Loading...
HomeMy WebLinkAboutTC Construction Co; 2004-03-24; 3583-1A Part 3 of 4SECTION 095 10 ACOUSTICAL CEILINGS PART 1 GENEFWL 1.01 SUMMARY A. Provide acoustical ceilings where shown on the Drawings, as specified herein, and as needed for a complete and proper installation. B. Related work 1. Documents affecting work of this Section include, but are not necessarily limited to, General Conditions, Supplementary Conditions, and Sections in Division 1 of these Specifications. 1.02 SUBMITTALS A. Product data: Within 45 Calendar Days after the Contractor has received the Agency's Notice to Proceed, submit: 1. Materials list of items proposed to be provided under this Section; 2. Manufacturer's specifications and other data needed to prove compliance with the specified requirements; 3. Shop Drawings in sufficient detail to show suspension, layout, lateral restraint, installation, anchorage, and interface of the work of this Section with the work of adjacent trades; 4. Manufacturer's recommended installation procedures which, when approved by the Agency's designated representative, will become the basis for accepting or rejecting actual installation procedures used on the Work. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. 1.04 DELIVERY, STORAGE, AND HANDLING A. Comply with pertinent provisions of Section 01600. 1.05 MAINTENANCE A. Deliver to the Agency for his use in future modifications, an extra stock of approximately 10% of each type of acoustical material installed, packaging each type of material separately, distinctly marked, and adequately protected against deterioration. Cannon Road Lift Station Project No. 3583 P:\City of CarIsbad-l682A3067%Lifl Station\7 Pro) Docs\7.2 Final Oocs\100 % SpecsW951O.doc Acoustical Ceilings 0951 0-1 PART 2 PRODUCTS 2.01 ’IT” GRlD SYSTEM A. Provide a complete system of supporting members, anchors, wall cornices, adapters for light fixtures and grilles, and accessories of every type required for a complete suspended ”T” grid system of the arrangements shown on the Drawings, in color or colors selected by the Agency’s designated representative from standard colors of the approved manufacturer, and complying with pertinent requirements of Underwriters Laboratories, Inc., and the governmental agencies having jurisdiction. B. Acceptable products: 1. Manufactured by Armstrong, P. 0. Box 4455, Fullerton, California 92634 (714) 773-9101 a. Ceiling System type 1 : 24” x 48” Standard Grid - Armstrong 2. Equal products of other manufacturers when approved in advance by the Agency’s designated representative. 2.02 ACOUSTICAL CEILING PANELS A. Acceptable products: 1. Manufactured by Armstrong, P. 0. Box 4455, Fullerton, California 92634 (714) 773-9101 a. Ceiling System type 1 : 24” x 48” Washable - Armstrong Ultima - Square lay-in 2. Equal products of other manufacturers when approved in advance by the Agency’s designated representative. Insure compatibility with ceiling suspension Gnd 2.03 OTHER MATERIALS A. Provide other materials, not specifically described but required for a complete and proper installation, as selected by the Contractor subject to the approval of the Agency’s designated representative. PART 3 - EXECUTION 3.01 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. Acoustical Ceilings 0951 0-2 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827U0679-Lifl StatimV Prq Docs\7.2 Final Docs\loO % Specs\09510.dOC 3.02 INSTALLATION, GENERAL A. Except as modified by requirements of governmental agencies having jurisdiction, recommendations of the manufacturer as approved by the Agency's designated representative, or specific directions of the Agency's designated representative, install in accordance with ASTM C636 and the pertinent UL design requirements. B. Lateral bracing: 1. Provide lateral bracing as required by pertinent codes and regulations. 2. Secure lateral bracing to structural members. Secure at right angles to the direction of the partition and four ways in large ceiling areas. C. Provide hold-down clips for ceiling boards only when so required by governmental agencies having jurisdiction. D. Make all grid level within a tolerance of one in 1000 and straight within a tolerance of one in 1000. 3.03 INSTALLATION OF ACOUSTICAL MATERIALS A. "T" grid system: Install acoustical ceiling boards so linearity of facing is as directed by the Agency's designated representative. 3.04 CLEANING UP A. In addition to other stipulated requirements for cleaning, completely remove finger prints and traces of soil from the surfaces of grid and acoustical materials, using only those cleaning materials recommended for the purpose by the manufacturer of the material being cleaned. END OF SECTION Cannon Road Lift Station Project No. 3583 P:\City of CarIsbad-1682A30679-Lift StationV Pro] Docs\7.2 Fmal Docs\100 % SpecsW95lO.doc Acoustical Ceilings 0951 0-3 This page intentionally left Blank. Acoustical Ceilings 0951 0-4 Cannon Road Lift Station Project No. 3583 P:\Ciiy of Carlsbad-1682A30679.Lifl Slatim\7 Prq Docs\7.2 Final Don\lM) % Specs\09510.doc SECTION 09902 PAINTING AND COATINGS PART 1 GENERAL 1.01 SCOPE OF WORK A. The work of this section consists of furnishing all materials, labor, equipment, and incidentals required and performing all the painting and coatings necessary to complete this Contract in its entirety. B. It is the intent of these specifications to paint all interior faces of CMU walls, the entire underside of the roof structure, all interior concrete where scheduled, exposed miscellaneous metal, pipe, fittings, supports, valves, equipment, and all other work obviously required to be painted unless otherwise specified. Minor items omitted in the schedule of work shall be included in the work of this Section where they come within the general intent of the specifications as stated herein. C. The following surfaces or items are not required to be painted: 1. Portions of metal, other than aluminum, embedded in concrete. This does not apply to the back face of items mounted to concrete or masonry surfaces, which shall be painted before erection. Aluminum to be embedded in or in contact with concrete or masonry shall be coated to prevent electrolysis. 2. Stainless steel. 3. Fencing. 4. Concealed surfaces of pipe or crawl spaces. 5. Tile. 6. Exterior concrete, unless otherwise specified. 7. Finish hardware, except door closers that are not finished. 8. Manhole frames and covers. 9. Fiberglass other than piping. 10. Packing glands and other adjustable parts, and nameplates and data plates of mechanical equipment. 1.02 RELATED WORK A. Signage is included in Section 10400. Cannon Road Lift Station Project No. 3583 P\Clty of Wsbad-1682W79-Ufl station\7 Pro) bcsV7.2 Final Doa\l M) % Specs\Oct 7.003 Add Spe~sW902.do~ Painting and Coatings 09902-1 1.03 REFERENCES A. American Association of State Highway and Transportation Officials (AASHTO) B. American Society for Testing and Materials (ASTM) 1. ASTM C150 - Standard Specification for Portland Cement 2. ASTM D4258 - Standard Practice for Surface Cleaning Concrete for Coating C. Occupational Safety and Health Act (OSHA) 1. Air Pollution Control Rules 2. Color Coding D. Steel Structures Painting and Coatings Council (SSPC) 1. SSPC SP 1 - Surface Preparation Specification - Solvent Cleaning 2. SSPC SP 2 - Surface Preparation Specification - Hand Tool Cleaning 3. SSPC SP 3 - Surface Preparation Specification - Power Tool Cleaning 4. SSPC SP 6 - Commercial Blast Cleaning 5. SSPC SP 10 - Near White Metal Blast Cleaning 6. SSPC SP 11 - Power Tool Cleaning to Bare Metal with a Surface Profile 1.04 SUBMITTALS A. Submit to the Engineer for review in accordance with SSPWC 2003 shop drawings, working drawings, and product data including manufacturer's specifications and data on the proposed pipeline coatings, paint systems and detailed surface preparation, application procedures and dry film thickness. Certify that the systems submitted meet all applicable volatile organic carbon regulations. Equivalent systems are to be submitted at no additional costs to meet any new regulations. B. Furnish to the Engineer for review one 8-in by 4-in by 16-in concrete block with one coat of the proposed surfacer and two coats of the proposed epoxy finish in a color selected by the Engineer. Furnish additional samples until one is approved. This sample, when approved by the Engineer, shall establish the quality of the painted surface where this application is indicated. C. Submit to the Engineer for review in accordance with SSPWC 2003 color cards, including standard and special colors, for initial color selections. Painting and Coatings 09902-2 Cannon Road Lift Station Project No. 3583 P:Uty of Cadsbad-16827W0679-tifl StaUonV Proj Docs\7.2 Final Docs\lOO % SpecsUkt 2003 Add Spea\WSOZ.dt% D. 1.05 A. 1.06 A. B. C. PART 2 2.01 A. Schedule of Painting and Coatings Operations: Submit to the Engineer for review a complete Schedule of Painting and Coatings Operations within 90 days after the Notice to Proceed. This Schedule is imperative so that the various fabricators may be notified of the proper shop prime coat to apply. Properly notify and coordinate the fabricators' surface preparation and painting and coatings operations with these specifications. This Schedule shall include for each surface to be painted, the brand name, the percent volume of solids, the coverage and the number of coats the Contractor proposes to use jn order to achieve the specified dry film thickness, and color charts. When the Schedule has been approved, apply all material in strict accordance with the approved Schedule and the manufacturer's instructions. Wet and dry paint film gauges shall be made available to the Engineer to verify the proper application while work is in progress. SPARE MATERIAL Furnish one unopened gallon can of each type and each color of paint used. PRE-PAINTING AND COATINGS CONFERENCE Well in advance of commencement of painting and coatings operations, but after major equipment has been delivered, a pre-painting and coatings conference shall be held. All parties with an interest in the painting and coatings work shall attend, including the Contractor, the Manufacturer, the Agency, the Engineer, and the painting and coatings sub-contractor. The Contractor shall contact each party and arrange the meeting. The conference shall include an inspection of the areas to be painted by all parties and a discussion of the conformance of each area with the specifications. Important issues such as environmental conditions, climate control systems, original primer, dry film thickness, and monitoring the number of coats that have been field applied shall be discussed and problems shall be resolved. A written record of the meeting shall be submitted to the Engineer. PRODUCTS MATERIALS All painting and coatings materials shall be hlly equal to those manufactured by the Tnemec Company Inc., Carboline Company, IC1 Paints, Sherwin-Williams Company, Ameron Paint Company, and PPG Industries. The painting and coatings schedule has been prepared on the basis of Tnemec, Carboline, IC1 Paints, Sherwin-Williams, Ameron, and PPG Industries products and recommendations for applications. No brand other than those named will be considered for approval unless the brand and type of paint proposed for each item in the following schedule together with sufficient data substantiated by certified tests conducted at no expense to the Agency, to demonstrate its equality to the paint(s) named, is submitted in writing to the Engineer for approval within 30 days after the signing of the Notice to Proceed. The type and number of tests performed shall be subject to the Engineer's approval. Color availability to match those colors specified will also be considered as an important property for equality. Cannon Road Lift Station Project No. 3583 P\clly of Cadsbad-1682N0679-Lifl StaUOn\7 Pa h\72 Final DOcS\lM) 9; SpW 2003 Add Spec~W9902.d0c Painting and Coatings 09902-3 B. C. D. E. F. 2.02 A. B. All painting and coatings materials shall be delivered to the mixing room in unbroken containers, bearing the manufacturer's brand, date of manufacture, and name. They shall be used without adulteration and mixed, thinned, and applied in strict accordance with manufacturer's directions for the applicable materials and surface and with the Engineer's approval before using. Shop priming shall be done with primers that are guaranteed by the manufacturer to be compatible with the finish paints to be used. Refer to Section 09902 for special primers. No paint containing lead will be allowed. Oil shall be pure boiled linseed oil. Work areas will be designated by the Engineer for storage and mixing of all painting and coatings materials. Materials shall be in full compliance with the requirements of pertinent codes and fire regulations. Proper containers outside of the buildings shall be provided and used for painting and coatings wastes, and no plumbing fixture shall be used for this purpose. All recommendations of the paint manufacturer in regard to the health and safety of workmen shall be followed. PAINTING AND COATINGS SYSTEMS All colors will be selected by the Engineer from color charts submitted by the Contractor. The following surfaces shall have the types of paint scheduled below applied at the dry film thickness (DFT) in mils per coat noted. Some colors will require an additional coat from what is listed to get the proper color coverage. 1. Interior Exposed Masonry a. Tnemec 1 Coat: 130-6602 Enviro-Fill @ 75 - 85 sq Wgal 2 Coats: 69-Color Hi-Build Epoxoline II (4 - 6 DFT per coat) b. Carboline 1 Coat: Epoxy Polyamide Catalyzed Masonry Filler (60 - 80 sq ftlgal) 2 Coats: 890 (4 - 6 DFT per coat) c. ICIPaints 1 Coat: Interlac 895 (60 - 80 sq ft/gal) 2 Coats: Intergard 760HS (5 DFT per coat) 1 Coat: Glid-Tile Basecoat 55 12 (75 sq ft/gal) 2 Coats: Glid-Guard HS Epoxy 5430 Series (4 - 6 DFT per coat) or d. Sherwin-Williams 1 Coat: Epoxy Ester Masonry FillerBealer, B61 Series (60 - 80 sq ft/gal) 2 Coats: Sher-Tile Hi Solids Epoxy, B67 Series (3 - 4 DFT per coat) e. Ameron 1 Coat: Amerlock 400 BF 2 Coats: Amercoat 385 (5 DFT per coat) Painting and Coatings 09902-4 Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad.16827\30679-Lifl Stabcn\7 Pro] Docs\7.2 Final Docs\lDO Y. Specs\Oct 2003 Add Specs\09902.doc f. PPG Industries 1 Coat: Epoxy Block Filler 97-685/686 1 Coat: High Build Aquapon@ 97-1301139 2. Exterior nonsubmerged ferrous metals (Apply a strip coat over all welded joints prior to the first coat) a. Tnemec 1 Coat: 69-Color Hi-Build Epoxoline II (4 - 6 DFT) 1 Coat: 73-Color Endura-Shield (2 - 5 DFT) b. Carboline 1 Coat: 890 (4 DFT) 1 Coat: 133HB (3 - 4 DFT) c. ICIPaints 1 Coat: Intergard 750HS (5 DFT) 1 Coat: Interthane 990HS or Interthane 870HS (2 DFT) or 1 Coat: Glid-Guard Corrosion Resistant HS Epoxy 546615469 (4 - 6 DFT) 1 Coat: Glid-Guard High Solids Urethane 5410 Series (2 - 5 DFT) d. Sherwin-W illiams 1 Coat: Recoatable Epoxy Primer, B62 Series (5 DFT) 1 Coat: Hi Solids Polyurethane, B65 Series (2.5 DFT) e. heron 1 Coat: Amercoat 385 (4 DFT) 1 Coat: Amercoat 450 HS (2.5 DFT) f. PPG Industries 1 Coat: Direct To Rust 97-1 141149 series 1 Coat: High Build Pitthane@ 97-84OAJC55575 3. Interior nonsubmerged ferrous metals (Apply a strip coat over all welded joints pnor to the first coat) a. Tnemec 2 Coats: 69-Color Hi-Build Epoxoline II (4 - 6 DFT per coat) b. Carboline 2 Coats: 890 (4 - 6 DFT per coat) c. IC1 Paints 1 Coat: Intergard 750HS (5 DFT) 1 Coat: Intergard 760HS (5 DFT) 2 Coats: Glid-Guard Corrosion Resistant HS Epoxy 5466/5469 (4 - 6 DFT per coat) or Cannon Road Lift Station Project No. 3583 P:\City of Cadsbad-16827W067S-Lifl Statim\7 Proj Docs\7.2 Final Docs\lOo ?A Specs\Ocl ZW3 Add SpeaU9902.doc Painting and Coatings 09902-5 d. Sherwin-Williams 1 Coat: Recoatable Epoxy Primer, B62 Series (4 - 6 DFT) 1 Coat: Sher-Tile Hi-Solids Epoxy, B67 Series (4 DFT) e. heron 2 Coats: Amercoat 385 (5 DFT per coat) f. PPG Industries 2 Coats: Direct To Rust 97-1441149 series 4. Exterior galvanized, and nonferrous metal a. Tnemec 1 Coat: 69-Color Hi-Build Epoxoline I1 (2 - 3 DFT) 1 Coat: 74-Color Endura-Shield (2 - 3 DFT) b. Carboline 1 Coat: 890 (2 - 3 DFT) 1 Coat: 133HB (3 - 4 DFT) c. ICIPaints 1 Coat: Intergard 447 (5 DFT) 1 Coat: Interthane 990HS or Interthane 870HS (2 DFT) 1 Coat: Glid-Guard Corrosion Resistant HS Epoxy 5466/5469 (3 - 5 DFT) 1 Coat: Glid-Guard High Solids Urethane 5410 Series (3 - 5 DFT) or d. Sherwin-Williams 1 Coat: Heavy Duty Epoxy, B67 Series (2 - 3 DFT) 1 Coat: Hi-Solids Polyurethane, B65 Series (2.5 DFT) e. Ameron 1 Coat: Amercoat 385 (4 DFT) 1 Coat: 450 HS (2.5 DFT) f. PPG Industries 1 Coat: Direct To Rust 97-144/149 series 1 Coat: High Build PitthaneB 97-84OLJC55575 5. Interior galvanized, and nonferrous metals a. Tnemec 2 Coats: 69-Color Hi-Build Epoxoline 11(2 - 3 DFT per coat) b. Carboline 2 Coats: 890 (2 - 3 DFT per coat) Painting and Coatings 09902-6 Cannon Road Lift Station Project No. 3583 P\Clty of Carlsbad-1682A30674Ufl StaUon\7 Pmj Docs\7.2 Find DoCs\100 K Specs\Oct 2003 Add SpecsxIS9OZ.doc c. ICIPaints 1 Coat: Intergard 447 (5 DFT) 1 Coat: Intergard 760HS (5 DFT) 2 Coats: Glid-Guard HS Epoxy 5430 Series (4 - 6 DFT per coat) or d. Sherwin Williams 2 Coats: Heavy Duty Epoxy, B67 Series (2 - 3 DFT per coat) e. Ameron 2 Coats: hercoat 385 (5 DFT per coat) f. PPG Industries 2 Coats: Direct To Rust 97-144/149 series 6. Metal surfaces exposed to temperatures above 250 degrees F to 400 degrees F a. b. C. d. e. f. Tnemec 2 Coats: 39-1261 Silicone Aluminum (0.7 - 1.5 DFT per coat) Carboline 2 Coats: 1248 (1 - 1.5 DFT per coat) IC1 Paints 2 Coats: Intertherm 503 (1.5 DFT per coat) 2 Coats: Glid-Guard Silicone Hi-Temp Coating Aluminum 5542 (0.5 - 0.7 DFT per coat) or Sherwin- Williams 2 Coats: Silver Brite Aluminum Paint-B 5952 (1 DFT per coat) good up to 400 degrees F Ameron 2 Coats: 878 Hi Best Silicone Aluminum (1.5 DFT per coat) PPG Industries 2 Coats: Aluminum Paint 6-230 7. Insulated Pipe (Block Insulation: Same systems only 3 coats at 2 - 3 DFT per coat) a. Tnemec 2 Coats: 6-Color Tneme-cryl(2 - 3 DFT per coat) b. Carboline 2 Coats: 3359 (3 DIT per coat) c. ICIPaints 2 Coats: Intercryl 530 WB (3 DFT per coat) 2 Coats: Lifemaster Pro HB Acrylic Coating 5440 (2 - 5 DFT per coat) or Cannon Road Lift Station Painting and Coatings Project No. 3583 09902-7 P:Wly of Carlsbad-1682730679-hft StabonV Proj Docs\7.2 Final Docs\lM) % specsx)d 2003 Add Specs\09402.doc d. Sherwin-Williams 2 Coats: DTM Acrylic Gloss or Semi-Gloss, B66 Series (2 - 3 DFT per coat) e. Ameron 2 Coats: Amerguard 220 (3 DFT per coat) f. PPG Industries 1 Coat: Pitt-Tech@ DTM 90-712 1 Coat: Pitt-Tech@ DTM 90-Line (satidgloss) 8. Aluminum in contact with dissimilar materials a. b. C. d. e. f. Tnemec 2 Coats: 69-Color Hi-Build Epoxoline (3 DFT per coat) Carboline 2 Coats: 890 (3 DFT per coat) IC1 Paints 2 Coats: htergard 750HS (5 DFT per coat) 1 Coat: Glid-Guard Corrosion Resistant HS Epoxy Gray 546545469 (3 DFT) 1 Coat: Glid-Guard HS Epoxy 5430 Series (4 DFT) or Sherwin-Williams 2 Coats: Heavy Duty Epoxy, B67 Series (3 DFT per coat) Ameron 2 Coats: Amercoat 385 (5 DFT per coat) PPG Industries 2 Coats: Direct to Rust 97-144/149 9. Plastic Piping - Interior (sanding mandatory) a. Tnemec 1 Coat: 69-Color Hi-Build Epoxoline I1 (2 - 4 DFT) b. Carboline 2 Coats: 890 (3 DFT per coat) c. ICIPaints 2 Coats: Intergard 750HS (5 DFT per coat) 2 Coats: Glid-Guard HS Epoxy 5430 Series (4 - 6 DFT per coat) or d. Shenvin-Williams 2 Coats: Sher-Tile Hi-Solids Epoxy, B67 Series (3 - 4 DFT per coat) Painting and Coatings 09902-8 Project No. 3583 Cannon Road Lift Station P:City ofCa(lsbad-16BZ7UO679-Lifl SWon\7 pmi Doa\7.2 Flnal Docs\lW % Specs\Oct 2003 Add SpecSw9902.dOC e. Ameron 2 Coats: Amercoat 385 (5 DFT per coat) f. PPG Industries 2 Coats: Direct to Rust 97-144/149 10. Plastic Piping - Exterior (sanding mandatory) a. Tnemec 1 Coat: 69-Color Hi-Build Epoxoline I1 (3 - 4 DFT) 1 Coat: 73-Color Endura Shield (2 - 3 DFT) b. Carboline 1 Coat: 890 (4 DFT) 1 Coat: 133HB (2.5 DFT) c. ICIPaints I Coat: htergard 750HS (3 - 5 DFT) 1 Coat: Interthane 870HS (4 DFT) 1 Coat: Glid-Guard HS Epoxy 5430 Series (4 DFT) 1 Coat: Glid-Guard HS Urethane 5410 Series (3 DFT) or d. Sherwin-Williams 1 Coat: Macopoxy 920 Pre-Prime, B58 Series (3 - 4 DFT per coat) 1 Coat: Hi-Solids Polyurethane, B65 Series (2.5 DFT) e. Ameron 1 Coat: 385 (4 DFT) 1 Coat: 450 HS (2.5 DFT) f. PPG Industries 1 Coat: Direct to Rust 97-1441149 1 Coat: High Build Pitthane0 97-840RJC55575 1 1. Parking Stall lines on asphalt pavement: Approved reflective pavement marking paint, white in color, conforming to AASHTO standards for materials and installation. a. PPG Industries 1 Coat: Traffic and Zone Marking Paint 1 1-3 Cannon Road Lift Station Project No. 3583 P:Uly of Cadsbad-16827W0679Lifl StaBmV Pmj oocS\7.2 Final Dws\l00 % specs\oct 2003 Add SpecSu)9902.dOC Painting and Coatings 09902-9 C. 2.03 A. B. C. 12. Interior Concrete Surfaces - Valve Vault, Spill Containment Area Drain, and Chemical Injection Manhole, and below-grade (below elevation 27.0) walls and floors located in Chemical Storage Room (Room 105). a. Apply coating to interior exposed concrete walls and floors as shown on the Drawings. b. The coating material shall be an aminecured epoxy material suitable for long-term immersion in water and for service where subjected to occasional splash and spillage of 3545% femc chloride. The finish coating material shall have a minimum solids content of 80% by volume. The filler-sealer shall be a 100 percent solids amine-cured epoxy material with silica and inert fillers. A 100 percent solids epoxy surface shall be used to fill holes and patch the concrete surface after abrasive blasting. 1. Prime coat (filler-sealer), applied in two coats to the entire surface using a squeegee to achieve a smooth, void-free surface, Carboguard 50 1, Tnemec Series 2 18 or 2 19, .or equal. Finish coats (2 or more, DFT = 12 mils), Carboguard 891m Tnemec Series 61 Tneme-Liner or equal. Following application of the finial finish coat, fine sand shall be sprinkled on the floor area. The second finish coat shall then be applied. This shall reduce the slipping hazard where the coating is applied to floor areas. 2. 