and end rating
Valve inlet pressure, psig
Valve differential pressure (max.), psig
Fluid
Temperature, OF
Operator
Materials of the body, disc, ball, plug, diaphragm, seat, etc.
Manufacturer’s model number
Service description and miscellaneous information.
1. Factory inspection, testing and correction of deficiencies shall be done in
accordance with the referenced Standards and as noted herein.
2. Provide certified hydrostatic test data, per manufacturers standard procedure or
MSS-SP-82 -Valve Pressure Testing Methods, for all valves.
3. In addition to all tests required by the referenced Standards, the following shall
also be factory tested:
a. Pressure regulating valves shall be factory tested at the specified pressures
and flows.
b. All types of air and vacuum valves.
C. Installation Instructions
1. Provide all necessary manufacturer’s installation instructions with all valves and
appurtenances shipped loose for installation by the Installation Contractor.
D. Operation and Maintenance Manuals
1. Operating and maintenance instructions shall be furnished to the Engineer as
provided in Section 01730. The instructions shall be prepared specifically for this
installation and shall include all required cuts, drawings, equipment lists,
IS1W.Valw and Appvrtcmnces.dos 15100-4 APRIL 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
E.
1.04
A.
B.
descriptions and other information required to instruct operating and maintenance
personnel unfamiliar with such equipment.
Certificates Warranties and Guaranties
1. For each valve specified to be manufactured, tested and/or installed in accordance
with AWWA, ASTM, ANSI and other standards, submit an affidavit of
compliance with the appropriate standards, including certified results of required
tests and certification of proper installation.
PRODUCT DELIVERY, STORAGE AND HANDLING
Reference is made to Sections 01610 and 0161 1 for additional information.
Packing and Shipping
1. Care shall be taken in loading, transporting and unloading to prevent injury to the
valves, appurtenances, or coatings. Equipment shall not be dropped. All valves
and appurtenances shall be examined before installation and no piece shall be
installed which is found to be defective. Any damage to the coatings shall be
repaired as acceptable to the District.
2. Prior to shipping, the ends of all valves shall be acceptably covered to prevent
entry of foreign material. Covers shall remain in place until after installation of
connecting piping is completed.
a. All valves 3-inches and larger shall be shipped and stored on site until time
of use with wood or plywood covers on each valve end.
b. Valves smaller than 3-inches shall be shipped and stored as above except
that heavy cardboard covers may be used on the openings.
c. Rising stems and exposed stem valves shall be coated with a protective oil
film, which shall be maintained until the valve is installed and put into use.
d. Any corrosion in evidence at the time of acceptance by the District shall be
removed, or the valve shall be removed and replaced.
3. Insofar as is practical, the equipment specified herein, shall be factory assembled.
The parts and assemblies that are shipped unassembled, shall be packaged and
tagged in a manner that will protect the equipment from damage and facilitate the
final assembly in the field.
4. Weight, handling instructions, type of storage required, and instructions for
protective maintenance during storage shall be included with each shipment to the
project site.
ISIW.V.lvcs and Appuncnmscr.doe 15100-5 APRIL 27,2001
City of carlsbad
Carlsbad Recycling Facility
MF EQUPMENT PROCIJREMEN~
C. Storage and Protection
1. Special care shall be taken to prevent plastic and similar brittle items f?om being
directly exposed to the sun, or exposed to extremes in temperature, to prevent
deformation.
2. See the individual valve specifications and manufacturer's information for hrther
requirements.
PART 2 - PRODUCTS
2.01 PROCESS SYSTEM DESIGN AND PERFORMANCE
A. General Valve Requirements
1. The use of a manufacturer's name andor model or catalog number is for the
purpose of establishing the standard of quality and general configuration'desired.
2. Valves and appurtenances shall have the name of the maker, nominal size, flow
directional arrows, working pressure for which they are designed and standard
referenced, cast in raised letters or indelibly marked upon some appropriate part
of the body.
3. Unless otherwise noted, items shall have a minimum working pressure of 150
psig or be of the same working pressure as the pipe they connect to, whichever is
higher and suitable for the pressures noted where they are installed.