3. Any surfaces not specifically named in the Schedule and not specifically accepted, shall be prepared, primed and painted in the manner and with materials consistent with these specifications. The Engineer shall select which of the manufacturer's products, whether the type is indicated herein or not, shall be used for such unnamed surfaces. No extra payment shall be made for this painting and coatings. COLOR CODING FOR PIPES AND EQUIPMENT When color coding is specified, it shall consist of color code painting and coatings and identification of all exposed conduits, trough items, and pipelines for the transport of gases, liquid, and semi-liquids including all accessories such as valves, insulated pipe coverings, fittings, junction boxes, bus bars, connectors, and all operating accessories that are integral to the whole functional mechanical pipe and electrical conduit system. Colors shall be as noted in the Paint and Color Coding Schedules attached at the end of this Section. All hangers and pipe support floor stands shall be painted the same color and with the same paint as the pipe it supports. The system shall be painted up to but not including the flanges attached to the mechanical equipment nor the flexible conduit connected to electrical motors. When more than one pipe system is supported on the same bracket, the bracket shall be painted the same color as the adjacent wall or ceiling. Colors shall be as noted in the Paint and Color Coding Schedule. All systems that are an integral part of the equipment, that is originating ffom the equipment and returning to the same piece of equipment, shall be painted between and up to but not including, the fixed flanges or connections on the equipment. Painting and Coatings 09902-1 0 Project No. 3583 Cannon Road Lift Station P\Cily of Cadsbad-1682NOg79-Lii Station\7 Proj Docs\7.2 Fmal Docs\100 K Specs\Oct 2003 Add SpecsW9902.doc D. E. 2.04 A. B. C. D. (in) (in) 314 to 1-114 112 1-112 to 2 314 2-1 12 to 6 1-114 at0 10 2-1 12 L More than 10 3-112 The color code establishes, defines, and assigns a definite color for each category of pipe. Pipelines that are not listed on the Schedule of Color Code Paints shall be assigned a color by the Engineer and shall be treated as an integral part of the Contract. Banding for pipes shall be as specified in the Paint and Color Coding Schedule. Bands shall be 2-in wide and located on each end of the pipe title, at 2-ft from the title bands, and at wall penetrations. LETTERING OF TITLES Each pipe system shall be labeled with the name of the materials in each pipeline and alongside this an arrow indicating the direction of flow of liquids. Titles shall be as so described in attached schedule. Titles shall not be located more than 20-linear-ft apart and shall also appear directly adjacent to each side of any wall the pipeline breaches, adjacent to each side of the valve regulator, flowcheck, strainer cleanout, and all pieces of equipment. Titles shall identify the contents by complete name. Identification title locations shall be determined by the Engineer but in general they shall be placed where the view is unobstructed and on the two lower quarters of pipe or covering where they are overhead. Title should be clearly visible fiom operating positions especially those adjacent to control valves. Titles on equipment shall be applied at eye level on machines where possible or at the upper most broad vertical surface of low equipment. Where more than one piece of the equipment item to be titled exists, the items shall be numbered consecutively as indicated on the mechanical drawings or as directed by the Engineer; for example Pump No. 1, Pump No. 2, etc. Titles shall be composed and justified on the left hand side as follows: PumpNo. 1 Application of titles 1. The color of the titles shall be black or white, as approved, to best contrast with the color of the pipes and equipment and shall be stencil applied. 2. Stencil text is to be in ALL CAPS worded exactly as shown in the Schedule. Titles are to be printed in a single line. 3. Letter sizes I Outside Diameter of Pipe or Covering I Size of Legend Letters I Equipment titles are to be 2-in high. 4. Arrow sizes. Where "a" is equal to 3/4 of outside diaineter of pipe or covering, the arrow shaft shall be 2 "a" long by 3/8 "a" wide. The arrow head shall be an equilateral triangle with sides equal to "a." Maximum "a" dimension shall be 6-in. Cannon Road Lift Station Proiect No. 3583 Painting and Coatings 09902-1 1 PGlty of Cadsbad-l682~79-L1fl Stabon\7 pro^ Docs\7.2 Final Docs\l W % &cs\oct 2003 Add Specs\09902.doc __~ 5. When using direction arrows, point arrowhead away fiom pipe markers and in direction of flow. If flow can be in both directions, use a double-headed directional flow. 2.05 METAL TAGS A. For pipelines smaller than 3/4-in in diameter, securely fasten metal tags, 2-1/2411 by 1/2-in, of Birmingham or Stubs 17 gauge brass with lettering etched and filled with enamel. Tags shall be approved by the Engineer. 2.06 FABRICATED EQUIPMENT A. Unless otherwise indicated, all fabricated equipment shall be shop primed and shop or field finished. B. All items to be shop primed shall be thoroughly cleaned of all loose material prior to priming. If, in the opinion of the Engineer, any prime coating shall have been improperly applied or if material contrary to these specifications shall have been used, that coating shall be removed by sandblasting to white metal and reprimed in accordance with these specifications. C. All shop prime coats shall be of the correct materials and applied in accordance with these specifications. Remove any prime coats not in accordance with these specifications by sandblasting and apply the specified prime coat at no additional cost to the Agency. D. Shop primed surfaces shall be cleaned thoroughly and damaged or bare spots retouched with the specified primer before the application of successive paint coats in the field. E. Be responsible for and take whatever steps are necessary to properly protect the shop prime and finish coats against damage fiom weather or any other cause. F. A shop finish coat shall be equal in appearance and protection quality to a field applied finish coat. If, in the opinion of the Engineer, a shop finish coat does not give the appearance and protection quality of other work of similar nature, prepare the surfaces and apply the coat or coats of paint as directed by the Engineer to accomplish the desired appearance and protection quality. Submit to the Engineer substantial evidence that the standard finish is compatible with the specified finish coat. G. Wherever fabricated equipment is required to be sandblasted, protect all motors, drives, bearings, gears, etc., fiom the enby of grit. Any equipment found to contain grit shall be promptly and thoroughly cleaned. PART 3 EXECUTION 3.01 PREPARATION OF SURFACES A. All surfaces to be painted shall be prepared as specified herein or in Section 09902 and shall be dry and clean before painting and coatings. Special care shall be given to thoroughly clean interior concrete and concrete block surfaces of all marks before application of finish. Painting and Coatings 09902-1 2 Cannon Road Lift Station Project No. 3583 P\CiIy of Cadsbad-1682A30679Lfl Statlm\7 Proj Docs\7.2 Final Docs\lW % SpeaOd 2003 Add Speo\OSBOZ.doc B. All metal welds, blisters, etc., shall be ground and sanded smooth in accordance with SSPC SP10. All pits and dents shall be filled and all imperfections shall be corrected so as to provide a smooth surface for painting and coatings. All rust, loose scale, oil, grease, and dirt shall be removed by use of approved solvents, wire brushing, or sanding. C. Concrete surfaces shall have been finished as specified in Division 3. Report unsatisfactory surfaces to the Engineer. Concrete shall be free of dust, oil, curing compounds, and other foreign matter, conforming to ASTM D425 8. D. All submerged concrete shall be brush off blast cleaned. Open all bag holes and air entrained holes with minimum aggregate exposure. Provide a uniform surface profile similar to #IO0 gnt sandpaper. E. Concrete block surface shall be smooth and cleaned of all dust, efflorescence, chalk, loose mortar, dirt, grease, oil, tar, and other foreign matter, conforming to ASTM D4258. F. All plastic pipe surfaces shall be lightly sanded before painting and coatings. G. Wood surfaces shall be dry. Sand to obtain a smooth surface. All encrustations shall be removed. H. Exposed Pipe: Bituminous coated pipe shall not be used in exposed locations. Pipe that shall be exposed after project completion shall be primed in accordance with the requirements herein. Any bituminous coated pipe that is inadvertently installed in exposed locations shall be sandblasted clean before priming and painting and coatings. After installation all exterior, exposed flanged joints shall have the gap between adjoining flanges sealed with a single component polysulfide sealant to prevent rust stains. I. Primed or Previously Painted Surfaces and Nonferrous Surfaces: All coated surfaces shall be cleaned prior to application of successive coats. All nonferrous metals not to be coated shall be cleaned. This cleaning shall be done in accordance with SSPC SP I, Solvent Cleaning. J. Shop-Finished Surfaces: All shop-coated surfaces shall be protected from damage and corrosion before and after installation by treating damaged areas immediately upon detection. Abraded or corroded spots on shop-coated surfaces shall be "Hand Cleaned" and then touched up with the same materials as the shop coat. All shop-coated surfaces that are faded, discolored, or that require more than minor touch-up in the opinion of the Engineer shall receive new surface preparation before being repainted. Cut edges of galvanized sheets and exposed threads and cut ends of galvanized piping, electrical conduit, and metal pipe sleeves, that are not to be finished painted, shall be "Solvent Cleaned" and primed with zinc dust-zinc oxide metal primer. K. Galvanized and Zinc-Copper Alloy Surfaces: These surfaces to be painted shall be "Solvent Cleaned" and treated as hereinafter specified. Such surfaces not to be painted shall be "Solvent Cleaned. L. Aluminum embedded or in contact with concrete must be painted according to the schedule for aluminum in contact with dissimilar materials. Cannon Road Lift Station Project No. 3583 P:!City of Carlsbad-16827wO679-Ufl Station\7 Proj Docs\7.2 Final Doa\lM) K Spaax)ct 2003 Add SpecSu19902.doc Painting and Coatings 09902-1 3 3.02 WORKMANSHIP A. General 1. 2. 3. 4. 5. 6. Primer (spot) and paint used for a particular surface shall, in general, be as scheduled for that type of new surface. Confirm with the paint manufacturer that the paint proposed for a particular repaint condition will be compatible with the existing painted surface. Sample repainted areas on the actual site will be required to insure this compatibility. Finished repainted areas shall be covered by the same guarantee specified for remainder of work. At the request of the Engineer, samples of the finished work prepared in strict accordance with these specifications shall be furnished and all painting and coatings shall be equal in quality to the approved samples. Finished areas shall be adequate for the purpose of determining the quality of workmanship. Experimentation with color tints shall be furnished to the satisfaction of the Engineer where standard chart colors are not satisfactory. Protection of hrniture and other movable objects, equipment, fittings and accessories shall be provided throughout the painting and coatings operations. Canopies of lighting fixtures shall be loosened and removed from contact with surface, covered and protected and reset upon completion. Remove all electric plates, surface hardware, etc., before painting and coatings, protect and replace when completed. Mask all machinery nameplates and all machined parts not receiving a paint finish. Dripped or spattered paint shall be promptly removed. Lay drop cloths in all areas where painting and coatings is being done to adequately protect flooring and other work from all damage during the operation and until the finished job is accepted. On metal surfaces apply each coat of paint at the rate specified by the manufacturer to achieve the minimum dry mil thickness required. If material has thickened or must be diluted for application by spray gun, the coating shall be built up to the same film thickness achieved with undiluted material. One-gallon of paint as originally furnished by the manufacturer shall not cover a greater area when applied by spray gun than when applied unthinned by brush. Deficiencies in film thickness shall be corrected by the application of an additional coat(s). On masonry, application rates will vary according to surface texture, however, in no case shall the manufacturer's stated coverage rate be exceeded. On porous surfaces, it shall be the painter's responsibility to achieve a protective and decorative finish either by decreasing the coverage rate or by applying additional coats of paint. Paints shall be mixed in proper containers of adequate capacity. All paints shall be thoroughly stirred before use and shall be kept stirred while using. No unauthorized thinners or other materials shall be added to any paint. Only skilled painters shall be used on the work and specialists shall be employed where required. B. Field Priming 1. Steel members, metal castings, mechanical and electrical equipment, and other metals that are shop primed before delivery at the site will not require a prime coat on the job. All piping and other bare metals to be painted shall receive one coat of primer before exposure to the weather, and this prime coat shall be the first coat as specified in the painting and coatings schedule. Painting and Coatings 09902-1 4 Cannon Road Lift Station Project No. 3583 P\City of Carlsbad-16E27U0674LM Station\7 Pro] Dors\7.2 Final Docs\lM) % specs\oct 2003 Add SpecsU)9902.doC 2. Equipment that is customarily shipped with a baked-on enamel finish or with a standard factory finish shall not normally be field painted unless the prefinished equipment is specifically color selected and unless the finish has not been damaged in transit or during installation. Surfaces that have been shop painted and have been damaged, or where the shop coats or coats of paint have deteriorated, shall be properly cleaned and retouched before any successive painting and coatings is done on them in the field. All such field painting and coatings shall match as nearly as possible the original finish. C. Field Painting and Coatings 1. 2. 3. 4. 5. 6. 7. 8. 9. All painting and coatings at the site shall be designated as Field Painting and Coatings. All paint shall be at room temperature before applying, and no painting and coatings shall be done when the temperature is below 50 degrees F, in dust-laden air, when rain or snow is falling, or until all traces of moisture have completely disappeared from the surface to be painted. Successive coats of paint shall be tinted so as to make each coat easily distinguishable fiom each other with the final undercoat tinted to the approximate shade of the finished coat. Finish surfaces shall not show brush marks or other irregularities. Undercoats shall be thoroughly and uniformly sanded with No. 00 sandpaper or equal to remove defects and provide a smooth even surface. Top and bottom edges of doors shall be painted and all exterior trim shall be back-primed before installation. Painting and Coatings shall be continuous and shall be accomplished in an orderly manner so as to facilitate inspection. All exterior concrete and masonry paint shall be performed at one continuous manner structure by structure. Materials subject to weathering shall be prime coated as quickly as possible. Surfaces of exposed members that will be inaccessible after erection shall be cleaned and painted before erection. All materials shall be brush painted unless spray painting and coating, is specifically approved by the Engineer. The Contractor shall be responsible for all damage caused by overspray or drifbng. All surfaces to be painted as well as the atmosphere in which painting and coatings is to be done shall be kept warm and dry by heating and ventilation, if necessary, until each coat of paint has hardened. Any defective paint shall be scraped off and repainted in accordance with the Engineer's directions. Before final acceptance of the work, all damaged surfaces of paint shall be cleaned and repainted as directed by the Engineer. Any pipe scheduled to be painted and having received a coating of a tar or asphalt-compound shall be painted with two coats of Kop-Coat's Inert01 Tar Stop, IC1 Paints' Tarset Standard 7000 or equal before successive coats are applied per the schedule. Tnemec recommends using 69 Hi-Build Epoxoline I1 over tar, but a test patch must be run initially to test the paint's compatibility with the tar. Cannon Road Lift Station Project No. 3583 P:CiIy of Cadsbad-l6827\30674Ufl Slatioot7 Prcj D0cs\72 Final DOes\lOO X Specs\Od 2003 Add SpeaWW2.doc Painting and Coatings 09902-1 5 3.03 A. B. 3.04 A. CLEANUP The premises shall at all times be kept free from accumulation of waste material and rubbish caused by employees or work. At the completion of the painting and coatings remove all tools, scaffolding, surplus materials, and all rubbish from and about the buildings, and leave work "broom clean" unless more exactly specified. Upon completion, remove all paint where it has been spilled, splashed, or splattered on all surfaces, including floors, fixtures, equipment, furniture, etc., leaving the work ready for inspection. PAINT General Notes and Guidelines 1. 2. 3. 4. All color numbers and names herein refer to master color card. Colors of specified equal manufacturers may be substituted with approval of the Engineer. Pipe lines, equipment, or other items that are not listed here shall be assigned a color by the Engineer and shall be treated as an integral part of the Contract. When color coding is specified or directed by the Engineer, it shall consist of color code painting and coatings and identification of all exposed conduits, through lines and pipelines for the transport of gases, liquids, or semi-liquids including all accessories such as valves, insulated pipe coverings, fittings, junction boxes, bus bars, connectors, and any operating accessories that are integral to a whole functional mechanical pipe and electrical conduit systems. The colors of the Finish Schedule shall be interpreted as follows: Colors White Orange Yellow Dark Yellow Green Light Green Brown Dark Green Tan Ivory Light Grey Medium Grey Dark Grey Red Blue Dark Blue Medium Blue Light Blue Aqua International Orange Dark Bronze Tank Blue Blue Green Magenta Painting and Coatings 09902-1 6 Tnemec # IC1 Paints # AA90 4550 White SC03 Safety Orange BW56 [SCO2] Medium Yellow BX36 Robotic Yellow (to match Ameron's Rapid Response Color RT-2404) AM52 Parrot (to match Ameron's Rapid Response Color RT-1404) -_ Crylight Green 90GY I01250 AF32 Bellows (to match Ameron's Rapid Response Color YE-2) BG62 2047 20YY 431083 (Scroll Beige) BK33 Silver Grey sco9 Safety Red SC06 Safety Blue (to match exterior dark blue tile) 2041 70BG 231276 2040 70BG 671126 AX42 Turquoise Green 82GG 331374 sco4 International Orange BM07 Architectural Brown 8842 70BG/40/284 Ax22 Blue Lagoon 81GG 101276 BP14 30RB 11/250 Carboline # S800 4444 6666 N625 6361 4372 321 6 C731 0746 2525 5555 SI 50 01 18 7107 4132 N498 2277 8155 A337 S585 Cannon Road Lift Station Project No. 3583 P:Cily of Carlabad-1 682No674uR Statim\7 Proj Doa\7.2 Final Doa\lW K specs\od 2003 Add SpecsH)9902.doc 5. All moving parts, drive assemblies, and covers for moving parts that are potential hazards shall be Safety Orange KA26. 6. All safety equipment shall be painted in accordance with OSHA standards. 7. All inline equipment and appurtenances not assigned another color shall be painted the same base color as the piping. The pipe system shall be painted with the pipe color up to but not including the flanges attached to pumps and mechanical equipment assigned another color. Tanks shaIl be painted the color of the piping system that they serve, unless the tank is fiberglass and levels are monitored through the tank. 8. All conduit shall be painted to match its background surface. 9. Building surface colors shall be painted as scheduled in the Finish Schedule or as selected by the Engineer. 10. Control panels shall be factory finished. PAINT AND COLOR CODING SCHEDULE Piping and Legend Color Bands Instrument Air Blue Drains Dark Grey Red Potable Cold Water Green Fuel Oil Red White Exterior Equipment, Valves, Gates, Fans, Galvanized Steel Louvers (including factory finished), Boiler Stacks, Platforms (except roof equipment) Exterior Roof Equipment, Fans, Vents, Hoods Dark Blue* H.M. Doors (Exterior) Dark Blue* H.M. Door Frames (Exterior) Dark Blue* Interior Equipment and Pumps (including factory finished) Dark Blue* Structural Steel (Interior) Brown Structural Steel (Exterior) Dark Blue* Masonry and Concrete Walls (Interior) Ceiling White Equipment and Building Color Dark Blue* Medium Grey H.M. Doors (Interior) Ivory H.M. Door Frames (Interior) Ivory Ductwork Dark Yellow Interior Air Handling and Ventilation Equipment Dark Yellow Valve and Gate Operator Handles Ivory Electrical Conduit and Junction Boxes Match Surface Mounted Submerged Concrete Tank Blue Dark Blue to match dark blue exterior tile END OF SECTION Cannon Road Lift Station Project No. 3583 PCib of Carkbad-1682N0679-LWt Statian\7 Proj Docs\7.2 Final Daa\lOO I SpecsWclxK13 Add Specs\09902.doc Painting and Coatings 09902-1 7 Painting and Coatings 09902-1 8 This page intentionally left Blank. Cannon Road Lift Station Project No. 3583 P:\City of Cadsbad-1682N0679-Lift S@tion\7 Pro] Docs\7.2 Final Docs\lOO % Specs\OcI2003 Add SpecsU)9902.dm SECTION 10200 ARCHITECTURAL LOWERS PART 1 1.01 A. 1.02 A. B. C. 1.03 A. 1.04 A. E?. GENEFWL SCOPE OF WORK Furnish all labor, materials, equipment, and incidentals required to install architectural louvers as shown on the Drawings and as specified herein. RELATED WORK Caulking is included in Section 07901. Dampers and ductwork are included in Division 15. Gnlls and regsters are included in Division 15. SUBMITTALS Submit, shop drawings showing louver dimensions, location, materials, construction and installation details, accessories, and appurtenances. Submittals shall include the following: 1. Two samples, 6-in square comer sample of metal finish to be used. Prepare samples on metal of the same gauge and alloy to be used. Samples will be reviewed for color and texture only. Compliance with all other requirements is the exclusive responsibility of the Contractor. 2. Samples of manufacturer's standard finishes and colors for each item specified herein. 3. Sample of bird screen and screen framing system to be utilized in units to be supplied. 4. Manufacturer shall submit certified AMCA 500 test data on 4-A by 4-A louver sections as part of the shop drawings. Tests results shall indicate compliance with product specifications, including free area and pressure drop versus velocity, plus water infiltration data. REFERENCE STANDARDS Air Movement and Control Association (AMCA) 1. Standard 500 - Test Methods for Louvers, Dampers and Shutters Aluminum Association (AA) 1. AA C22A41 - C22 Chemically Etched Medium Matte finish; A41 Anodic coating, Architectural, Class I(0.7 mil min) clear 2. AA C22A42 - C22 Chemically Etched Medium Matte finish; A42 Anodic coating, Architectural, Class I (0.7 mil min) integral color Cannon Road Lift Station Architectural Louvers Project No. 3583 P.lCity of Car%bad-l6827W0679-Lift StationV Pro] DOa\7.2 Final Docs\100 % Specs\lO2~.doc 10200-1 3. 6063-T5 - T5 Artificial Aging After an Elevated-Temperature Fabrication Process 4. 6063-T52 - T2 Heat-Treated; T5 Stress-Relieved by Compressing C. American Architectural Manufacturer's Association (AAh4A) 1. AAMA 605.2 - Voluntary Specification for High Performance Organic Coatings on Architectural Extrusions and Panels 2. AAMA 607.1 - Voluntary Guide Specification and Inspection Methods for Clear Anodic Finishes for Architectural Aluminum 3. AAMA 608.1 - Voluntary Guide Specification and Inspection Methods for Electrolyhcally Deposited Color Anodic Finishes for Architectural Aluminum D. American Society for Testing and Materials (ASTM) 1. ASTM E90 - Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements 2. ASTM E413 - Classification for Rating Sound Insulation E. Sheet Metal and Air Conditioning Contractor's National Association (SMACNA) 1. Architectural Sheet Metal Manual F. Where reference is made to one of the above standards, the revision in effect at the time of the bid open shall apply. 1.05 QUALITY ASSURANCE A. Fabrication practices, construction details, and installation procedures shall conform to the practices of SMACNA as recommended in the Architectural Sheet Metal Manual. B. The Contractor shall verify the size, location, and placement of all louvers prior to fabrication. The Contractor shall coordinate field measurements and shop drawings with fabrication and shop assembly to minimize field adjustments, splicing, mechanical joints, and field assembly of units. Whenever possible, louver units shall be assembled before shpment to the site. Where a conflict occurs between the requirements of this Section and the Code, the more stringent requirement shall apply. 1.06 SYSTEM DESCRIPTION A. Aluminum Members: Alloy and temper recommended by manufacturer for strength, corrosion resistance, and application of required finish. Architectural Louvers 10200-2 Cannon Road Lift Station Project No. 3583 P:\City of Ca~sbad-16827B0679-Lift Station\7 Pro) Docs\7.2 Final Docs\IW % Specs\10200.doc B. C. D. E. 1.07 A. PART 2 2.03 A. B. C. Fasteners: Aluminum, non-magnetic stainless steel, or other material warranted by manufacturer to be non-corrosive and compatible with aluminum components. 1. Do not use exposed fasteners except where unavoidable. Brackets and Reinforcements: Manufacturer's high-strength aluminum units where feasible; otherwise, non-magnetic stainless steel. Coating protection at dissimilar materials: See Section 09902 - Painting. All louvers, fasteners, and supports shall be designed to meet a wind loading of not less than 30 pounds per square foot (psf). DELIVERY, STORAGE AND HANDLING Deliver materials in manufacturer's original unopened and undamaged packages with labels legible and intact. Store materials in unopened packages in a manner to prevent damage from the environment and construction operations. Handle in accordance with manufacturer's instructions. PRODUCTS ACOUSTICAL LOWERS Acoustical louvers shall be 12-in deep, high performance inverted V-blade Acoustical Model A12350 by Construction Specialties; AFS-120 by Greenheck; or approved equal. Frame shall be 6063-T5 alloy, minimum 0.081-in thick aluminum. Exterior of blade shall be 1 100 series alloy minimum 0.081 -in thick aluminum. The interior of the blade shall have fiberglass insulation with fire retardant polyester sheeting. 1. The louver shall provide a free field noise reduction in decibels at the following center frequencies and ASTM E413 as follows: 63 Hz-15 dB, 125-13 dB, 250-16 dE3, 500 Hz-20 dB, 1,000 Hz-28 dB, 2,000-30 dB, 4,000 Hz-29 dB, 8,000 Hz-28 dB). Submitted data shall show the 4-ft by 4-ft unit to have a minimum free area of 3.47-sq-fi. 2. Free area based upon 4-ft by 4-ft sample shall be 21 percent minimum (MAC). 3. Pressure drop at 1,000 fpm shall be 0.24-in maximum (MAC). Vertical I-aluminum mullions, finished the same as the louver, shall be used at the joints between louvers so that there are not exposed fasteners. Provide continuous perimeter plates and angles of same material as louvers. Fasteners shall not penetrate into mineral fiber wool. Angles and fasteners shall be designed to withstand 30-psf wind loading. Fasteners shall be stainless steel. Jamb fasteners shall be used so that exposed angles are not necessary and so that the overall thickness of the louver is accommodated by the thinner precast concrete section. Cannon Road Lift Station Project No. 3583 P:\Oly of Carlsbad-16827\30679-Lift SlatimV Proj Docs\7.2 Final Docs\lMI % Specs\lOZW.doc Architectural Louvers 10200-3 2.05 SCREENS A. All louvers connected to ductwork shall be furnished with 1/2-in aluminum mesh, 0.080-in (0.71- mm) diameter wire intercrimp bird screen secured within a rewireable extruded aluminum frame. All louvers not connected to ductwork shall be furnished with 18 x 14 aluminum mesh insect screen 0.0123-in (0.3 12-mm) diameter wire within a rewireable extruded aluminum frame. Screw fasten to inside face of louver frame. Structural supports shall be designed to carry a wind load of 30 psf. B. Finish the same as the louver. 2.08 SILL EXTENSIONS A. Sill extensions shall be provided as extruded 12-gauge (0.081-in) formed 8-gauge (0.125-in) aluminum finished the same as the louver where it is used. 2.09 LOUVER FINISH A. Finish: Louvers shall have a 70 percent Kynar 500 or 500 fluoropolymer finish, applied after assembly, with a 10-year warranty against color fading. Finish shall meet or exceed AAMA 605.2. Color shall be as selected by the Architect. PART 3 EXECUTION 3.01 INSTALLATION A. Locate and place louver units plumb, level and in proper alignment with adjacent work. B. Use concealed anchorages wherever possible. Provide brass or lead washers fitted to screws where required to protect metal surfaces and to make a weathertight connection. C. Form tight joints with exposed connections accurately fitted together. Provide reveals and openings for sealants and joint fillers, as indicated. D. Protect galvanized and non-ferrous metal surfaces from corrosion or galvanic action by application of a heavy coating of bituminous paint on surfaces, which will be in contact with concrete, masonry, or dissimilar metals. E. Provide concealed gaskets, flashings, joint fillers, and insulations, and install as the work progresses to make the installations weathertight. END OF SECTION Arch i tectura I Louvers 10200-4 Cannon Road Lift Station Project No. 3583 P:\City of Carisbad-1682~30679-bfl StaSm\7 Pro] Docs\7 2 Final Dodl 00 % Specs\i 0200 doc SECTION 10400 SIGN AGE PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor, materials, equipment, and incidentals required and install signage as shown, as scheduled and specified herein. B. Types to be furnished are as follows: 1. Room Identification Signs. 2. RestrictiveKaution Signs and Hazard Identification Signs. 3. Interior Informational Signs. 1.02 RELATED WORK A. Field painting, piping, and equipment identification is included in Section 09900. B. Illuminated exit signs and electrical connections for illuminated signs are Division 16. 1.03 SUBMITTALS A. Submit for review the manufacturer's complete color range and type styles. B. Submit, in accordance with SSPWC 2003 shop drawings and product data showing details of construction, electrical work, where required, and erection details. C. Submit sign layouts for review as follows: 1. Scale layout of all exterior building signs. 2. Full size layout-typical room identification sign. D. Submit two each of the following samples for review. Resubmit as required until approved: 1. Minimum 6-in square sample of rigid plastic and pressure sensitive vinyl cut into letters in each of the colors proposed for the color scheme. E. Submit full size rubbing of the dedication plaque. F. Submit for review cleaning and maintenance instructions for all signage components. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-l6827\30679Lift StationV Pro] Docs\7.2 Final Docs\100 X Specs\lo4W.doc Signage 10400-1 1.04 REFERENCES A. National Fire Protection Association (NFPA) 1. NFPA 49 - Hazardous Chemicals Data 2. NFPA 325 - Guide to Fire Hazard Properties of Flammable Liquid, Gases, and Volatile Solids 3. NFPA 704 - Identification of Fire Hazards of Materials B. Occupational Safety and Health Administration (OSHA) 1. Standards PART 2 PRODUCTS 2.01 MATERIALS A. Signs shall be manufactured by AS1 Sign Systems, Dallas, TX (214-352-9140); equal by Architectural Graphics Inc., Norfolk, VA or equal. Catalog numbers indicated are those of Architectural Signing Inc. (ASI), unless otherwise indicated. All lettering shall be Helvetica Medium, sized and both in upper and lower case as specified and scheduled. B. Room Identification Signs and other associated instructions and with graphic representations where scheduled shall be AS1 LTV Series, pressure sensitive letters applied directly to doors. All numbers and letters shall be 1-1/2-in high Helvetica Medium, upper and lower case. Numbers and letters shall be die-cut from 3.5-mils thick, pressure sensitive vinyl film and prespaced on carrier tape. The adhesive and finish surface shall be protected with one piece removable liners. Graphics and text shall be as scheduled. Color shall be dark blue to match exterior equipment color. See Section 09900. C. Signage 10400-2 Restrictive/Caution Signs and Hazard Identification System shall be AS1 Group 1 SPF constructed of 0.080-in vinyl laminated to a 0.080-in acrylic backing. Letters or symbols shall be screen printing or ASP process both in subsurface locations. Restrictive/Caution Signs shall have 1-in radius rounded comers. Size of sign: 10-in by 14-in. Color of acrylic and letters shall be in accordance with OSHA standards. All other aspects of the Restrictive/Caution Sign shall be in accordance with OSHA standards. Hazard identification system shall conform to National Fire Protection Association (NFPA) NFPA 704 with a large diamond shape made up of four smaller diamonds with numbers on the diamonds corresponding to the labels for the chemical represented. Small diamonds are to be 5-in on a side with 4-in letters. The overall diamond shall be 10-in on a side. The health diamond shall be blue with a white number. The flammability diamond shall be red with a white number. The Reactivity diamond shall be yellow with a blue number. The unusual reactivity diamond shall be white with a red symbol. Health diamond is on the left. Flammability diamond is on the top. Reactivity diamond is on the right. Special reactivity diamond is on the bottom. Reference for the contents of these signs for each chemical is NFPA 49. If OSHA standards do not apply, the color of the acrylic shall be red with white letters 1-in high. Signs shall be wall surface mounted generally by the SA method fastening of AS1 or equal, continuous across sign with concealed fasteners. Other means of fastening may be used on fences and other unusual mounting locations such as tanks. Signs shall be suitable for interior or exterior use. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-1682A30679-Lifl SLationV Proj Docs\7.2 Final Docs\100 % Specs\lD400.doc D. Handicapped Sign shall be manufactured the same as the Exterior Signs with a single aluminum post fastened to a concrete base that is 4-ft deep minimum. The background shall be white with a blue international symbol for the handicapped on the upper two-thirds of the sign. The sign shall be 841 flag by Architectural Signing, Inc., or equal. Sign shall be 30-in tall and 24-in wide. E. Exterior Signs 1. The exterior signs shall be made of thermosetting polyester resin reinforced with chopped glass fiber strands and fabricated in a 6-in, %in, or 12-in profile seamless construction depending upon the standard design that is reinforced to eliminate cupping and warping plus withstand a 50-psf windload. Graphics shall be subsurface, integral with the molded sign face structure, protected with a polyurethane resign coating system containing ultraviolet inhibitors, and using Helvetica Regular upper and lower case letters. Medium bronze or blue letters and arrows on a tan background shall be used for the site signs as scheduled with blue noted and all other medium bronze. Lettering shall appear on both faces of the signs indicated in the schedule by sides marked "a" and "b." Size shall be as scheduled for the plant sign and site signs. The following colors by AS1 Sign Systems are for reference: White Tan Light Beige Medium Bronze Black Dark Blue Medium Blue Blue SC/90 1 SC/80 1 SC/806 SCl804 SC1904 SCf603 SCl602 SCl60 1 Green Red Dark Yellow Yellow Orange Peacock Turquoise Aqua SC/502 sc120 1 SCl40 1 SC1400 SC/30 1 SC1532 sa53 1 SC/52 1 2. Mounting position shall be as detailed utilizing a concrete foundation and aluminum anchoring system with aluminum supports finished as specified above for plaque. PART 3 EXECUTION 3.01 INSTALLATION A. Signage shall be installed at the locations as directed, in accordance with the manufacturers' recommendations and shop drawings. B. Damaged items shall be removed and replaced at no additional cost to the Agency. C. Signage shall be cleaned to the satisfaction of the Engineer using the approved methods, and upon completion of the installation and again, just prior to acceptance of the project. Cannon Road Lift Station Project No. 3583 PICily of CarIsbad-1682n30679-Lifl StahonV Pro] Docs\7 2 Final Docs1 00 % Specs\1040D.doc Signage 10400-3 D. Sign Schedule: DoorNo. I Room Name 1. Door Signs (Room Identification Signs): Sign Copy I Location* P-1 01 -1 Pump Room Pump Room P-I 0 1 -2 PumD Room Pump Room Exit X I X P- 1 04- 1 P-104-2 E. Restrictive Signs Chlorine Room Chlorine Room X Exit I Chlorine Room Chlorine Room X Exit I Quantity 4 4 F. Hazard Identification System - Reference: National Fire Protection Association (NFPA) NFPA 49, 325, and 704. Sign Copy Location DANGER: Equipment may start without One (1) on each wall of the Pump Room. To be warning located by the Engineer. One (1) on each end of Electrical MCC. One (1) on DANGER: High Voltage each door, located on the opposite door face of the room named. DANGER: Oxygen breathing apparatus may One (1) each on the wall outside each Chlorine Room be required named. High Noise Area, Ear protection required One (1) on the wall outside each Pump Room Door. One per door or storage vessel for each of the areas containing the following: Chemical I Sign Copy I Location Chlorine 0 1 Beside the two doors 30 ox Signage 10400-4 END OF SECTION Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-l6BZ7\30679-~fl Stabm\7 Pro] Docs\7.2 Final Docs\100 96 Specs\IMW.dOC TECHNICAL PROVISIONS SECTION 10522 FIRE EXTINGUISHERS AND BRACKETS PART 1 GENERAL 1.01 SUMMARY A. Provide fire extinguishers and brackets where shown on the Drawings, as specified herein, and as needed for a complete and proper installation. B. Related work 1. Documents affecting work of this Section include, but are not necessarily limited to, General Conditions, Supplemental General Conditions, and Sections in Division 1 of these Specifications. 1.02 SUBMITTALS A. Comply with pertinent provisions of SSPWC 2003. B. Product data: Within 35 Calendar Days after the Contractor has received the Agency's Notice to Proceed, submit: 1. Materials list of items proposed to be provided under this Section; 2. Manufacturer's specifications and other data needed to prove compliance with the specified requirements; 3. Dimensioned drawings as needed to depict the space required for these items, and their interface with the work of other trades. 4. Manufacturer's recommended installation procedures which, when approved by the Agency's Representative, will become the basis for accepting or rejecting actual installation procedures used on the Work. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. Cannon Road Lift Station Fire Extinguishers and Brackets Project No. 3583 10522-1 P\Cify of Carlsbad-1682~0679-Lift StationV Pro1 Docs\7.2 Final Docs\IOO % Specs\Specs from 90%\10522.dw PART 2 2.01 A. B. PART 3 3.01 A. 3.02 A. B. C. PRODUCTS BRACKET AND FIRE EXTINGUISHER At each fire extinguisher location, provide an merex 0 B ABC Dry Chemical Fire extinguisher with appropriate hanging bracket. For bidding purposes, assume four (4) extinguishers. Locate Extinguishers as directed by the building official. Service, charge, and tag each fire extinguisher not more than five Calendar Days prior to the Date of Substantial Completion of the Work as that Date is established by the Agency. EXECUTION SURFACE CONDlTIONS Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. INSTALLATION Coordinate as required with other trades to assure proper and adequate provision in the work of those trades for interface with the work of this Section. Install the work of this Section in strict accordance with the original design, the approved Shop Drawings, pertinent requirements of governmental agencies having jurisdiction, and the manufacturer's recommended installation procedures as approved by the Agency, anchoring all components firmly into position for long life under hard use. Locate additional bracket-mounted extinguishers where directed by the Agency and the Fire Department official. END OF SECTION Fire Extinguishers and Brackets 10522-2 Cannon Road Lift Station Project No. 3583 P:\Clty of Carlsbad-16827U0679-Lifl StationV Prq Doc5\7.2 Final Docs\lOO % SpecsSpecs from 90%\10522.doc SECTION 10800 TOILET ACCESSORIES PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor, materials, equipment and incidentals required and deliver all toilets and shower accessories as shown on the Drawings and as specified herein. 1.02 SUBMITTALS A. Submit, in accordance with SSPWC 2003, complete shop drawings, manufacturer's catalog cuts and data sheets, complete parts list including gauge and type of material and all fasteners, installation requirements and construction details. Submittals shall include the following: 1. One representative sample of each item and model specified, if requested. 2. Certificate of verification by an independent testing organization of grab bar strength and installation. 3. Furnish at the time of delivery of materials, four complete sets of maintenance instructions. 1.03 DELTVERY, STORAGE AND HANDLING A. Deliver materials in manufacturer's original unopened and undamaged packages with labels legible and intact. Store materials in unopened packages in a manner to prevent damage from the environment and construction operations. Handle in accordance with manufacturer's instructions. 1.04 GUARANTEE A. Guarantee all mirrors for 10 years against silver spoilage. Furnish four copies of the guarantee along with maintenance instructions. PART 2 PRODUCTS 2.01 MATERIALS A. Products specified by number are products as manufactured by Bobrick Washroom Equipment Inc. and are used only to determine quality, appearance, workmanship, gauge of metal, capacity and finish. Products by Bradley Washfountain Co.; Watrous Inc. or equal, will be acceptable, if, in the opinion of the Engineer, they meet the intent of this Section as stated immediately above. Accessories furnished shall be the products of one manufacturer. Provide items complete with all screws, bolts and anchoring devices required for installation. Cannon Road Lift Station Project No. 3583 P'\Cily of Carisbad.16827I30679.Lift StatimV Pro1 DoCsV.2 Final Docs\IOO % Swcs\lOEOO.doc Toilet Accessories 10800-1 B. Grab bars shall be 1-1/4-in diameter, 1-1/2-in clear to wall, Type 304 stainless steel, not less than 18 gauge with peened non-slip gripping surface and satin finish elsewhere, complete with wall returns, stainless steel flanges and concealed mountings. Grab bars shall be mounted to dimensions shown. Completed installation shall be able to support the loads as required by the [Massachusetts Architectural Access Board]. C. All accessories shall be stainless steel, except as specified otherwise. 2.02 ACCESSORIES -REFER TO DRAWINGS FOR ACCESSORY ITEM NUMBERS KEYING TO SPECIFIED MODEL NUMBERS. PART 3 EXECUTION 3.01 INSTALLATION A. Coordinate rough opening size and location of masonry recesses with masonry work. Provide mason with rough opening dimensions. B. Use concealed fastenings where so designed. C. Attach accessories securely to walls and partitions in locations as shown or directed. D. Mounting height for accessories used by handicapped shall conform to the applicable code. E. Where required, install concealed mounting devices and fasteners fabricated of the same material as the accessories, or of galvanized steel, as recommended by manufacturer. F. Elsewhere, install exposed mounting devices and fasteners finished to match the accessories. G. Secure toilet accessories in accordance with the manufacturer's instructions for each item and each type of substrate construction. END OF SECTION Toilet Accessories 10800-2 Cannon Road Lift Station Project No. 3583 PICity of Cafisbad-16827\30679-hfl Slalion\7 Proj Docs\7.2 Final Docs\100 % Specs\lOBOO.doc SECTION 1 1260 CHEMICAL FEED AND METERING PUMPS PART 1 GENERAL 1.01 A. B. 1.02 A. B. C. D. E. F. G. H. I. J. K. L. 1.03 A. SCOPE OF WORK This section covers the chemical feed and metering pumps to be installed at the Cannon Road Lift Station for ferric chloride. The Contractor shall furnish all labor, materials, equipment and incidentals necessary to install the chemical feed and metering pumps as shown on the Drawings and as specified herein. RELATED WORK Operation and Maintenance is included in Section 01730. Anchor bolts are included in Section 05500. Concrete coatings for containment areas are covered in Section 09902. Painting is included in Section 09902. High-density polyethylene is included in Section 1 1346. General process instrumentation and control system requirements are included in Section 13300. Double wall chemical piping systems are included in Section 15066. PVC pipe and fittings are included in Section 15064. Valves and appurtenances are included in Section 15 100. General piping requirements are included in Section 15050. Pipe testing requirements included in Section 15050. Electrical work is included under Division 16. SUBMITTALS Shop drawing submittals shall be made in accordance with the requirements of the Green Book, except as modified herein. 1. Equipment and system information: Shop drawings shall be submitted showing details of fabrication and installation. 2. Descriptive literature, bulletins, and/or catalogs of the pumps, valves, and accessories. Cannon Road Lift Station Project No. 3583 PICity of Carlsbad-l6627\30679bft StationV Proj DoCs\7.2 Final Dw\lM) K Specs\l12M).doc Chemical Feed and Metering Pumps I 1260-1 3. Data on the characteristics and performance of each pump. Data shall include performance curves of similar units, which show that they meet the specified requirements for fluid, head, capacity, efficiency, NPSHR, and brake horse power. Curves shall be submitted on individual 8-1/2-in by 1 l-in sheets, at as large a scale as is practical. 4. Complete wiring diagrams and suitable outline drawings showing such details as are necessary to locate conduit stubups and field wiring. Standard preprinted sheets or drawings simply marked to indicate applicability to this Work will not be acceptable. 5. Calculations for each metering pump to determine the suitability of each pump to the suction and discharge conditions of the application point. 6. Complete bill of materials and motor data. 7. Data demonstrating compatibility of the materials of construction and ferric chloride for all items. 8. The Contractor shall submit detailed written startup and testing procedures for the chemical equipment furnished. These procedures shall be detailed as to the item and function that will be tested. The test procedures shall test all equipment, instruments and each function thereof, throughout the operating range of the equipment. The procedures shall be separated into a startup and test procedures plan for each chemical system. Provide recommended backpressure setpoints for the equipment being hished. 9. Piping layout shop drawings per Section 15050. 