4. Joints, size and material - unless otherwise noted or required by the Engineer:
a. Except where noted, all joints referred to herein shall be of the same type,
nominal diameter, material and with a minimum rating equal to the pipe or
fittings they are connected to.
b. Valves and appurtenances shall be of the same nominal diameter as the pipe
or fittings they are connected to.
5. Provide all special adapters as required to ensure compatibility between valves,
appurtenances and adjacent pipe fittings.
6. Valves and actuators located outdoors but not within a building; within maximum
2-ft above liquid; in vaults or piping trenches; or where otherwise noted shall be
designed for submerged service where water may completely submerge the valve
and operator. All other units shall be as a minimum weather tight.
B. General Valve Actuator Requirements
ISIW.VaIws mdAppurtnuncer.doc 15100-6 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT Carlsbad Recycling Facility
1. The valve manufacturer shall supply and integrally, rigidly mount all actuators,
including any type of manual or electric actuators, on valves at the factory. The
valves and their individual actuators shall be shipped as a unit. Electric actuators
shall be tested and adjusted on the valve for which it is supplied by the valve
supplier, the operator manufacturer, or an authorized distributor and service
facility for the actuator.
2. All actuators shall be capable of moving the valve from the full open to full close
position and in reverse and holding the valve at any position part way between
full open or closed.
3. Each operating device shall have cast on it the word "OPEN" and an arrow
indicating the direction of operation.
4. All position indication and direction of opening arrows shall be embossed,
stamped, engraved, etched or raised decals.
5. Unless otherwise noted, all valves larger than 3-in nominal diameter shall be
provided with position indicators at the point of operation.
2.02 EQUIPMENT DESIGN AND FABRICATION
A. Manual Valve Operators
1. Unless otherwise noted, valves shall be manually actuated; non-buried valves
shall have an operating wheel, unless otherwise shown or specified. The lever
type operators may be supplied on quarter-turn type valves, 2-inches and smaller,
if recommended by the valve manufacturer. Buried valves and those with
operating nuts shall have a non-rising stem with an AWWA 2-in square nut.
2. Except as otherwise shown on the Drawings or specified herein, all valves 3-in
diameter or larger, with the valve center line located 6.5-ft or more above the
operating floor, shall be provided with chain wheel operators complete with chain
guides and 316SS chain, which loop within 4-ft of the operating floor.
3. Gear Actuators
a. Unless otherwise noted, gear actuators shall be provided for the following:
all valves of larger than 4-in nominal diameter; all buried valves with
operating shaft mounted horizontally (butterfly, plug, etc.); where specified
and/or indicated on the Drawings; where manual operator effort is greater
than 40 ft-lbs rim pull.
b. Gear actuators shall be of the worm or helical gear type with output shaft
perpendicular to valve shaft, having a removable hand wheel mounted on
I5IW.VaIvss and Apputcnmcer.doe 15100-7 APRIL 27,2001
City Of Carlsbad Carlsbad Recycling Facility
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the output shaft. Unless noted, they shall conform to AWWA C504, except
with butterfly valves, they need not be certified.
c. Actuators shall be capable of being removed from the valve without
dismantling the valve or removing the valve from the line.
d. Gearing shall be machine-cut steel designed for smooth operation. Bearings
shall be enclosed and permanently lubricated, with bronze bearing bushings
provided to take all thrusts and seals and to contain lubricants. Housings
shall be sealed to exclude moisture and dirt, allow the reduction mechanisms
to operate in lubricant and be of the same material as the valve body.
e. Manual operator input effort to the handwheel shall be a maximum of 40
A-lbs for operating the valve from full open to full close, under any
conditions. Gear actuators shall indicate valve position and have adjustable
stops. Maximum handwheel size shall be 24-in diameter.
f. Operators located beneath trench grating shall be 2-inch square nut gear
operators.
B. Pneumatic Valve Operators
1. Designation: P1
a. Description: General service quarter turn butterfly and ball valves
b. Operating Conditions: Install where noted or shown.
c. Design Requirements:
Cylinder actuators shall have working mechanism fully enclosed, and
shall be sized for operation using 80 psig pneumatic supply.
Cylinder actuators shall have pilot valves where indicated on the
drawings.