10. Operating and Maintenance Data and Training a. Operating manuals covering instructions and maintenance sheets on each type of equipment supplied shall be furnished in accordance with Section 01730. b. A factory representative who has complete knowledge of operation and maintenance for each piece of equipment shall provide training as described in Section 0 17 15. Submit training agenda and information. 1.04 REFERENCE STANDARDS A. National Fire Protection Association 1. NFPA 70, National Electrical Code B. National Electrical Manufacturers Association 1. 2. NEMA MG 1 - Motors and Generators NEMA ICs 6 - Industrial Control and Systems Enclosures C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. Chemical Feed and Metering Pumps 1 1260-2 Cannon Road Lift Station Project No. 3583 P.\City of Carlsbad-1682A30679-Uft Stahon\7 Proj Docs\7.2 Final Docs\l00 % Specs\llZMl.doc 1 .OS MAINTENANCE A. Extra Materials: 1. Special Tools: For each pump specified, provide 1 set of all special tools required for complete assembly or disassembly of the pump system components. 2. Spare Parts: For each pump specified, provide spare parts packaged and labeled for warehouse storage: a. Ball check set (balls, seats, gaskets) for suction and discharge ball check valves. b. Disc diaphragm assembly (per type of pump) for each pump. c. One set of seals complete. 1.06 QUALITY ASSURANCE A. General 1. All equipment furnished under this specification shall be new and shall be the standard product of a manufacturer who is fully experienced, reputable, qualified and regularly engaged for at least 5 years in the manufacture of the equipment to be furnished. 2. The Contractor shall assume responsibility for the satisfactory installation and operation of the chemical feed and metering pumps specified. Upon completion of pump installation, the equipment manufacturer(s) shall inspect and shall submit a certificate of proper installation. B. Equipment Factory Testing 1. Dual Chemical Metering Pumps a. Conduct tests on actual equipment to be hished to the job site, including pump head and motor. b. Notify the Engmeer two weeks prior to equipment factory tests. c. Furnish certified test reports which include test data sheets, performance test logs, and equipment performance curves over the specified operating range. Indicate separately equipment guaranteed operating points. PART 2 PRODUCTS 2.01 GENERAL A. Stainless steel nameplates giving the name of the manufacturer, model number and serial number, capacity and other pertinent data shall be attached to each item of equipment. 1. Pump nameplates shall include capacity, head, speed and any other pertinent information. 2. Motor nameplates shall include horsepower, speed, voltage, amperes, service factor, motor enclosure, efficiency and any other pertinent data. Cannon Road Lift Station Project No. 3583 P:\City of Ca~sbad-l682A30679-L1fl StabonV Pro] Docs\7 2 Final Docs\lW % Specs\i 1260.d~ Chemical Feed and Metering Pumps 11 260-3 B. Nameplates giving the name and number of each pump or item of equipment shall be rigidly fastened to all items. All pushbuttons, selector switches, lights, etc., shall be properly labeled such that the hction of each component is clearly identified. C. Supports: Design pump and driver supports on a common base and anchor bolts to withstand a minimum of 1.5 times the maximum imposed operating loads of 1 .O times the imposed seismic loads, whichever is greater. D. Pump and proposed accessories shall be coordinated with the tank discharge piping orientation shown on the Drawings. 2.02 DUAL METERING PUMP DOSING PACKAGE A. The system shall be a corrosion resistant, completely self-contained package with dual chemical metering pumps, and all necessary piping and fittings including pressure relief valve and diaphram- isolated pressure gauge, assembled and tested by the chemical metering pump manufacturer. The chemical metering pumps, all fitting and accessories shall be mounted on a Polyethylene (PE) stand. B. The chemical metering pumps shall be positive displacement of the simplex hydraulically balanced diaphragm type, wherein a volume measuring piston reciprocates within a cylinder and causes hydraulic oil to deflect a flat diaphragm. Tubular diaphragms will not be permitted. All pumps shall incorporate an internal, automatic pressure relief valve to prevent over-pressurization. B. Equipment Manufacturers 1. Dual Metering Pumps and Accessories: a. Pulsafeeder, Pulsar Series; b. Prominent, Sigma series; c. or equal. 2. AC Motors: a. Reliance. b. Or equal. C. Mechanical Drive Assembly: 1. The internal drive assembly shall consist of a worm gear that drives a cam, which in turn actuates the reciprocating piston. 2. Manual capacity adjustment shall be accomplished by changing piston stroke length form 0 to 100% through a mechanical lost-motion device. Device actuation shall be active with the pump idle or running, through a fi-ame mounted control knob (handwheel). The handwheel shall incorporate an integral auto-loclung mechanism to prevent drift and detent positioning with a resolution of iO.5 percent. Chemical Feed and Metering Pumps 1 1260-4 Cannon Road Lift Station Project No. 3583 P:\Ctly of Ca1Isbad-1682A30679-Lift StaIionV Pro] Docs\7.2 Fmal Docs\100 % Specs\l1260.doc 3. Mechanical drive system components shall be segregated in non-vented gear box and eccentric chambers. The gear box shall be filled with a heavy duty gear oil and eccentric box shall be filled with a hydraulic oil. All moving parts shall be flooded. A rotary type lip seal arrangement shall positively seal and separate the two oils of the gear box and the eccentric box. 4. The worm and eccentric shaft shall be supported by ball type bearings. The eccentric shaft shall be a non-axially loaded, single piece design. The main input speed reduction shall be accomplished via a precision cut Dynalloy gear and hardened steel worm shaft. D. Hydraulic System Accessories: 1. Hydraulic Performance Valve: Diaphragm actuated cartridge design which functions to replenish hydraulic fluid as required. This shall serve to realign the diaphragm to a precision controlled start point for each stroke. 2. Hydraulic Diagnostics Package: Provide for instant visual indication of normal hydraulic operations, system over-pressure, and proper oil level. 3. Hydraulic Purge Valve: Manually actuated, externally accessible. The valve shall provide for confirmation of air-free hydraulics and/or diaphragm integrity without system disassembly. 4. Lubricants: The manufacturer shall provide all lubricants required for pump startup and commissioning . E. Metering Head: 1. The metered liquid shall enter the reagent head at the bottom and exit at the top through gravity seating three component ball-type valves. a. Valves shall be free seating type with valve seats having knife-edge contact. b. Valves shall be 4-point guided to accurately control vertical and sideward movement. c. Valve and seat shall be individually replaceable and sealed by O-ring or flat gasket. d. Valve assemblies shall not incorporate any threading other than the process pipe connections. e. Valves shall be serviceable without removing piping. f. Diaphragm shall be a composite design with integral O-ring. The diaphragm shall be capable of sealing under full head-bolt torque limits without stressing the diaphragm. Materials shall be per the individual system specifications. g. Each pump shall include an internal pressure relief valve, externally adjustable over a range of 35 to 95 psig. Valves shall be direct diaphragm, spring controlled type. Initial pressure setting for all pumps shall be as specified in the detailed system specifications which follow. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827U0679-Lifl Slabon\? Proj Docs\7.2 Final D0~5\100 % Specs\11260.doc Chemical Feed and Metering Pumps 1 1260-5 h. The metering head shall be a four-bolt tie bar design, which resists connection forces and helps promote leak-free performance. Materials of the tie bolts shall be resistant to the pumped fluid to protect them from incidental contact. i. Process connections shall be FNPT F. Motor Mount: 1. Arranged for vertical mounting of a C-face motor. 2. The mounting arrangement shall eliminate exposure to rotating couplings. The coupling enclosure shall be totally enclosed and part of the motor mounting assembly. G. Performance Requirements: 1. Pumps shall be selected such that the maximum operating capacity point is achieved at a point between 40 and 60 percent of the available stroke adjustment. 2. The pump shall be capable of operating with suction and/or discharge valves closed without damage. 3. The pump shall be capable of operating with a net positive suction pressure available as low as 3 psi. 4. Flow adjustment shall be from 0 to 100 percent with a guaranteed accuracy of *0.5% steady state on setpoint at the flow required. H. Motors 1. Type: AC. 2. Size: 1/3 hp, minimum. 3. Armature: 115 VAC. 4. Speed: 1750rpm. 5. ServiceFactor: 1.0. 6. Enclosure: TEFC. 7. Insulation: NEMA Class F, non-hygroscopic, rated at 180°C. 8. Ratings: NEMA Class B temperature rise of 100 "C over 40 "C ambient. 9. Time Rating: Continuous. 10. Bearings: Double sealed ball type. 1 1. Power Supply: NEMA Code K, for constant torque over a 10: 1 speed range with a free wheeling diode. Chemical Feed and Metering Pumps 1 1260-6 Cannon Road Lift Station Project No. 3583 P,\Cily of Carlsbad-16827l30679-Lifl StabOn\T Proj Docs\7.2 Final Docs\lW % SpeCs\l1260 doc 12. Accessories: a. Motor shall be furnished with an AC or DC type tachometer generator with a NEMA C face attached to the motor output shaft, factory mounted by the motor manufacturer. b. Conduit Box: Oversized, top mounted with F1E2 conduit connection and permanently marked leads. c. Thermostat: Factory set to protect motor from damage due to overtemperature. Provide one Form C dry N.O. contact for remote alarm indication. I. Motor Drive System 1. Type: constant speed. 2. Power Supply: 120 VAC. 3. Number: Each metering pump furnished shall be supplied with its own drive controller. 4. Mounting: Each drive shall be mounted in a separate NEMA 4X rated enclosure as specified below. 5. Features: a. The drive controllers shall be provided with isolated voltage and current feedbacks. b. Adjustable drive parameters shall include minimum speed, maximum speed, acceleration rate, deceleration rate, current limit and IR compensation. c. Power semi-conductors shall be contained in easily accessible power cubes for rapid replacement in the field. d. An integral surge suppressor shall be provided to protect semi-conductors from line transients. e. A fail-safe relay shall be provided within the drive control circuit to prevent automatic restart following power outage. f. An integral current limit shall be provided within the drive controller to protect the driven equipment from damaging current or torque levels. 6. Signal Interface: a. In REMOTE mode, the drive shall start and stop based on a control signal from the PLC indicated on the Drawings. b. Provide the following drive status outputs: 1) Dnve controller RUN, SPST dry contact rated 5A at 120 VAC. 2) Drive controller COMMON ALARM, SPST dry contact rated 5A at 120 VAC. 3) Drive controller HIGH PRESSURE, SPST dry contact rated 5A at 120 VAC. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-1682A30679-Lift StatimV Pro1 Docs\7.2 Final Docs\lOO K Specs\ll26o.doc Chemical Feed and Metering Pumps 1 1260-7 c. Alarm signals: 1) Each drive shall accept a minimum two shutdown signals. When either signal is energized, the drive shall shutdown via hardwired latching time delay control circuits, independent of control mode. 2) Provide SPDT dry contact for each alarm output, rated 5A at 120 VAC. 3) Discrete input signals fkom the PLC shown on the Drawings will be 24 VDC. Provide any interposing relays required to interface with the specified panel control circuits. 2.03. PUMP ACCESSORIES A. Pulsation Dampeners: 1. Size: Selected by the metering pump manufacturer to match the capacity of the pump. 2. Style: The pulsation dampener shall consist of two separate chambers separated by an elastomeric diaphragm. The lower section shall be wetted by the process fluid, while the upper section shall be isolated from the fluid and filled with compressed air. 3. Process Connection: FNPT, 1/2-inch minimum. 4. Materials of Construction: As specified in the individual system specifications which follow. 5. Accessories: a. Pressure gauge for local indication of pressure within the air chamber. b. Air charging valve for loading the compressed air chamber. c. One air charging assembly for use with all installed pulsation dampeners. B. Calibration Columns: 1. Size: Selected by the metering pump manufacturer to provide 2 minutes of testing at the maximum capacity of the pump (100 percent stroke, 100 percent speed), or 170 mL, whichever is greater. 2. Style: Clear cylinder with graduations marked in liters and gallons. A minimum of five intermediate graduations shall be provided. 3. Process Connections: FNPT, 1/2-inch minimum, located in the top and bottom end caps. 4. Materials of Construction: As specified in the individual system specifications which follow. C. Back Pressure Regulating Valves: 1. Size: Selected by the metering pump manufacturer to provide backpressue on the chemical injection line, as shown, for field installation at the injection point. Chemical Feed and Metering Pumps 1 1260-8 Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827U0679Lift Stahon\7 Pro] Doc5\7.2 Final Docs\100 Oh Specs\l1260 dDc 2. Style: Internal spring actuated diaphragm type. Valve shall be capable of closing without an external source of pressure. Pressure setting shall be externally adjustable between 0 and 150 psig via a top mounted adjustment screw. Operation: The valve shall maintain a constant upstream pressure higher than the downstream injection pressure. When the pressure on the upstream side of valve reduces below the set pressure, the valve shall close, eliminating siphoning into the process line andor back-mixing in the injection line. Process Connections: FNPT, 1/2-inch minimum. Materials of Construction: As specified in the individual system specifications which follow. 3. 4. 5. D. External Pressure Relief Valves: 1. 2. 3. 4. 5. Size: Selected by the metering pump manufacturer to provide external pressure relief on the chemical injection line, as shown, for field installation on the pump discharge line. Style: Internal spring actuated diaphragm type, 3 port design. Valve shall be capable of closing without an external source of pressure. Relief pressure setting shall be externally adjustable between 0 and 150 psig via a top mounted adjustment screw. Operation: The valve shall remain closed with injection line pressures below the setpoint. When the setpoint relief pressure is exceeded, the valve shall open and relieve pressure to the metering pump suction line. Process Connections: F"T, 1/2-inch minimum. Materials of Construction: As specified in the individual system specifications which follow. E. Relief Line Flow Indicators: 1. Description: Pumps shall be supplied with a visual flow indicator installed in the relief valve exhaust line. 2. Style: The indicator shall be of double wall construction with a Pyrex inner cylinder, plexiglass outer cylinder, and stainless steel fasteners. Flow indication shall be accomplished visually without the use of internal streamers or other moving parts. 3. Process Connections: 1/2-inch FNPT. 4. Port Materials: Materials for wetted connections shall be per the individual system specifications which follow. F. Chemical Diffuser: 1. Size: Selected by the chemical pump manufacturer to provide the required injection capacity at maximum pump operating conditions and provide adequate mixing. 2. Style: Solution Diffuser C-265 by Chlorine Specialties, Inc or equal. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-1682i'I30679-Lifl Statid7 Proj Docs\7 2 Final Oocs\100 % Specs\l1260.doc Chemical Feed and Metering Pumps 1 1260-9 3. Process Connections: a. The injection line shall interface with the difiser via a flanged connection. b. The diffuser shall interface with the process line via a flanged connection on the process line. 4. Materials of Construction: PVC. 5. Manufacturers: a. Chlorine Specialties Inc, Burlingame, CA b. Orequal. 2.04 FERRIC CHLORIDE ADDITION SYSTEM A. Equipment Numbers: 1. Metering pumps, constant speed. 2. Calibration cylinders. 3. Pulsation dampeners. 4. Backpressure valves. 5. Pressure relief valves. 6. Relief line flow indicators. 7. Injection quills. B. Pumped Liquid: 1. Name: Ferric Chloride; 3545% solution. 2. pH: 2.0 3. Temperature Range: 60 to 85 OF. 4. Specific Gravity: 1.4 at 64 OF. 5. Viscosity: 12.1~~ for a 40% solution C. Performance Requirements: 1. Operating Capacity: 6 gph per pump. D. Equipment Materials of Construction: 1. Pump Head: PVDFC. 2. Pump Diaphragms: Teflon faced composite. 3. Check Valves (including seats): PVC. 4. O-rings: Teflon. 5. Pulsation Dampeners: PVC (upper and lower chambers) with Viton diaphragm. 6. Calibration Columns: PVC. Chemical Feed and Metering Pumps 1 1260-1 0 Cannon Road Lift Station Project No. 3583 P:\City of Ca~sbad-16827WD679-Ltff StaBon\7 Pro1 Docs\7.2 Final Dm\100 V" Specs\l12M).doc . 7. Backpressure Regulator/Pressure Relief Valves: PVC body, Type 3 16 stainless steel top, with PTFE faced EPDM diaphragm. 8. Flow Indicators: PVC with Viton seals. 9. Injection Quill and Check Valve: PVC. 10. Suction Piping: Single wall socket welded PVC conforming to the requirements specified in Section 15077. 1 1. Injection Piping: PVC carrier pipe in a clear PVC secondary containment pipe conforming to the requirements specified in Sections 15066. E. F. G. For system level, pressure and flow instrumentation, see Section 13300. For system valves, see Section 15100. For the ferric chloride bulk storage tank, see Section 11346. PART 3 EXECUTION 3.01 A. B. 3.02 A. B. C. 3.03 A. SHIPMENT, HANDLING, AND STORAGE The equipment specified herein, shall be factory assembled and ready for installation and connection to the piping as shown on the drawings. The parts and assemblies that are shipped unassembled, shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. INSTALLATION The Contractor shall be responsible for the proper installation of all chemical metering pumps and accessories. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer’s printed instructions, and approved shop drawings. Chemical metering pumps shall be installed on reinforced concrete equipment pads no less than 12- inches. Pump base plates shall be set on grout and securely anchored to the pad per the applicable details on the Drawings. Provide support frames for installation of the local control panels as specified in Section 13300. Securely anchor each frame to the concrete pad and/or chemical area wall. PAINTING Shop and field painting of components shall be in accordance with requirements specified in Section 09902. Cannon Road Lift Station Proiect No. 3583 Chemical Feed and Metering Pumps 11 260-1 1 P\City of Carlsbad-16627Wffi79-Lifl StaIion\7 Prq Don\7.2 Final Docs\1OO Oh 6pecs\l1260.doc -_ 3.04 OPERATIONS AND MAINTENANCE MANUALS A. The Contractor shall provide operations and maintenance manuals for components of the chemical feed systems meeting the requirements of Section 01730. 3.05 FIELD SERVICES A. General 1. A qualified representative of each of the equipment manufacturers, as required, shall be present at the job site or classroom designated by the Engineer for the services herein described, travel time excluded a. Provide representatives of equipment manufacturers for installation assistance, inspection, and certification of their equipment. Contractor shall submit certification in accordance with Sections 01730 and 01750. b. Provide representatives for training and operations assistance. B. Training 1. The Contractor shall provide training in accordance with Section 01 730. C. Field Testing 1. Testing and Startup Responsibilities a. Perform all Work for equipment functional and performance tests specified herein. b. Complete all Work associated with the unit and related processes before testing, including related manufacturer's representative services. I c. Provide all related operating and maintenance manuals, and spare parts and special tools as specified before testing any unit or system. d. Furnish qualified manufacturer's representatives when required to assist in testing. e. Utilize an approved Manufacturer's Certificate of Proper Installation Form, supplemented as necessary, to document all functional and performance procedures, results, problems, and conclusions. f. Schedule and attend pretest (functional and performance) meetings related to test schedule, plan of test, materials, chemicals, and liquids required, facilities' operations interface, Engineer and Contractor involvement. 2. Functional Testing a. Conduct an initial functional test on installed equipment with water as the test medium to demonstrate their proper installation and operation. Submit a report documenting each test in a format acceptable to the Engineer. Chemical Feed and Metering Pumps 1 1260-1 2 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-1682A30679-hfl Station\7 Pro] Oocs\7.2 Final DOct\100 96 Specs\l1260.doc b. Inspect all metering pumps for proper alignment, quiet operation, and acceptable vibration levels. c. Following successful completion of all testing, drain and dry the associated piping and components. 3. Performance Testing a. Prior to initiating lift station startup, components of the chemical feed system shall undergo individual performance tests to demonstrate and confirm that the chemical feed system meets the performance requirements specified herein. b. Prepare a compliance report documenting each test in a format acceptable to the Engineer. c. Conduct performance tests with the process chemical as the test fluid: Operate each installed pump and plot an actual family of rate-of-flow curves, based on a minimum of 16 operating points. Points shall include at least four intermediate percentages of total stroke length; and at each point, four intermediate percentages of pump stroke frequency. Plot final curves in a format acceptable to the Engineer. Units of flow shall be gallons per hour. Units of stroke length and speed shall be as percent-of-maximum. Test each pump for response to the appropriate control signal(s). The steady state operating speed of each unit shall be within +_5 percent of set point over the full operating range. Include the curve(s) in the startup file for each pump. Units failing to operate continuously and reliably or units not capable of meeting specified performance requirements shall be replaced with conforming units. END OF SECTION Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16B27W067!3-L1ft StabOn\7 Proj Don\7.2 Final Docs\100 % Specs\11260.doc Chemical Feed and Metering Pumps 1 1260-1 3 This page intentionally left Blank. Chemical Feed and Metering Pumps 11260-14 Cannon Road Lift Station Project No. 3583 P:\City of Catisbad-t6827\3067$-Lifl StationV Proj Docs\7.2 Final Docs\lOO % Specdl 1260.dOC SECTION 1 13 10 SUBMERSBLE PUMPS PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor, materials, equipment and incidentals to install and test three submersible pumps, ready for operation and with all accessories as shown on the Drawings and as specified herein. 1.02 RELATED WORK A. Yard piping is included in SSPWC 2003 and Division 2. B. Concrete work is included in Division 3. C. Instrumentation and controls, other than those specified herein, are specified under their respective Sections of Division 13. D. Electrical work is included under Division 16. 1.03 SUBMITTALS A. Submit copies of all materials required to establish compliance with this Section. Submittals shall include the following: 1. Descriptive literature, bulletins and/or catalogs of all equipment used, excluding pumps and accessories and appurtenances described in Paragraph 2.04. 2. All information required by Section 01600. 3. Complete description of surface preparation and shop prime painting. 1.04 REFERENCE STANDARDS A. American National Standard Institute (ANSI) B. American Bearing Manufacturers Association (ABMA) C. National Electrical Manufacturers Association (NEMA) D. National Electrical Code (NEC) E. Factory Mutual (FM) F. Underwriters Laboratories (UL) Cannon Road Lift Station Project No. 3583 P:\clly d Carisba616827\30679-LfI Station\7 Prq Docs\7.2 Final Docs\lW % Specs\ll310-r.doc Submersible Pumps 11310-1 G. PART 2 2.01 A. 2.02 A. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. PRODUCTS MATERIALS AND EQUrPMENT General 1. The three submersible pumps and accessories and appurtenances described in Paragraph 2.04 to be installed under this section have been prepurchased by the Agency, and are in storage at a local Agency storage site. 2. Contractor shall schedule with the Agency a suitable time to pick up the pumps, accessories, and appurtenances from the Agency storage site. Contractor shall be responsible for furnishing acceptable lifting equipment and hauling to transport equipment from Agency storage site to the project location. 3. Agency-provided equipment shall be available for pick up and installation 140 working days after the Notice to Proceed. 4. This Section is intended to give a general description of what is required, but does not cover all details which will vary in accordance with the requirements of the equipment as offered. It is, however intended to cover all materials, equipment and appurtenances for the complete pumping units as herein specified, whether specifically mentioned in this Section or not. 4. For all units there shall be furnished and installed all necessary and desirable accessory equipment and auxiliaries whether specifically supplied to Contractor or mentioned in this Section or not and as required for an installation incorporating the highest standards for the type of service. 5. Pump bases and/or base elbows shall be rigidly and accurately anchored into position on concrete and all necessary foundation bolts, plates, nuts and washers shall be furnished and installed. Anchor bolts shall be Type 304 stainless steel. 6. All electrical materials and equipment shall be UL listed or FM approved and NEMA rated, and shall otherwise be equal to that supplied under Division 16, where applicable. PUMP CONSTRUCTION The pumps shall be totally submersible, solids handling, nonclog, screenless sump pumps. The pumps shall be mounted on a guide rail system to allow the pumps to be easily removed for inspection or service, requiring no bolts, nuts or other fastenings to be removed for this purpose and no need for personnel to enter the wet well. Each pump shall be fitted with a stainless steel lifting chain of adequate strength and length to permit raising the pump for inspection and removal. Per the Contract Drawings, the pumps shall be pedestal mounted, not anchored to the floor and removable by breaking the discharge piping, which shall include a union for that purpose. Submersible Pumps 1 131 0-2 Cannon Road Lift Station Project No. 3583 PCity of Ca~sbad-l662~79-~n SWon\7 Prci Docs\7.2 Final Docs\lOO % Specs\ll3lO~r.dcc B. Submersible Pumps pre-purchased by Agency shall be for submersible use and as follows: 1. Drive Unit Horsepower: 130 (nominal). 2. Capacity and Head: 1,650 gallons per minute (gpm) at 188 feet TDH; 1,200 gpm at 208 feet TDH. 3. Minimum Solids Passing Size: 3-inch. C. Guide rail system: 1. Each pump discharge elbow connection shall be permanently installed in the wet well along with the discharge piping. Each pump shall be automatically connected and sealed to its discharge connection elbow when lowered into place and shall be easily removable. Each pump shall be mounted on a sliding guide bracket which is used to guide the pump into place with the discharge connection elbow. The sliding guide bracket and the pump casing shall have a machined angle connection with yoke to connect with the cast iron discharge connection, which shall be bolted to the sump floor pedestal and so designed as to receive the pump angle connection without the need of any bolts or nuts. Provide Type 304 stainless steel anchor bolts for attachment to the floor. 2.03 PUMP CONTROLS A. The control system shall utilize a bubbler to operate at preset liquid levels in the pump well to control the pumps. The bubbler and control system shall be furnished by Contractor. 2.04 ACCESSORIES AND APPURTENANCES A. Pump accessories and appurtenances shall include, but not be limited to: 1. Lifting chains (all pumps). 2. Safety chain hooks. 3. Access hatch (for wet well). 4. Guide rails (all pumps). 5. Upper guide bar brackets (all pumps). 6. Discharge elbows (all pumps). 7. Mounting brackets (all pumps). 8. Cable holder (all pumps). 9. Power and signal cables (all pumps). B. The access hatch shall be cast into the wet well slab flush with the surface. Hatch openings shall be suitably sized for the removal of the pumps. Hatch shall be'of aluminum fabrication, designed for H-20 loading. Hatch shall be equipped with diamond pattern cover plate, channel frame complete with anchor flange, pintel hinges, at least two spring operators, automatic hold open arm and release handle, removable key wrench and slam-lock and flush grip handle. Each access opening shall incorporate a safety grating to prevent accidental falls. The grating shall have openings at least 5-inch by 5-inch in size. Cover plate and channel frame shall be at least %-in thick. Hardware shall be stainless steel throughout. Aluminum components shall be mill finished with bituminous coating on the exterior of the frame. Underside of hatch covers shall be insulated Cannon Road Lift Station Project No. 3583 PGity of Carlsb&16827UJ679-M SIatim\7 Pw DocscI.2 Final DoCs\100 % SpecsU 1310-r.dw Submersible Pumps 11310-3 with fiberglass insulation fully covered and protected with an 18-gauge aluminum cover liner. Hatch shall be provided by Agency complete with heavy-duty padlock with stainless steel core. 2.05 SURFACE PREPARATION AND PRIME PAINTING A. All equipment furnished under this Section shall be shop primed and finish painted as specified in Section 09902 and herein. PART 3 EXECUTION 3.01 INSTALLATION A. Installation shall be in strict accordance with the manufacturer's instructions and recommendations in the locations shown on the Drawings. Installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer's recommendations. Anchor bolts shall be set in accordance with the manufacturer's recommendations. B. The pumps and motors shall be installed to avoid the generation of objectionable noise or vibration. 3.02 INITIAL STARTUP, INSPECTION, AND TESTING A. Agency shall provide a technical representative of the pump manufacturer, who has complete knowledge of proper operation and maintenance, for one day to instruct Agency operators on proper operation and maintenance and to observe and assist during initial startup. B. After all pumps have been completely installed and initial startup has been completed, conduct in the presence of the Engineer and Agency operator such tests as are necessary to indicate that pump efficiency and operating points conform to the requirements specified. Field tests shall be performed on all pumps furnished under this Section. Supply all electric power, potable water, labor, and auxiliary equipment required to complete the field tests. Contractor may purchase water from nearby fire hydrant connection for testing purposes; see Section 7-8.5 of the Supplemental Provisions regarding the requirement for a construction meter and payment terms. 1. Contractor shall vary flow into the wet well to cause the liquid level to rise and fall to test the pump start and stop operating levels. 2. Contractor shall vary flow into the wet well to test one and two-pump operations. 3. Contractor shall test guide rails and latching mechanism on discharge elbow by raising and lowering each pump. C. 24-Hour Potable Water Testing. A successful 24-hour operating period of the pumps with Contractor-supplied potable water will be required before commencement of the 30-day final test period. During this 24-hour operating period, supply all electric power, potable water, and auxiliary equipment necessary. i Submersible Pumps 11310-4 Cannon Road Lift Station Project No. 3583 P:Lclty of CeIisbad1682M067SLiH Sration\7 Pro/ Docs\7.2 Final Docs\100 36 Specs\llBlO_r.doc 1, Prior to commencing %-hour operating period, Contractor shall furnish sufficient potable water to completely fill sewage forcemain to the point of gravity discharge at approximate Station 60+02.50 as shown on the Drawings. D. 30-Day Test Period. Upon successful completion of the 24-hour operating period, a 30-day test period shall be commenced for final acceptance. The 30day test period shall utilize the 20-inch sanitary sewer as influent to the wet well. Supply all electric power and auxiliary equipment as necessary during this 3Oday period. E. Any component parts which are damaged as a result of testing or which fail to meet the requirements specified shall be replaced, reinstalled and retested at the Contractor's expense. END OF SECTION Cannon Road Lift Station Project No. 3583 PUXy of Carkbad-16W7UC1679-Lifl Slation\7 Pmj Docs\7.2 Final Docs\lOO % ~\llJlO~.doc Submersible Pumps 11310-5 Submersible Pumps 11 31 0-6 This page intentionally left blank. Cannon Road Lift Station Project No. 3583 P\C& ol Carlsbad-1682A30679-Utl Statlon\7 Pro} Docs\7.2 Final Docs\lOO % Spew\ll3lO~r.doc SECTION 11346 CROSS-LINKED POLYETHYLENE TANKS PART 1 GENERAL 1.01 A. 1.02 A. B. C. 1.03 A. SCOPE OF WORK Furnish all labor, materials, equipment and incidentals required and install, field test, complete and make ready for service vertical cross-linked polyethylene storage tanks as shown on the Drawings and as specified herein. RELATED WORK Painting is included in Section 09902. Instrumentation and controls, other than those specified herein, are specified under their respective Sections of Division 13. Piping, valves and appurtenances and pipe hangers and supports are included in Division 15. SuBMlTTALS Submit, in accordance with the Greenbook, shop drawings showing details of construction and erection for each tank as follows: 1. Dimensions of tank, fittings and attachments. 2. Wall thicknesses. 3. Seismic design calculations shall be furnished in accordance with Section 01 172 or 01600. As a minimum, these shall demonstrate that each tank will adequately transfer the seismic forces from the main vessels to the anchor bolts at the foundation. Calculations shall be stamped and signed by a California Registered Professional Engineer. 4. Locations of fittings and attachments. 5. Resin used and complete description of chemical resistance for all materials that will come in contact with materials stored. 6. Weight of tank. 7. Statement that fabrication is in accordance with this Section. 8. Installation list of tanks with similar applications. 9. Shop Test Reports, if requested. 10. Instructions for handling, storage and installation of tanks. Cannon Road Lift Station Project No. 3583 P:\Clly of Carisbad-l6827\30679-lJft Station\7 Pro] Docs\7 2 Final Docs\lOO % Specs\ll?d6.doc Cross-Linked Polyethylene Tanks 1 1346-1 1.04 REFERENCE STANDARDS A. American National Standards Institute (ANSI) 1. ANSI B 16.5 - Pipe Flanges and Flanged Fittings. B. American Society for Testing and Materials (ASTM) ' 1. ASTM D638 - Standard Test Method for Tensile Properties of Plastics. 2. ASTM D746 - Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact . 3. ASTM D790 - Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials. 4. ASTM D883 - Standard Terminology Relating to Plastics. 5. ASTM D1505 - Standard Test Method for Density of Plastics by the Density-Gradient Technique. 6. ASTM D1525 - Standard Test Method for Vicat Softening Temperature of Plastics. 7. ASTM D1593 - Standard Specification for Nonrigid Vinyl Chloride Plastic Sheeting. 8. ASTM D1998 - Standard Specification for Polyethylene Upright Storage Tanks. 9. ASTM D2765 - Standard Test Method for Determination of Gel Content and Swell Ratio of Cross-linked Ethylene Plastics. C. Association of Rotational Molders (ARM) 1. ARM Standards - Low Temperature Impact Resist. (Falling Part Test) D. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. 1.05 QUALITY ASSURANCE A. Tanks shall be constructed by a firm that has at least 5 years prior experience in construction of polyethylene tanks of similar applications. 1.06 SYSTEM DESCRIPTION A. A Femc chloride storage tank will be located indoors and will store ferric chloride solution at a 35- 45% concentration. Cross-Linked Polyethylene Tanks I 1346-2 Project No. 3583 Cannon Road Lift Station P:\City of Cadsbad-16827W0679-Lifl StaIionV Proj Docs\7.2 Final Docs\IOO % Specdl 1346.doc DELIVERY, STORAGE AND HANDLING 1.07 A. B. C. D. The Contractor shall require the manufacturer to assume responsibility for packaging to prevent damage to the tanks during normal transit and handling. Flange faces shall be protected from damage. All openings are to be securely covered to prevent the entrance of dirt, water and debris. Tanks shall be mounted on cylindrical tank support members so constructed as to provide easy handling for fork truck or similar device and shall be provided with lifting lugs, cleats, etc, to permit handling by crane. Nozzles or other fittings shall not be used for lifting. Manway may be used for lifting only if recommended by manufacturer and only according to procedures submitted by manufacturer (See Paragraph 1.03A above). Instructions shall be provided with delivery for unloading and installation of tanks. PART 2 PRODUCTS 2.01 GENEW A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired. Like items of materials, equipment shall be the end products of one manufacturer in order to provide standardization for appearance? operation, maintenance, spare parts and manufacturer's service. Anchor bolts or hold-down devices, if required, shall be provided by the manufacturer. Tanks shall be by Poly Processing Co. Inc., Monroe LA or equal. B. C. 0. 2.02 MATERIALS A. Plastic 1. The tanks shall be molded from high-density cross-linked polyethylene. The molding powder used shall be Marlex CL-200 JN by Phillips Petroleum Company, Plastics Division or powders of equal physical and chemical properties. B. Fillers and Pigments 1. The plastic shall not contain any fillers. All plastic shall contain a minimum of 0.25 percent UV stabilizer and maximum of 0.50 percent. Pigments may be added as desired by the Agency or as designated by the manufacturer, not to exceed 0.5 percent of dry blended or 2 percent if melt compounded of the total weight of the tanks. Cannon Road Lift Station Project No. 3583 P City of Carlsbad-16B27W0679-LiR Slation\7 Pro] Oocs\7 2 Final Docs\100 % Specs\11346 doc Cross-Linked Polyethylene Tanks 1 1346-3 2.03 POLYETHYLENE TANKS A. The polyethylene tanks shall be designed for the following: 1. Ferric chloride Bulk Storage Tank a. b. C. d. e. f. g. h. 1. j. Nominal Dimensions: 1) Diameter: 8’ 2” 2) 3) Nominal Volume (at side shell height): 4,050 gallons Chemical (percentages) and Specific Gravity: Ferric chloride at 3545% solution and 1.4 SG Tank Color: Black Number of Tanks: 1 Full Drain (integrally molded flanged outlet): Yes Mixer: none Interior Baffles: no Exterior Access Ladder: no Nozzle Materials: 1) Bolts: PVC with Titanium 2) Gaskets: Viton Side shell height = 10”” Height: 12’ 10’’ (Maximum Height) 2. Dome Fittings a. Vent Fitting: Universal Ball Dome 1) Bolts: PVC Bulkhead 2) Fume Gasket:Viton 3) Body Gasket: Viton b. Fill Fitting: Universal Ball Dome 1) Bolts: PVC Bulkhead 2) Fume Gasket: Viton 3) Body Gasket: Viton Cross-Linked Polyethylene Tanks 1 1346-4 Project No. 3583 Cannon Road Lift Station P:\City of Carfsbad-l6827\30679-L1ft StaI10nV Proj Docs\7.2 Final Docs\100 % Specs\l1346.doc c. Ultrasonic Level Fitting: Universal Ball Dome 1) Bolts: PVC Bulk Head 2) Fume Gasket: Viton 3) Body Gasket: Viton B. The cross-linked polyethylene tanks shall be constructed by the rotational molding process. C. The minimum of the properties of the material are as follows based on molded parts: PROPERTY ASTM SPECIFICATION VALUE Density Specific Gravity ESCR Spec. Thickness 125 mils F 50 Ultimate 2-idmin. Break 2-idmin. Tensile Strength Elongation at Vicat Softening Temperature Brittleness Flexural Temperature Modulus D1505 0.933 to 0.940 D1593 Type IV Spec Type N Spec D746 D790 59 lb/cu fi 900 to 1000 hrs D638 2600psi D638 400 percent D1525 240 degrees F minus 180 degrees F 100,000 to 110,000 psi D. Tanks shall be cylindrical, flat-bottomed and vertical with dimensions, details and accessories as shown on the Drawings and as specified herein. Where specified or shown on the Drawings, full- draining tanks shall have integrally molded flanged outlets. The finished surface shall be as free as commercially practicable from visual defects, such as; foreign inclusions, air bubbles, pinholes and craters. E. The tank diameter shall be measured externally. Tolerance on the outside diameter including out of roundness shall be plus or minus 1 percent. Measurement shall be taken in a horizontal position. The knuckle radius at bottom to wall shall be a minimum of 1 -in. F. The minimum wall thickness shall be %-in. G. The tanks (wall thickness at tank bottom) shall be designed with a hoop stress value of no greater than 600 psi at 100 degrees F, with a safety factor of no less than 2, using the Barlow formula for calculating wall thickness. A minimum liquid specific gravity of 1.9 shall be used for wall thckness calculations. H. All edges cut out, such as manway, shall be trimmed to have smooth edges. I. Type 304 stainless steel clips, bolts and accessories shall be provided to securely anchor the tank to the cylindrical tank support member. Cannon Road Lift Station Project No. 3583 Cross-Linked Polyethylene Tanks 1 1346-5 P\Clly of Carisbad-16827\30679-L1fl StabmV Pro1 Docs\7.2 Final DoCs\lOO % Specs\ll346.do~ 2.04 ACCESSORIES A. The polyethylene tank shall be equipped with the following accessories as shown on the Drawings: 1. Nozzles as shown in the size and location indicated on the Drawings and specified herein. a. One 2-in fill. b. One 4-in vent. c. One 2-in outlet. d. One 3-in overflow. e. One 3-in drain. 2. Identification labels (6-in high lettering) with tank designation per Paragraph 2.03A. B. Nozzles 1. All nozzles attached to the chemical storage tanks below the full level of the tanks shall be two- flanged style. The flange attached to the tank wall shall be 150 lb ANSI and be constructed of PVC. Flanges greater than 3-in shall have machined back face to contour of tank. There shall be a minimum of four %-in diameter all thread bolts with bolt heads encapsulated in polyethylene. The polyethylene encapsulation shall fully cover the bolt head and a minimum of %-in of the threads closest to the bolt head. Each bolt shall have a gasket which is on the inside of the tank and each flange shall have a gasket on the outside of the tank. Nozzle for outlet shall be sized to allow opening equal to full inside diameter of outlet piping. C. DomeFittings 1. Fume-tight Dome Fittings. Universal dome flanged type fittings, with fume gasket shall have flange attached to the tank wall of 150 lb ANSI and constructed of CPVC. Provide a minimum of four %-in diameter all thread bolts with bolt heads encapsulated in color-coded polyethylene. The polyethylene encapsulation shall fully cover the bolt head and a minimum of %-in of the threads closest to the bolt head. Each bolt shall have a %-in body gasket which is on the inside of the tank and each flange shall have a %-in body gasket on the outside of the tank. Body gaskets shall be Viton. A flanged connection matching ANSI 150 lb dnlling shall be provided for connection of the nozzle to the pipe. 2. Non-Fume Tight Dome Fittings a. Universal dome flanged type fittings can be used for non-fume tight applications. D. Furnish and install all precautionary labeling and hazardous material signage as recommended by the Manufacturing Chemists Association for each of the chemicals to be stored. E. Ultrasonic Level Sensor: The polyethylene tank shall be furnished with an ultrasonic level sensor on top of the tank. The sensor shall be mounted at least 24" fiom the side wall so that it will have a clear path perpendicular to the liquid surface. The ultrasonic level sensor shall be the Probe as manufactured by Miltronics or equal. Cross-Linked Polyethylene Tanks 1 1346-6 Project No. 3583 Cannon Road Lift Station P\City of Cadsbad-16827i30679-LIR Statron\7 Pro) Doa\7.2 Final Docs\lOO % Specs\l1346.doc F. G. 2.06 A. B. C. D. Liquid Level Indicator: The polyethylene tank shall be furnished with an exterior float type level gauge. The float shall be connected to a tape or wire that is in turn connected to an indicator on the outside of the tank. Changes in the liquid level of the tank raise or lower the float, which moves the indicator cable. Cable movement drives the indicator up and down the gaugeboard on the side of the tank. All wetted parts shall be fabricated from fiber reinforced plastic (vinyl ester). The exterior level gauge shall be 6700 Liquid Level Indicator by Endress + Hauser Systems & Gauging Norcross (Atlanta) GA; or equal. Initial Ferric Chloride Delivery: Contractor shall provide the initial filling of the storage tank with 3545% Femc Chloride. SHOP TESTING The tank manufacturer shall have quality control procedures adequate to ensure that all fabrications comply with the requirements specified herein. Quality control shall include a final inspection by the manufacturer and written record of this final inspection. The objective of manufacturer's quality control and inspection procedure shall be to have the tank comply with this Section and the Drawings at the time of first inspection, thus eliminating any need for rework by the manufacturer or a second inspection by the Engineer. Inspection records shall be made for each tank. Inspection records shall be available to the Engineer. Upon request, manufacturer shall send a copy of hisher inspection records to the Engineer for review prior to inspection by the Engmeer. Final acceptance by the Engineer may be contingent upon satisfactory inspection upon arrival, delivery, installation and testing at the job site. The tank manufacturer shall perform the tests described below prior to shipping. Test samples shall be taken from the manway cut out areas or where fittings are inserted in each tank. The Engineer or hisher representative shall have the option of witnessing these factory tests. Notification of these tests shall be forwarded to the Engineer at least 10 working days before the scheduled testing date. 1. Impact Test: ASTM D746 Standard method shall be used in this test. Sample shall not shatter at 120 ft-lbs with sample at minus 20 degrees F for a %-in wall thickness. For a wall thickness less than %-in, the sample shall not shatter at 100 ft-lbs and minus 20 degrees F. 2. Degree of Cross-linlung Test: ASTM D2765 as modified by Phillips PTC Report 193 shall be used in this test. A minimum of 70 percent Gel must be obtained. 