Units shall have adjustable end position stops.
All valve actuators shall include limit switches unless otherwise
shown or specified.
Pneumatic actuators shall be capable of producing a minimum of 1.5
times the required operating torque.
Provide valve disc position indicator on operator.
15100-8 APW 27,2001
City of Carlsbad
Carlsbad Recycling Facility
MF EQUIPMENT PROCUREMENT
d. Materials:
1) Actuator Body: Aluminum.
2) Piston: Nylon or Aluminum.
3) Seals: Nitrile or EPDM.
4) Pinion Shaft: Carbon Steel.
e. Manufacturers:
1) Keystone, Model 79U,
2) Bray, Series 90/91;
3) Ultraflo, Ultratorq.
2. Designation: P2.
a. Description: Cyclic and modulating service quarter turn butterfly and ball
valves (scotch yoke design).
b. Operating Conditions: Install where noted or shown
c. Design Requirements:
1) Cylinder actuators shall have working mechanism fully enclosed, and
shall be sized for operation using 80 psig pneumatic supply.
2) Cylinder actuators shall have pilot valves and positioners where
indicated on the drawings or noted herein.
3) Units shall have adjustable end position stops.
4) All valve actuators shall include limit switches.
5) Pneumatic actuators shall be capable of producing a minimum of 1.5
times the required operating torque.
6) Provide valve disc position indicator on operator.
d. Materials:
1) Actuator Body : Painted Ductile Iron andor Stainless Steel
2) Piston: Nylon or Aluminum
1SIW.Valvss and Appmrunsrr.doc 15 100-9 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
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3) Seals: Nitrile or EPDM
4) Pinion Shaft: Carbon Steel
e. Manufacturers:
1) Keystone (Morin), Model 79B;
2) Jamesbury, Type BC;
3) Rotork, Series SP.
2.03 EQUIPMENT AND COMPONENTS
A. Solenoid Valves
1. Designation: SVl .
a. Description: 4-way direct acting solenoid, manifold base mounted type with
flow controls.
b. Operating Conditions: Install where noted or shown
c. Design Requirements:
1) Enclosure: NEMA 4 rated.
2) Power Supply: 24 VAC, 60 Hz, single phase or 24 VDC; as required
by the MFEM for his system.
3) Coils: Class F.
4) Maximum Operating Pressure: 150 psig.
d. End Connections: FNPT tube fittings.
e. Power Actuator: Solenoid actuated.
f. Manual Actuator: Locking extended type.
g. Materials:
1) Body: Forged brass (Alloy UNS C23000) or bronze (ASTM B62 -
Standard Specification for Composition Bronze or Ounce Metal
Castings).
2) Internal Plunger: Stainless steel; Types 302,304 or 305.
ISIW.Valves and Appurtemn~er.dac 15100-10 APRIL 27,2001
City of Carlsbad
MF EQUIPMENT PROCUREMENT
Carlsbad Recycling Facility
3) Core Tube: Stainless steel; Types 302, 304 or 305.
4) Plunger Spring: Stainless steel; Types 302,304 or 305.
5) Cage Assembly: Stainless steel; Types 302,304 or 305.
6) Seats: PTFE.
7) Seals: PTFE.
8) Fasteners: Type 316 stainless steel.
h. Manufacturers:
1) MAC, 45 Series;
2) Or equal.
2. Designation: SV2.
a. Description: 4-way solenoid operated pilot, plug-in sub-base mounted.
b. Operating Conditions: Install where noted or shown.
c. Design Requirements:
1) Enclosure: NEMA 4 rated.
2) Power Supply: 24 VAC, 60 Hz, single phase or 24 VDC; as required
by the MFEM for his system.
3) Coils: Class F.
4) Maximum Operating Pressure: 150 psig.
d. End Connections: FNPT tube fittings,
e. Power Actuator: Solenoid actuated.
f. Manual Actuator: Locking extended type.
g. Materials:
1) Body: Forged brass (Alloy UNS C23000) or bronze (ASTM B62 -
Standard Specification for Composition Bronze or Ounce Metal
Castings).
15IW.VaIve~ and Appwmncer.dac 15100-11 APRIL 27,2001