3. Hydrostatic Test: Each tank shall be filled with water and checked for leaks no less than one hour after filling. PART 3 EXECUTION 3.01 INSTALLATION A. Install the cross-linked polyethylene tanks in accordance with the Drawings and the manufacturer's instructions. Cannon Road Lift Station Cross-Linked Polyethylene Tanks Project No. 3583 I1 346-7 P:\City of Ca1lsbad-l6827\30679-Lift Slat1cn\7 Pro1 Doa\7.2 Final Docs\l00 % Specs\l1346 doc B. Tanks shall be installed on five layers of 30 Ib roofmg felt, or other resilient support as recommended by the manufacturer on a grout pad as shown on the Drawings, or another approved means as recommended by the manufacturer to provide for an even bearing on the concrete pad. C. Make all pipe connections to tanks as shown on the Drawings. D. Following the field test and repair of leaks, tanks and support members shall be anchored in their final position according to the manufacturer's recommendations. 3.02 FIELD TESTING A. After installation, each tank shall be field tested by filling with water. The tank and fittings shall hold water without loss, evidence of weeping or capillary action for a period of 24 hours prior to acceptance. The Engineer may also inspect each tank for defects, damage and conformance with the Section. B. After testing, the tanks shall be thoroughly cleaned and dried. C. Should any defects become evident during inspection, testing, or within the guarantee period, repair or replace the defective tank or fitting as approved by the Engineer. END OF SECTION ! Cross-Linked Polyethylene Tanks I 1346-8 Project No. 3583 Cannon Road Lift Station P:\city of Carlsbad-16827U0679-Ltfl Stabm\7 Pro) Docs\7 2 Flnal Docs\lM) % Specs\l1346.doc SECTION 1 1400 HYDRAULIC SPECIALITIES PART 1 1.01 A. 1.02 A. B. C. D. E. F. 1.03 A. GENERAL SCOPE OF WORK Furnish all labor, materials, equipment and incidentals to install various hydraulic equipment and components ready for operation and with all accessories as shown on the Drawings and as specified herein. RELATED WORK Yard piping is included in Division 2. Concrete work is included in Division 3. Field painting is included in Section 09902. Instrumentation and controls, other than those specified herein, are specified under their respective Sections of Division 13. Mechanical piping and valves are included in the respective Sections of Division 15. Electrical work is included under Division 16. SUBMITTALS Submit in accordance with SSPWC 2003, copies of all materials required to establish compliance with this Section. Submittals shall include the following: 1. 2. 3. 4. 5. 6. Certified shop and erection drawings showing all important details of construction, dimensions and anchor bolt locations for all equipment and components described in Paragraph 2.0 1. Descriptive literature, bulletins and/or catalogs of each of the equipmentkomponents. Data on the characteristics and performance of the pump. Data shall include guaranteed performance curves, based on actual shop tests of duplicate units, which Data shall indicate that pump meets the specified requirements for head and capacity, and horsepower. Hydraulic calculations for Storm Drain Litter Removal Box to establish compliance with Paragraph 2.01 (F)(7). The total weight of the equipment including weight of the single largest item. A complete total bill of materials for all equipmentkomponents. Cannon Road Lift Station Project No. 3583 P:City of Carlsbad-1662~C67~Ltfl SIationV pml Oocs\7.2 Final Docs\IOO % Specs\l1400.doc Hydraulic Specialties 1 1400-1 7. A list of the manufacturer's recommended spare parts with the manufacturer's current price for each item. Include gaskets, packing, etc, on the list. List bearings by the bearing manufacturer's numbers only. 8. Complete description of surface preparation and shop prime painting. B. Operation and Maintenance Data 1. Copies of an operating and maintenance manual for each piece of equipment described in this Section, in accordance with Section 0 1730. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc, that are required to instruct operating and maintenance personnel unfamiliar with such equipment. 1.04 REFERENCE STANDARDS A. American National Standard Institute (ANSI) B. American Bearing Manufacturers Association (ABMA) C. National Electrical Manufacturers Association (NEMA) D. National Electrical Code (NEC) E. Factory Mutual (FM) F. Underwriters Laboratories (UL) G. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. PART 2 PRODUCTS 2.01 MATERIALS AND EQUIPMENT A. Dedicated Flowmeter 1. Flowmeter shall be installed in the location indicated on the Drawings. Flowmeter shall be a non-intrusive (clamp-on) ultrasonic transit-time flowmeter requiring no cutting of the pipe. 2. The clamp-on transducers shall be of the type and size recommended by the manufacturer for this installation. 3. Flowmeter shall have a 4-20 mA output, and a calibratable accuracy of less than 1.0%. Flowmeter shall be model 10 10N by Controlotron, Hauppauge, NY or equal. Hydraulic Specialties 1 1400-2 Cannon Road Lift Station Project No. 3583 P:\clty ofCarlsbad-lE82N0679-Lifl Station\7 Proj Docs\7.2 Final Docs\lW % Specs\i 1400.doc B. Dedicated Sump Pump and Check Valve 1. Sump Pump shall be installed in the location indicated on the Drawings. Sump Pump shall be a cast iron sewage ejector pump with integral float control, and shall have the following characteristics: a. Nominal Horsepower: !4 HP b. c. d. e. Capacity and Head: 80 gallons per minute (gpm) at 10 feet TDH Minimum Solids Passing Size: 2-inch Threaded Discharge: 2-inch NPT female Electrical: 115 VAC, 60 Hz, 1-ph. 2. Sump Pump Check Valve shall be installed in the location indicated on the Drawings. Check Valve shall be a PVC Y-Pattern Check Valve, and shall have the following characteristics: a. Nominal Size: 2-inch b. c. Cracking Pressure: less than 0.5 psi Fully compatible for wastewater use. C. Flexible Expansion Joints 1. Flexible expansion joints shall be installed in the locations indicated on the Drawings and shall be manufactured of ductile iron conforming to the material properties of ANSVAWWA C153/A21.53. 2. Each flexible expansion joint shall be pressure treated against its own restraint to a minimum of 350 psi (250 psi for flexible expansion joints 30 inches and larger). 3. Each flexible expansion joint shall consist of an expansion joint designed and cast as an integral part of a ball and socket type flexible joint, having a minimum of 15 degrees deflection per ball and 4-inches minimum expansion. 4. All internal surfaces and seal contact surfaces parts shall be lined with a minimum of 15 mils of hsion-bonded epoxy conforming to the applicable requirements of ANSVAWWA C213 and shall be holiday tested with a 1500 volt spark test Conforming to said specification. 5. All external surfaces shall be coated with a catalyzed coal tar epoxy conforming to the material requirements of AWWA C2 10. 6. All buried flexible expansion joints shall be installed with polyethylene encasement per AWWA C105. 7. All flexible expansion joints shall be FLEX-TEND as manufactured by EBAA Iron Inc., Eastland, TX, or equal. Cannon Road Lift Station Project No. 3583 P:\city of Carlsbad-l8827\306794fl SbtiOn\T Prq Oocs\72 Final Doa\lOO K Specs\l1400.doc Hydraulic Special ties 1 1400-3 D. Sleeve Couplings 1. Sleeve couplings shall be installed in the locations indicated on the Drawings and shall be manufactured in conformance with the following standards: a. Followers: AIS1 C1012/ASME SA36 b. Middle Ring: ASTM A5 13/ASTM A635/ASME SA675 GR60 c. Bolts: AWWAClll/ANSIA21.11 2. All buried sleeve couplings shall be installed with polyethylene encasement per AWWA C105. 3. Sleeve couplings shall be Style 38 Dresser Couplings as manufactured by DresserDMD, Bradford PA, or equal. E. Precast Concrete Trench Drain 1. Precast concreate drain shall be installed in the locations indicated on the Drawings and shall be manufactured of precast polymer concrete utilizing vinyl ester resin. 2. Precast trench units shall have a minimum slope of 0.6%. 3. Horizontal anchoring ribs shall be located along the bottom of the channel that mechanically engage into the concrete. Rib or bulb shall be a minimum of sixty (60) percent of the channel length. 4. Channel base to be four and three-eighths inches (4-3/8”) wide to provide maximum load distribution. 5. The trench channel shall have the following physical properties: a. Accelerated Service to retain 75% of its strength, <2% change in weight or dimension per ASTM D756-E. b. Chemical Corrosion to retain 75% strength, <2% change in weight or dimension per ASTM D543. c. Water Absorption <1% per ASTM D570. i. No cracking, crazing, checking, blistering or surface pitting is allowed. Changes in color acceptable when not indicative of physical degradation. 6. Trench drain shall be Polycast 600 Series manufactured by Strongwell, Lenoir City, Tennessee, or equal. 7. Channel grate material shall be fiberglass Polycast DG0644 or equal. Hydraulic Specialties 1 1400-4 Cannon Road Lift Station Project No. 3583 P:City d Carlsbad-l6827\30674Lifl SLatiOn\7 Pro1 Docs\7.2 Final Docs\lOO % Specs\l1400.doc F. Storm Drain Litter Removal Box 1. Storm drain litter removal box shall be installed in the location and elevations shown on the Drawings. Confirm diameters of existing 36-inch and 42-inch storm drains prior to sizing and/or designing Litter Removal Box. 2. Storm drain litter removal box shall receive influent fiom one 42-inch RCP pipeline, and discharge to one 36-inch and one 42-inch diameter RCP pipelines as shown on the Drawings. 3. Litter removal box shall capture and hold litter and other debris %-inch in diameter and larger as typically encountered in residential storm sewers. 4. Access hatches and/or removable grating shall be incorporated into the cover of the litter removal box to facilitate periodic cleaning by a Vactor truck, and shall be sufficiently secure as to prevent tampering and unauthorized access to box. 5. Cover of litter removal box, including all hatches andor grating, shall be suitable for H-20 loading. 6. Litter removal box shall not retain water after a storm event. 7. Litter removal box shall be designed and constructed to limit headloss across the box to 1.3 feet or lower based on a 1 00-year return period flow of 84.4 cubic feet per second. 8. All metal components within the litter removal box, including but not limited to those associated with a screen or mounting hardware, shall be stainless steel. 9. Outer walls, floor, and cover of litter removal box shall be constructed of Portland Cement Concrete. 2.02 SURFACE PREPARATION AND PRIME PAINTING A. All equipment hmished under this Section shall be shop primed and finish painted per the manufacturer's recommendations and as described on the Drawings. PART 3 EXECUTION 3.01 INSTALLATION A. Installation shall be in strict accordance with the manufacturer's instructions and recommendations in the locations shown on the Drawings. Installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer's recommendations. Anchor bolts shall be set in accordance with the manufacturer's recommendations. B. Any component parts which are damaged as a result of testing or which fail to meet the requirements specified shall be replaced, reinstalled and retested at the Contractor's expense. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827W679-Lifl Station\T Proj Docs\7.2 Final Docs\lW X Specs\i 1400.d~ Hydraulic Specialties 1 1400-5 Hydraulic Specialties 1 1400-6 END OF SECTION Cannon Road Lift Station Project No. 3583 PIClty ofCarlsbad-16827U0679Lifl SbtionV Pmj Docs\7.2 Fmal Docs\lDO K Specs\l1400.dOC SECTION 13300 INSTRUMENTATION AND CONTROLS PART 1 GENERAL 1.01 THE REQUIREMENTS A. TASK: The system supplier shall furnish and place into service a control system to provide for control of the three pump station constant speed starters, monitor station wet well level as well as perform all logic fhctions specified and provide telemetry communication to the Carlsbad MWD Administration Building. B. SYSTEM SUPPLIER: The complete control system shall be furnished by a single supplier who shall assume responsibility for the satisfactory performance of the complete system. Only those suppliers who can demonstrate that they possess the prerequisite capabilities and experience will be considered. Any supplier wishing to qualify must apply in writing to the Engineer a minimum of 21 days prior to the bid opening date. Each applicant will be thoroughly examined, investigated, and then judged as to capability to execute the Scope of Work required on this project within the time frame allotted. Each applicant will be notified as to his approval or disapproval at least 7 days prior to the scheduled bid opening. Each applicant will be evaluated for the following minimum criteria. I. Demonstrate the company's ability to successfully complete projects of similar size and nature. Provide references (including contact name and telephone number) for at least three projects where the following tasks were performed by personnel directly employed by your firm as a system supplier; system engmeering and documentation including panel assembly, schematics, and wiring diagrams; software configuration and documentation; field testing, calibration, and start-up; and operating instructions and maintenance training. 2. Name the individual persons who will be responsible for office engineering and project management; software configuration; field testing, calibration and start-up; and operator instruction and maintenance training. References called for in the previous item shall include recent project of these individual persons. 3. Document that the company is actively in the business of finishing integrated instrumentation, telemetry, control and electrical equipment for the water and waste water'industries. 4. Have a qualified service facility with permanent employees located within 100 miles of the job site. Facility to include all tools, spare parts, and test equipment to repair, calibrate, test and start-up the equipment to be provided on this contract. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827U0679-Ufl Station\? Proj Docs\7.2 Final Dccs\lW X Specs\Oct 2003Add Specs\13300.doc Instrumentation and Controls 13300-1 For this project the prequalified system suppliers are as follows: C. 1. NEAL ELECTRIC, Poway (858) 513-2525 2. INTEGRATED CONTROLS, Orange (714) 516-9531 3. SYNTECH AUTOMATION, San Diego (858) 712-3460 4. FREEDOM AUTOMATION, Oceanside (760) 231-6192 5. TEAM 2 CONTROLS, Simi Valley (805) 955-9200 6. TESCO CONTROLS, INC., Cemtos (310) 614-0841 7. MANUFACTURING AUTOMATION SOLUTIONS, INC. (949) 95 1-2775 CERTIFICATION BY SYSTEM SUPPLIER: At the time of quoting to his Contractor prior to bid opening, the prospective system supplier shall execute and submit a written certification of intent to assume full responsibility for the complete requirements of the Contract Documents. A signed copy thereof shall be supplied to each prospective Contractor for inclusion by him with his Bidding Documents. Failure by a bidding system supplier to provide this written certification shall be treated by the Contractor as NO BID and that system supplier will not be acceptable. The Contractor shall include with his proposal the certification, required above, only for the system supplier for whom he has inserted a price in the Bidding Documents. The certification shall be on the named system supplier's letterhead, it shall be signed by his authorized responsible representative, and it shall include the following statements: 1. (Corporate name of system supplier) hereby certifies intent to assume and execute full responsibility to select, furnish, install, test, calibrate and place into operation all specified instrumentation, equipment and accessories needed for a complete and operational instrumentation and control system all in full compliance with the requirements of the Contract Documents. 2. In addition, it is certified that drawings and data will be prepared and submitted, specified field services will be performed by qualified personnel and the Agency's operating and maintenance personnel will be instructed and trained. Technical manuals will be prepared and submitted as required. 3. Finally, it is certified that the quotation offered provides for full and complete compliance with the requirements of the Contract Documents without exception. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Electrical work specified hereunder shall conform to the requirements of this section and the applicable requirements of section entitled "Electrical General Provisions''. (See Section 16020). 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. The installation and fabrication of all items within the scope of this section of the specifications shall be accomplished according to the requirements of the regulatory agencies as specified in Electrical Section 16020 and the referenced standards listed including UL, IEEE, ICEA, and NEMA. The primary reference standards for this Section 13300 Instrumentation shall be ISA-Instrument Society of America. Instrumentation and Controls 13300-2 Project No. 3583 Cannon Road Lift Station P\CPy of Carlsbad-16827W0679-Lifl Stabon\7 Prq Docs\7.2 Final Doa\100 % Specs\od 2003 Add Spacs\13300.doc Without limiting the generality of other requirements of these specifications, all work specified herein shall conform to or exceed the applicable requirements of the referenced documents to the extent that the requirements therein are not in conflict with the provisions of this section; provided, that where such documents have been adopted as a code or public ordinance by the public agency having jurisdiction, such code or ordinance shall take precedence. 1.04 CONTRACTOR SUBMITTALS A. General Submittal Requirements: 1. Shop Drawings shall fully demonstrate that the equipment and services to be furnished will comply with the provisions of these Specifications and shall provide a true and complete record of the equipment as manufactured and delivered. 2. Submittals shall be bound in separate three-ring binders, shall be complete, neat, orderly with an index and sectional dividers, with all Drawings reduced to a maximum size of 1 1-in by 17- in, then folded to 8-1/2-in by 11 -in for inclusion within the binder. 3. Exceptions to the Specifications or Drawings shall be clearly defined by the INSTRUMENT SYSTEM SUPPLIER (ISS) in a separate section of each submittal package. The submittal shall contain the reason for exception, the exact nature of the exception and the proposed substitution so that a proper evaluation may be made by the Engineer. 4. If, in the opinion of the Engineer, a submittal is not clear or complete, it will be returned to the ISS with the markings "Revise" and "Resubmit". The decision of the Engineer on the acceptability of any submittal shall be final. B. Submittals - Hardware and Shop Drawings 1. Shop Drawings shall be complete; giving at least equipment specifications, details of connections, wiring, I/O address lists, radio/PLC address, range and dimensions. Submittals consisting of only general sales literature will not be acceptable. 2. Submit detailed information for each instrument, power or control device, including manufacturer's descriptive literature and a data sheet for each device which shall include as a minimum: a. b. c. Input/output characteristics. d. e. f. g. Product (item) name and tag number (if applicable) as indicated on the Contract Drawings. Manufacturer's name and complete model number. Range, size, span, setpoint, deadbands, etc. Physical size with dimensions, enclosure NEMA classification and mounting details. Materials of construction of all components. Instrument or control device sizing calculations where applicable. 3. Submit a detailed loop connection diagram for each monitoring and control loop defined. The format shall be based on the Instrument Society of America, Standard for Instrument Loop Diagrams, ISA45.4. The loop diagrams shall show all components of the loop including Cannon Road Lift Station Instrumentation and Controls Project No. 3583 13300-3 P:\Clty of Carlsbad-18827U0679-Lfl Stahon\7 Proj Docs\7.2 Final Doa\laO H Specs\Oct 2003 Add Specs\13300.doc electrical relays, switches, and other devices necessary for the proper operation of the loop. Each loop diagram shall show all wiring and piping details, identify all field termination and grounding points within cabinets and panels and identify connection points on all devices. 4. Submit detailed drawings for control panels including: a. Cabinet assembly and layout drawings to scale. The assembly drawing shall include a bill of material on the drawing with each panel component clearly defined. The bill of material shall be cross-referenced to the assembly drawing so that a non-technical person can readily identify any component of the assembly by manufacturer and model number. Include equipment provided by others (seismic controller, etc.). b. Fabrication and painting specifications. c. Point to point wiring diagrams depicting wiring within the panel as well as connections to external devices. Heat calculations for each panel supplied. Heat calculations shall be based on a minimum ambient temperature of 259; and a maximum ambient temperature of 105T. d. 5. PLC Hardware Submittals a. Catalog cuts and descriptive literature for PLC and radio equipment including central processing unit, input modules, output modules, radios, multiplexers, interface modules, power supplies, etc. Block diagrams showing the inter-connections between major hardware components, modules, interface devices, radio and plug in circuit boards and a complete inpudoutput signal listing. b. 6. Written indication of any specific exceptions taken to the interconnection and control intent as shown on the Drawings and specified. C. Software submittals: 1. 2. 3. 4. 5. An "InputlOutput Record Form", tabulating the module number, channel number, address number, inputloutput designation name and/or number, and description of each item of input and output. A "Constant Memory Assignment Record", tabulating the area, location number, and description of each variable stored in memory. A "Variable Memory Assignment Record", tabulating the area, location number, and description for each variable stored in memory. A typewritten document containing startup, operation, and maintenance procedures. Details of communication link for RTU operation. Hardware and software configuration information in sufficient detail to verify adequacy of RTU. Include details of any necessary Instrumentation and Controls 13300-4 Project No. 3583 Cannon Road Lift Station P:Clly of Carlsbad-1682N0679-tifl Staticm\7 Praj Docs\7.2 Final DoCs\100 X Spcs\Od 2003 Add Specs\13300.doc expansion boards, special interface requirements (e.g., cables, jacks, etc.), description of driver and impact of driver on PLC memory configuration. 6. Documentation of all user configurable software selections. D, Submittals - Test Procedures, Spare Parts, and Agency Training 1. Test Procedures: Submit the procedures proposed to be followed during each test. Procedures shall include test descriptions, forms, and checklists to be used to control and document the required tests. 2. Test Documentation: Upon completion of each required test, document the test by submitting a copy of the signed off test procedures. Testing documentation shall consist of the following: a. The summary check-off index shall be an index of all PLC and telemetry systems in the project and shall include the following as a minimum for each system: 1. System description. 2. Physical installation check-off box. 3. 4. 5. Comments box. 6. Functional check-off box for each point. Satisfactory completion check-off box for each point. Sign-off area for the ISS, the Engineer, and the Agency. b. The individual instrument sign-off sheet(s): 1. 2. 3. 4. 5. 6. 7. 8. 9. The instrument tag number. The manufacturer and part number. Description of instrument. Power requirements. Calibration procedure including calibration ideal vs. actual chart for O%, 20%, 50%, 8O%, and 100% of full scale value. Calibration range. Calibration data (setpoint, deadband, etc.). Switch settings. PLC I/O address (es). 10. Additional comments as required. 11. Signoff space for the ISS, the Engineer, and the Agency. Cannon Road Lift Station Project No. 3583 P:\Clly Of Caflsbad-1682~0679-Lift StationV Proj Docs\7.2 Final Docs\100 % SpecJ\oct 2003 Add Specs\13300.doc Instrumentation and Controls 13300-5 c. The ISS shall submit the Test Plan and receive a satisfactory review approval by the Engineer before any witnessed testing can occur. 3. The ISS shall submit a training plan. This training plan shall include: a. b. c. An overview of the training plan explaining why specific courses are proposed. Prerequisite training and experience of attendees. Course content - a topical outline. 4. Course location - training center or jobsite. 5. The system supplier shall provide a minimum of two days training on the operation and maintenance of all items provided as part of this section. The training may be performed concurrently with system testing and start-up if approved by the Agency. 6. Provide the services of a factory trained and field experienced instrumentation Engineer to conduct group training of designated personnel in the operation of each instrument system. This training shall be for the time period of at least 1 day and shall be performed during the operational testing period. Include instruction covering basic system theory, operating principals and adjustments, routine maintenance and repair, and "hands on" operation. The text for this training shall be the operation and maintenance manuals hmished under these specifications. Supplemented text prepared outlining actual operation of the system in practical application, 7. The training program shall include operational theory and hands-on instruction for each system supplied. This training shall cover functional operation of the system from the control panel, troubleshooting techniques, removal and replacement of various types of panel devices including modems, PLCs, controllers, indicators, etc., and field devices such as pressure switches, etc. 8. The cost of training programs shall be included in the Contract price, and shall be conducted with designated Agency personnel, covering operation and maintenance of the system. The training and instruction shall be directly related to the System being supplied. E. Submittals - Operations and Maintenance Manuals 1. Operation and Maintenance (O&M) Manuals shall be prepared respective to the Work of this Instrumentation Section. Preliminary and final O&M Manuals shall be submitted for Engineer approval in accordance with the provisions of Specification Section 01730. 2. O&M Manuals shall include the following information and documentation (as a minimum): a. b. c. d. As-built panel layout drawings. e. Configuration documentation. Field instrument operation and maintenance information. Panel instrument operation and maintenance information. As-built field and panel wiring drawings. instrumentation and Controls 13300-6 Cannon Road Lift Station Project No. 3583 P:City d Cadsbad-1682N0679-Lifl StatianV Proj Docs\7.2 Final Docs\IOO % Specs\Oct 2003 Add Specs\13300.doc 3. 4. 5. The manuals shall contain all illustrations, detailed drawings, wiring diagrams, and instructions necessary for installing, operating, and maintaining the equipment. The illustrated parts shall be numbered for identification. All information contained therein shall apply specifically to the equipment furnished and shall only include instructions that are applicable. All such illustrations shall be incorporated within the printing of the page to form a durable and permanent reference book. If the ISS transmits any documentation or other technicaiinformation which he considers proprietary, such information shall be designated. Documentation or technical information which is designated as being proprietary will be used only for the design, construction, operation, or maintenance of the System and, to the extent permitted by law, will not be published or otherwise disclosed. The minimum requirements for the ISS's O&M Manual are as follows: a. Field and panel instrument operation and maintenance information: This portion of the ISS's O&M Manual shall include information on the installation operation, calibration, assembly, and disassembly of various field mounted instruments provided under this Specification Section. A replacement parts list with cost and availability data shall be included for every field mounted instrument provided. In addition, the manual shall include the address and phone number of the party from whom replacement parts can be obtained. This portion of the O&M manual shall be tailored for use by maintenance personnel with technical instrumentation backgrounds. b. As-built field and panel wiring drawings: This portion of the ISS's O&M Manual shall present previously submitted wiring drawings in as-built form. Wiring diagrams shall be complete in every aspect. All terminals shall be identified. All wires shall be labeled. The direction of all 4-20 mA current flows shall be clearly indicated. YO termination points shall be labeled and identified as to whether they are an analog input, analog output, discrete input, or discrete output. Additionally, all I/O termination points shall have their software equivalent identifier clearly printed next to the termination point. c. As-built panel layout drawings: This portion of the ISS's O&M Manual shall present previously submitted panel drawings in as-built form. These drawings shall reflect all changes made since approval drawings were submitted. The exact location of all panel mounted instruments, indicator lamps, selector switches, pushbuttons, etc., shall be indicated and appropriately labeled. d. PLC configuration, code, setting of all hardware switches, etc. F. SPARE PARTS LISTS: The recommended spare parts list for the equipment fimished under this section shall be annotated to indicate which items, if any, are hished as a part of this contract. Cannon Road Lift Station Instrumentation and Controls Project No. 3583 13300-7 P:\city of Carisbad-lE82~~79-Lift %Uor\7 Pro] Docs\7.2 Final Docs\lM) K Specs\oct 2003 Add Specs\l\13300.doc 1.05 QUALITY ASSURANCE A. FACTORY TESTS: Prior to shipment from the factory, the control panel system shall be assembled, connected, and all software loaded for a full functional test of the integrated system. Test procedures shall be developed by the system supplier to show that the integrated system hardware and software is fully operational and in compliance with the requirements of the Contract Documents. Attention is directed to the specification section entitled "PART 3 - EXECUTION" for additional requirements relative to this test. B. INSTALLATION SUPERVISION: The system supplier shall furnish services and technical information as necessary to insure that the equipment furnished by him is installed in a proper and satisfactory manner. These services shall include, but not be limited to, providing the installing Contractor with information and direction prior to the commencement of the installation work, periodic inspection during the construction period, answering of all Contractor questions regarding the installation and hookup, and a complete check of the completed installation to insure that it is in conformance with the requirements of the equipment and the Contract Documents. C. CALIBRATION: The system supplier shall furnish the services of a trained technician to perform a complete system calibration. This shall provide that those components having adjustable features are set for the specific conditions and applications, and that the components and system are within the specified limits of accuracy. Defective elements which cannot achieve proper calibration or accuracy, either individually or within the system or subsystem, shall be replaced. A complete record of the calibration checks and adjustments shall be made and delivered to the Engineer upon completion of the system calibration. D. TESTING: Systems shall be exercised through operational tests in the presence of the Engineer in order to demonstrate achievement for the specified performance. Attention is directed to the specification section entitled "PART 3 - EXECUTION" for additional requirements relating to testing. E. INSTRUMENTATION: Spare parts list - The recommended spare parts list for the equipment furnished under this section shall be annotated to indicate those items that are provided as part of this contract. There shall be a minimum of $2000.00 in spare parts furnished under this section. The value of the spare parts will be determined by the manufacturer's current published list price. Any additional recommended spare parts will be evaluated during the submittal process to determine the final selection of approved spare parts. 1.06 ACCEPTANCE TEST A. GENERAL: After startup has been completed, the control system will be given an acceptance test. The complete system must run continuously for 7 consecutive days. During this period, all system functions shall be exercised, and my system interruption and accompanying component, subsystem, or program failure shall be logged for cause of failure, as well as time of occurrence and duration of each failure. The Contractor shall provide a competently trained technician or programmer at the Agency's site during all normal working days from the start of the acceptance test until final acceptance of the system. Instrumentation and Controls 13300-8 Cannon Road Lift Station Project No. 3583 P:City ofCarlsbad-1682A30679-Lifl Station\7 Pmj Docs\7.2 Final Docs\lOO K Spea\Ocl2003 Add Specs\133OO.doc B. PART 2 2.01 A. B. C. D. TESTING: The systems to be tested on-line shall include the level control system, switches, interlocks, telemetry, and autodialer. Failure of any part of the system during the 7-day program testing shall be considered as indicating that the program or system does not meet the requirements of the specifications and corrective action must be taken. Any failure will require a restart of a full 7- day acceptance test. Only those components, subsystems, and systems covered in hs specification and supplied under this section of this contract shall be considered for this acceptance test. Problems and failures of other systems shall not be considered part of this test. PRODUCTS ENCLOSURES General: The RTU and Bubbler Control Panel enclosures shall be NEMA 12, shall be constructed as shown on the Contract drawings, and shall meet industry standards for quality and suitability for the environment in which it shall be installed. Whenever any material, article, device, product or fixture is indicated or specified by patent or proprietary name, by name of manufacturer, or by catalog number, such specifications shall be deemed to be used for the purpose of establishing a standard of quality and facilitating the description of the material or process desired. This procedure is not to be construed as eliminating from competition other products of equal or better quality by other manufacturers where fully suitable in design, size, etc., and shall be deemed to be followed by the words "or equal'' the decision relative to equality shall be determined solely by the Engineer. Control panel shall be constructed in accordance with the layouts shown on the contract drawings. Unless specifically noted to the contrary, control panel shall be a fully enclosed cabinet. Face- mounted equipment shall be flush or semi-flush mounted. Panels shall be fabricated and instruments and/or components installed and wired in the manufacturer's factory. All wiring shall be completed and tested prior to shipment. The Contractor shall submit shop drawings for approval showing control panel construction, component mounting, panel layout, installation details, as well as internal and external Wiring prior to fabrication of control panel. Drawings shall indicate approximate clearance lines of major components with suitable section views. Components: All control components shall be industrial specification grade and shall be as specified in this section and as shown on the Contract Drawings. Control Functions: The schematic diagrams are intended as a guide to the Contractor. Completed panels shall provide successful process control as specified in this section, and as shown on the Contract Drawings. Matching Style, Appearance and Type: All instruments to be panel mounted shall have matching type and general appearance. Instruments performing similar functions shall be of the same type, model, or class and shall be of one manufacturer. Components inside panel, having the same or similar functions shall be of matching style, appearance, type and manufacturer. All components shall be permanently identified. Cannon Road Lift Station Project No. 3583 P:\Clly oi Carlsbad-1682W0679-l~fl Stabon\7 Pro] Doc6\7.2 Final Docs\lOO 96 Specsu)cl2003 Add Specs\13300.doc - - Instrumentation and Controls 13300-9 E. Construction 1. General: Exterior surfaces shall be free from holes, seams, dents, weld marks, loose scale or other imperfections, and shall not be drilled or welded for the attachment of wiring or devices where such holes or fastenings would be visible from the exterior of the enclosure. Panel cutouts for instruments and devices shall be precisely cut, punched or drilled and shall be smoothly finished with chamfixed edges for a precision fit. 2. Wiring: Wiring within panel shall be routed and secured in a neat and workmanlike manner and shall be harnessed and supported to form a neat and solid appearance. All control components not flush mounted on the fiont cover of the panel shall be mounted on hlly accessible supports or sockets located within the enclosure and shall be readily accessible for maintenance. All conductors leaving the control panel shall terminate on terminal blocks and shall be permanently numbered to facilitate field connections. Wire shall be UL 101 5, 105C tinned copper, 16 gauge, as manufactured by Waytek or equal. 3. Size: Enclosure shall be of sufficient size to adequately enclose all instruments specified as "panel-mounted", plus ample interior clearance to allow for installation, general servicing and maintenance of the instruments. 4. Exterior Panel Color: Exterior panel finish shall be light gray. Shop applied, baked and polished. 5. Finish: After fabrication, all external welds shall be ground smooth. The entire unit shall be thoroughly degreased, filled and sanded. At least one coat of synthetic primer shall be applied, baked-on and hand rubbed. They shall be followed by two coats of baked-on synthetic acrylic enamel. The average overall finish shall be at least five mils in thickness. All damage to the finish during installation shall be touched up at the job site as directed and approved by the Agency. 6. Input-Output Terminals: Input-output terminals shall be labeled for easy identification directly at the terminal with the appropriate number. The conductors and terminals shall also be numbered. Input and output terminals shall be located in a single location in the panel. Terminal board shall be rated 20 Amps. 600V. F. Control Circuit Devices and Components 1. General: All components except those on the front door of the panel shall be mounted on the inner panel. Terminal blocks for field connections shall be located on the right inner side of the panels and clear of the conduit entry area. Panels shall be located so as not to prevent access to the terminal blocks and other components located within the panel. Components shall also be arranged to allow fiee panel door movement and shall not restrict clearance and maintenance requirements of the components. 2. Terminal Blocks: Terminal blocks shall be 20 Amp one piece molded plastic with screwlclamp type terminals and barriers rated at 600 volts. Terminals shall be supplied with removable covers to prevent accidental contact with live circuits. Terminals shall have permanent, legible identification numbers clearly visible with protective cover installed. Provide Entrelec M 4/6 terminal blocks or approved equal. Instrumentation and Controls 13300-1 0 Project No. 3583 Cannon Road Lift Station P:\City of Cadsbad-lWZ7'33679-LHI Staiion\7 Proj Docs\7.2 Final Docs\lM) X Specs\Oct 2003 Add Specs\l33OO.doc Terminal blocks shall be provided for all wiring external to the enclosure. Provide a minimum of 25 percent spare terminals for fiture use. G. Control Circuit Wiring 1. Wire Type and Sizes: AC Conductors shall be 600V, #14AWG MTW/AWM 105C tinned copper stranded. DC Conductors shall be 600V, #16AWG MTW/AWM 105C tinned copper stranded. Interconnecting panel mounted equipment and external equipment conductors shall be terminated at numbered terminal blocks. All control conductors shall also be permanently numbered . 2. Control Panel Color Code: 3. Conductor Installation: All incoming & outgoing conductors shall be run in listed conduit and enclosures. Wiring run to control devices on the front panels shall be harnessed together at 2" maximum intervals and secured to the inside face of the panel using wire tie bases. Bases shall be of the "snap-in" or "screw-on" type. Thomas & Betts or approved equal. Adhesive back type supports shall not be used. Conformance to the above wiring installation requirements shall be reflected by details shown on the shop drawings for the Engineer's review and approval. 4. Wire Marking: Each signal, control, alarm and indicating circuit conductor connected to a given electrical point shall be designated by a single unique number which shall be shown on all shop drawings. Each wire shall be identified by its number as shown on the final accepted vendor's drawings. Identification shall be by means of markers impervious to moisture. Identification shall be at each end of wire. Identification shall be made for all wiring inside and outside of vendor's equipment throughout the entire project. Wire numbers external to factory wired equipment shall not be duplicated. These numbers shall be furnished on all components at every terminal using white plastic-coated cloth numbered wire markers, Thomas and Betts "E-2 Code", or approved equal, or shall be permanently marked and sealed with clear mylar shrink tubing. All conductors shall bear its own number at all terminations. Wire numbers shall be one, two, three or four digits. H. Panels shall be internally lighted by fluorescent lamps, provided with guards and a three-way switch located convenient to each access door. Two duplex grounded twist lock type receptacles shall be provided in each panel section. The lights and receptacles shall be wired to outgoing terminal blocks for 120-volt, 6O-hertz, single phase supply. Cannon Road Lift Station Instrumentation and Controls Project No. 3583 13300-1 1 P:\Cily of Carlsbad-1682N067S-Lifl Statim\7 Proj Docs\7.2 Final DOn\lOO % Specs\Oct 2003 Add Specs\13300.doc 2.02 LEGEND PLATES A. Legend plates shall be black with white lettering and shall be engraved at the factory. See legend plate schedule for requirements as indicated on the contract drawings. 2.03 SOLDERLESS TERMINALS A. Contractor shall provide all wire and terminals required to complete all wiring. Terminals shall be of the nylon self-insulating type. B. Connection of conductors to terminals posts shall be made without damaging the conductor and shall be made by means of solderless pressure type terminals or lugs made up tight. C. Terminals for all stranded wires No. I4AWG or smaller shall be solderless pressure type, flanged fork tongue, nylon insulated T&B "Stakon" or equal as approved by the Engineer. D. Wire nuts shall not be permitted on control conductors. 2.04 GROUNDING A. All work shall be installed in strict conformance with NEC Article 250. Code requirements shall be considered minimum standards. B. A green equipment grounding conductor shall be included in all conduit runs. Size shall be as required by NEC. 2.05 CONDUITS AND BUSHINGS A. All conduits terminating at MCP shall enter cabinet precise and straight. Each conduit shall be terminated with a nut and an insulating bushing. All throughout job, bushings shall be high impact thermosetting phenolic, 1 SOC, Oz Gedney type A. Where wiring is run through to adjacent MCC, Contractor shall furnish a minimum of (2) 2" chases for control and (1) 1 1/2" chase for analog signals. All analog signals shall be routed &harnessed separate from current carrying conductors. Chases shall be Gedney Type ABB bushings made up tight. 2.06 UNINTERRUPTABLE POWER SUPPLY (UPS) A. Line interface, "No-Break'' type as manufactured by Powerware or equal. Noise isolation shall be 38db common mode, 47db normal mode. Adjust output voltage to 130V maximum. UPS shall be sized for the connected load and provide an 8 hour backup on loss of input power. Provide load calculations with submittal. The UPS shall be Powerware or approved equal. 2.07 SYSTEM TELEMETRY A. An @to 22 tone telemetry system is used as the remote telemetry unit @TU) at the pump station. Status signals and alarms are transmitted to Carlsbad MWD administration building over a leased telephone line. Central programming and hardware configuration at the CMWD will be performed by others and is not part of this contract. An autodialer will act as redundant alarm reporting for critical alarms. Instrumentation and Controls 13300-1 2 Project No. 3583 Cannon Road Lift Station P\City ofCadsbad-l6827\30679Ufl Slabon\7 Pmj Docs\7.2 Final Don\100 % specS\Oct 2003 Add Specs\13300.doc 2.08 A. B. 2.09 A. B. 2.10 A. 2.11 A. AUTODIALER Certain signals will be transmitted via an autodialer via a standard “dial-up” line. The autodialer shall be RACO Verbatim Gateway which supports DH-485. No equals. Autodialer Input Listing: Intrusion Power Failure PitNault Flood Wetwell Float High-High Level Wetwell Float Low-Low Level Generator Run Pump # 1 Fail Pump # 2 Fail Pump # 3 Fail DI DI DI DI DI DI DI DI DI MULTIPLEXER Pump station status shall be transmitted to the Agency’s SCADA center via a leased telephone line. The Agency has standardized on the hardware specified herein and substitutions are not allowed. Provide multiplexer manufactured by Opt0 22 in Temecula, California (800) 321-6786. Provide the following components with associated cables and appurtenances: 1. Two (2) SNAP-B3000 Brain Board 2. Two (2) SNAP-BSM 8-Module Rack 4. One (1) SNAP-AIMA 4-Channel Analog Input Module 5. Thirteen (13) SNAP-IDCS-SW 4-Channel Discrete Input Module 6. One (1) AC7A RS-232/485 Converter 3. TWO (2) SNAP-PSS 5 VDC POW^ Supply MODEM The modem shall be provided by Black Box Corporation (412) 746-5500. No substitutions allowed. Provide the following with associated cables and appurtenances: 1. One (1) Modem Model 3600 Rackmount Card, Part No. MDlOOOC 2. One (1) Modem Model 3600 Standalone, Part No. MDlOOOA PROGRAMMABLE LOGIC CONTROLLER Major hardware components of the PLC shall include: 1. Central Processing Unit (CPU). 2. I/O modules. 3. Chassis. 4. Power supply. Cannon Road Lift Station Instrumentation and Controls Project No. 3583 PCily of Carlsbad-16827U0679-LifI Statim\7 Pro1 Docs\7.2 Final Docs\lM) K Spea\Oct 2003 Add Specs\l3300.dcc 13300-1 3 5. Graphic interface. B. General 1. The PLC shall be an intelligent microprocessor based device that can collect data and process control functions. The PLC system shall be an Allen Bradley SLC 5/03 system. No substitutions allowed. 2. All components of the PLC system shall be of normally recognized industry standards and regularly sold for industrial installations. All components shall be assembled by the PLC manufacturer into structurally sound housings. All connecting cables, switches, and other operator-controlled devices shall be constructed so as to withstand, without damage, all normal use and handling. 3. The PLC system shall be of modular design with a plug-in processing unit, power supply unit, bus controller unit, or assemblies. All components shall be marketed and supported by the one manufacturer. All necessary cables shall be included. 4. Electrical supply voltage to the PLC shall be 115VAC t15%, 48-63Hz. PLC system power supplies shall be fused for overload protection. C. Central Processing Unit (CPU) 1. The PLC CPU shall be supplied with RS232 communications capabilities for interface with the programming laptop. 2. The PLC System shall be supplied with a slotted I/O chassis sized to house the PLC, I/O modules, and communication interfaces. Provide PLC battery. 3. UO Modules a. General 1. The system shall include 15 percent active I/O points for future use. 2. Minimum isolation between input/output and logic voltage shall be 1500V RMS per NEMA standards via opto-isolation. 3. All outputs, including spare points, shall be furnished with field replaceable fuse protection and blown fuse indicators. Fuses shall be located as near as possible to the relay output modules. All I/O points, including spare points, shall be wired to terminal blocks. b. Discrete input and output modules shall be 16 point modules, Allen Bradley Series 1746. The supplier shall label each input on the module with the appropriate I/O address number. Each output shall be capable of powering a 2 amp continuous load or switching a power load up to 125 VA. For outputs used on loads greater than 2 amps an interposing relay shall be provided. Instrumentation and Controls 1 3300-1 4 Cannon Road Lift Station Project No. 3583 P:City of Carisbad-lWZ7UC679-M StationV Proj Docsc1.2 Final Dccs\lOO H Spacs\Oct 2003 Add Specs\l33W.doc c. Analog input and output modules - The analog input/output block shall accept up to 4 analog inputs or generate up to 4 analog outputs. The unit shall be supplied with an internal power supply capable of powering loads up to 300 ohm for each output point. The inputs and outputs shall be 4-20 ma DC. The supplier shall label each UO point with the appropriate I/O address number. d. 24 VDC power for powering analog instrument loops shall be provided by the system supplier as a part of the system. e. The system supplier shall provide and configure the complete PLC program. Provide one copy of RSLogix 500 development software (AB Part #9324-RL0300ENE) licensed to the Carlsbad Municipal Water District. 2.12 PLC I/O LISTING: ZA-26A 1 RTU Intrusion ZA-27A I Station Intrusion I DI I Cannon Road Lift Station Project No. 3583 Instrumentation and Controls 13300-1 5 P:\Cily of Carlsbad-1682A30679-Lm SlaIion\7 Proj Docs\72 Final Docs\lW X Specs\Oct 2003 Add Specs\13300.d% Scrubber 2 Run Instrumentation and Controls 13300-1 6 Project No. 3583 Cannon Road Lift Station P\Cily of Carlsbad-1682N0679-Ufl Slation\7 Pruj Das\7.2 Final Docs\lM) % Specs- 2003 Add Specs\lWO.doc 2.13 A. B. 2.14 A. 2.15 A. 2.16 A. 2.17 A. 2.18 A. OPERATOR INTERFACE TERMINAL Provide an Allen Bradley Panelview Plus 1000 (Part #271l-PTlOC6Bl) graphic interface. The graphic interface shall communicate with the PLC with DH-485 protocol. Provide screen development for a minimum of five screens per direction of the Agency. The system supplier shall provide and configure the complete OIT software. Provide one copy of RSView Studio software (AB Part #970 1 -VWSTENE). LAPTOP COMPUTER The system supplier shall provide and configure a laptop computer for PLC program development. The laptop shall be a Dell Latitude D800 or approved equal. The laptop and all software shall be licensed and delivered to the Agency. 24 VDC POWER SUPPLY Contractor shall hmish (1) 24 volt D.C. power supply for driving current loops and other D.C. powered equipment. It shall be solidly mounted, labeled and located in plain view oriented for ease of maintenance. Unit shall be sized based on 200% of load requirements of equipment actually furnished. Power One #HI3-24-2.4A or approved equal. INTRINSICALLY SAFE RELAYS Contractor shall krnish intrinsically safe relays for all wetwell associated devices. Relays shall be as manufactured by Gems or Diversified Electronics. Care shall be taken to install relays where they are highly accessible and shall be located in a separate, insulated area. Area shall be suitably marked by an engraved nameplate, red in color. Attach to panel via 3 16 S.S. screws. 1/2" high minimum. "Danger: Intrinsically Safe Barriers". De-energize circuit before attempting repairs. RELAY SOCKETS Sockets for control relays and electronic plug-in type timers shall be rated 10 amperes with brass inserts on all terminal screw points. Terminals screws shall be on the "Pressure Screw" type. Bases shall be mounted to tapped holes in panel via 316 S.S. screws. Sockets shall be as manufactured by Custom Connector, FU3 Series. Sockets shall be mounted via din rail and related hardware. GENERAL PURPOSE RELAYS Relays shall be of the 120VAC 1 1 pin, 10 amp, plug-in type. Contacts shall be silver cadium oxide unless otherwise noted on the contract drawings. Drop out speed shall be 12 milliseconds typical. Coil windings shall be polyurethane insulated. Contact arrangement shall be Form C, 3PDT. Each unit shall be furnished complete with coil pilot light to aid troubleshooting. Relays shall be as furnished by Eagle Signal 22 Series. Cannon Road Lift Station Project No. 3583 P:\City of Cadsbad-1682A30679-Lifl Slation\7 Prcj Docs\7.2 Final Docs\iW Sb Spea\Od 2003 Add Specs\13300.doc instrumentation and Controls 13300-1 7 2.19 A. 2.20 A. 2.21 A. 2.22 A. 2.23 A. 2.24 A. 2.25 A. 2.26 INDUCTION RELAYS Provide induction relays for monitoring mechanical seal failure interface with moisture detectors on submersible pump motors. Relays shall be MagneTek B/W 1500 series or equal by Warrick. Primary coil shall be 1 15 volts, secondary coil shall be approved by the pump manufacturer. Provide output contacts indicated in control diagrams. TIME DELAY RELAYS Timers shall be solid state, 120VAC, 10 amp, 2 PDT. As manufactured by Diversified Electronics. Type and function shall be as indicated on the contract drawings. CABLE TIES Cable ties shall be self-locking with stainless steel locking tabs as manufactured by Thomas & Betts. Adhesive backed type mounting bases shall not be used. WIRING DUCT Wiring duct shall be manufactured of Noryl and shall be of the restricted slot design, white in color. Panduit or approved equal. Size shall be based on actual wiring requirements. All duct shall be precisely cut for a precision fit. All covers shall be readily accessible. All analog signals shall be run in separate ducts. TERMINALS Terminals, where required, shall be of the solderless type with vinyl insulators as manufactured by Thomas & Betts. Vinyl insulators shall not be damaged during installation. TERMINAL BLOCKS Terminal blocks shall be din rail mounted, ZOA, and 600V with provision for dual level marking as manufactured by Altech Corp. All terminals shall be complete with marking tags. DIN RAIL MOUNT CIRCUIT BREAKERS Circuit breakers shall be 115 VAC, type QCR, single pole as manufactured by Cutler Hammer or approved equal. LIMIT SWITCH 1. Each intrusion alarm limit switch shall transmit a signal when the monitored door or hatch is not in the closed position. 2. Each limit switch shall be SPDT, rated 5 amps. Conduit entrance and terminals shall be epoxy sealed. Limit switch mounting and actuator shall be determined by the Contractor to provide a reliable, positive, and accurate indication of entrance. The switch shall be normally open (actuated closed when the door or hatch is closed). Switch shall be mounted for minimum obstruction of access. Limit switches shall be Type "C" by Square D, Allen Bradley 802T, or equal. Instrumentation and Controls 1 3300- 18 Cannon Road Lift Station Project No. 3583 P:Clty of Carfsted-1682A30679-Lfl StaticnV Proj Dc€s\7.2 Final Docs\IW % Specs\oct 2003 Add Spacs\133OO.doc 2.27 SELECTOR SWITCH A. Selector switch shall be 115 VAC, type 10250T, oil tight as manufactured by Cutler Hammer or approved equal. 2.28 WETWELL LEVEL CONTROLLER A. A bubbler system will be used to monitor and control the wet well level. The control system allows for manual or automatic alternation of the pumps and will be set for automatic alternation. The level controller shall be a Did-Gage 2300 manufactured by EG Controls (904) 292-01 10. The pumps will cutout on a backup low-low level float switch. Backup high and low level float switches will control all three pumps as a group should the bubbler system fail to operate. This abnormal condition would be alarmed through the telemetry system for immediate action. The two pumps duty pumps are selectable by a maintenance switch behind the control panel door. B. The wetwell control setpoints are as follows: Level EL 8.3 Float switch actuated high-high level alarm and backup start of three pumps. EL 7.8 Level controller actuated standby pump call, high water alarm (standby pump locked out if on generator power). EL 7.3 Level controller actuated lag pump call. EL 6.8 Level controller actuated lead pump call. EL 3.1 Level controller actuated, lag and standby pump off. EL 2.6 Level controller actuated lead pump off. EL 2.1 Level controller actuated low level alarm. EL 2.1 Float switch actuated low-low alarm and backup stop of all three pumps should level controller contacts remain closed. 2.29 LEVEL SWITCH A. Level switches shall be Form C mechanical microswitches in a plastic casing, fieely suspended at the desired height from its own cable. The switch will tilt and not float when submerged. B. The switch casing shall be polypropylene with a PVC cord and protective EPDM rubber sleeve. The switch body shall be hermetically sealed without use of adhesives. C. The level switches shall be FLYGT ENM-10 or approved equal. Cannon Road Lift Station Project No. 3583 PUty of Carlsbad-l6827\30674Lifl StaUon\7 Roj M\72 Final Docs\lOO X spect\oci 2003 Add Specs\13300.doc Instrumentation and Controls 13300-1 9 2.30 A. 2.3 1 A. 2.32 A. B. 2.33 A. B. C. D. E. FLOOD SWITCH Switch shall be a stem mounted float device with 304 stainless steel stem, Buna N Float Material, Lucite Slosh Shield, IMO/GEMS Model LS-270 or approved equal. PILOT LIGHT Pilot Lights shall be 115 VAC, type 10250T, oil tight as manufactured by Cutler Hammer or approved equal. IDENTIFICATION Each separately packaged instrument shall be marked to identify its location, tag number and function in the system. Identification shall be predominantly displayed on outside of package. A permanent stainless steel or other non-corrosive material tag firmly attached and permanently and indelibly marked with the instrument tag number, as given in the instrumentation list, shall be provided on each piece of equipment supplied under this Section. Equipment not identified in the instrumentation list shall be identified with a unique number in conformance with the established instrument identification scheme for this project. TUBING, PIPE, FITTINGS AND SUPPORTS General: Instrument tubing listed below is required for all instruments and control valves. Select the appropriate tubing materials to satisfy service conditions except where specifically shown on Installation Detail Drawing. Copper Tubing: Soft annealed copper tubing shall be 1/4-inch O.D. x 0.0300-inch wall, 3/8-inch O.D. x 0.032-inch wall, or 1/2-inch O.D. x 0.032-inch wall as shown on the Drawings. Copper tubing shall be seamless copper, Type DHP, bright annealed after coiling, dehydrated and sealed in 50-foot aluminum coils, per ASTM B75. Use for instrument or valve connections only. Copper Tubing: Hard-drawn copper tubing shall be in accordance with ASTM B88. Sizes shall be 3/8-inch standard: 3/8-inch O.D. x 0.030-inch wall; 1/2-inch standard: 1/2-inch O.D. x 0.035-inch wall; or 5/8-inch standard: Yg-inch O.D. x 0.040-inch wall in 20-foot straight lengths with plastic capped ends. Use for header or branch service only. Stainless Steel: Stainless tubing shall be Type 304 seamless, cold drawn and annealed per ASTM A269. Sizes shall be 1/4-inch O.D. x 0.045-inch wall, 3/8-inch O.D. x 0.035-inch wall or 1/2-inch O.D. x 0.035-inch wall. Use for instrument or valve connections. Fittings: 1. Copper tube: Solder joint fittings shall be seamless wrought copper per ASTM B75. 2. Stainless steel tube: Weld joint fittings shall be Type 304 stainless. 3. Supports for tubing: Supports located in areas exposed to the weather or corrosive atmosphere shall be Type 304 stainless steel Unistrut or equal made to the weather or corrosive atmosphere shall be carbon steel painted. Instrumentation and Controls 13300-20 Project No. 3583 Cannon Road Lift Station P:\Clty of Carlsbad-1682A30679-UR79-Lift Slation\7 Proj Docs\7.2 Final Docs\lOO % Specs\Oct 2003 Add Spen\l33oo.dOC F. 2.34 A. PART 3 3.01 A. 3.02 A. 3.03 A. 3.04 A. 4. Weld joint fittings shall be permitted for header and branch service only. Use unions as necessary to simplify instrument removal. Valves: 1. Pipe, pipe fittings and valves: Main-line piping material and root valves for instrumentation shall be as specified in Section 15. 2. Instrument valves shall be 1/4-inchY 3/8-inch or 1/2-inch from Whitey or Hoke to match tubing material and size. PORTABLE INSTRUMENTATION Provide a portable gas analyzer. The analyzer shall be assigned and delivered to the City. The analyzer shall be complete with carrying case. Provide Interscan Model 4 170-2 hydrogen sulfide monitor with 0-19.99 ppm range. EXECUTION INSPECTION Inspect each instrument and piece of equipment for damage, defects, completeness and correct operation before installing. Inspect previously installed related work and verify that it is ready for installation of instruments and equipment. PREPARATION Ensure that installation areas are clean and that concrete or masonry operations are completed prior to installing instruments and equipment. Maintain the areas in a broom-clean condition during installation operations. FACTORY TESTING ON CONTROL PANELS Verify, at the factory, wiring continuity and verify panel operation by simulated inputs and outputs. Provide report certifylng the control panels are operable and meet the specifications. Factory testing shall be witnessed by Agency personnel. Provide two weeks notice to the Agency prior to testing. SYSTEM INSTALLATION AND SUPERVISION Furnish the services of authorized factory personnel especially trained and experienced in the installation of the equipment to: 1) supervise the installation in accordance with the approved Instruction Manual, 2) be present when the instruments and equipment are first put into operation, 3) inspect, check, adjust as necessary and approve the installation, 4) calibrate the instruments, in accordance with the specifications herein, until all trouble or defects are corrected and the installation and operation are acceptable, and 5) prepare and submit the specified Certified Report. Cannon Road Lift Station Instrumentation and Controls Proiect No. 3583 13300-21 P:\City of Carlsbad-16627\30679-Lin SWon\7 Pro) Don\7.2 Final Doa\lM) % &ecs\Oct 2003 Add %JeCS\l3300 doc _- __ 3.05 INSTRUMENT CALIBRATION A. Provide the services of factory trained instrumentation technicians, tools and equipment to field calibrate each instrument to its specified accuracy in accordance with the manufacturer's specifications and instructions for Calibration. Each instrument shall be calibrated at 0 percent, 50 percent and 100 percent of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 5 times greater than the specified accuracy of the instrument being calibrated. Such test instruments shall have accuracies traceable to the National Bureau of Standards, as applicable. Provide a written report to the Agency on each instrument certifylng that it has been calibrated to its published specified accuracy. This report shall include a listing of the published specified accuracy, permissible tolerance at each point of calibration, calibration reading as finally adjusted within tolerances, defects noted, correction action required and correction made. This requirement does apply to all Analog Inputs to the system even though the devices are furnished by others. B. Provide certified calibration stamps on instruments with calibration date and next required calibration date. 3.06 SYSTEM VALIDATION A. Provide the services of factory trained and field experienced control system Engineer(s) to validate each system is operational and performing its intended function. During system validation, make provisional settings on level, alarms, etc. Verify controllers by observing that the final control element moves in the proper direction to correct the process variable as compared to the set point. Cause malfunctions to sound alarms or switch to standby to check system operation. Check all systems thoroughly for correct operation. Test equipment for this function shall be specified under "Instrument Calibration". Immediately correct all defects and malhnctions disclosed by tests. Use new parts and materials as required and approved and retest. Provide a report certifying completion of system validation. This report shall indicate that the system meets the complete intent of these specifications. 3.07 FINAL OPERATIONAL TESTING AND ACCEPTANCE A. Upon completion of system validation, test all systems under process conditions. The intent of this test is to demonstrate and verify the operational interrelationship of the system. This testing shall include, but not be limited to, taking process variables to their limits (simulated or process) at the field device to verify all wiring, alarms, failure interlocks, and operational interlocks between systems and/or mechanical equipment. Immediately correct defects and malhnctions with approved methods and materials in each case and repeat the testing. Upon completion of final operational testing, submit certified report indicating that total ICM System meets all the functional requirements specified herein. Upon agreement that the system is operational and acceptable, the Engineer shall countersign this report and it shall constitute final acceptance of the system. instrumentation and Controls 13300-22 Cannon Road Lift Station Project No. 3583 PCity ofCarlsbad-16B2N0674Lift Station\7 Prq Docs\7.2 Final Doa\lW H Specs\Od 2003 Add Spau\133W.doc Testing shall be observed by the Engineer or his representative. Notify the Engineer in writing a minimum of 72 hours prior to the proposed date for commencing the test. Upon completion of this test the ICM System Integrator shall begin or have begun system startup. 3.08 MOUNTINGS A. Mount and install equipment as indicated. Mount field instruments on pipe mounts or other similar means in accordance with supplier’s recommendation. Where mounted in control panels, mount according to requirements of that section. B. Equipment specified for field mounting shall be suitable for direct pipe mounting or surface mounting, surface-mounted indicators and equipment with calibration adjustments or requiring periodic inspection shall be mounted not lower than 3 feet 6 inches nor higher than 6 feet above walkways, platforms, catwalks, and the like, unless shown or specified. C. Note that applicable specifications require detail drawings showing seismic sway bracing design and anchorage requirements for their equipment. Seismic zone requirements are specified in Division 1. D. All devices shall be accessible to Agency for servicing, operating, reading, etc. 3.09 PROCESS CONNECTIONS A. Provide instrument impulse tubing, where required, to meet the intended process service and ambient environmental condition for corrosive resistance, etc. Install impulse tubing with a continuous slope according to service to promote self draining or venting back to the process. Terminate connection to process lines or vessels in a service rated roof valve, provided under other Divisions that will permit closing off the impulse line or removal of the element without requiring shut down of the process. Include blowdown of drip legs and valves for terminations of impulse lines at the instruments. B. Process vessels, line penetrations, and root valves shall be furnished and installed by others. Instrument tubing is installed as part of this Specification. END OF SECTION Cannon Road Lift Station Project No. 3583 P:\clly Of Carlsbad-1682A30679-Ufl Station\7 Proj Docs\7.2 Final Dow\lM) W Specs\Oct 2003 Add Specs\133OO.doc Instrumentation and Controls 13300-23 Instrumentation and Controls 13300-24 This page intentionally left Blank. Cannon Road Lift Station Project No. 3583 P\City of Carlsbad-I6827\30679LKt StaTon\7 Proj Docs\7.2 Final Docs\lOO % Specs\Od 2003 Add S~~~~\13300.d% PART 1 1.01 A. 1.02 A. B. 1.03 A. B. C. D. SECTION 15050 PIPING - GENERAL REQUIREMENTS GENERAL SCOPE OF WORK This Section specifies the basic administrative and testing requirements for piping. Specific piping materials, systems and related installation and testing requirements are specified in other Sections of SSPWC 2003 and Divisions 2,11, and 15. RELATED WORK Piping materials and systems are included in other Sections of SSPWC 2003 and Divisions 2, 1 1, and 15. Valves are included in Section 15100. SUBMITTALS Submit general submittals for piping and piping systems as listed below. It is not intended that all submittals listed below be provided for all piping materials and systems. Refer to individual System or Piping Sections for specific submittals. Shop Drawings and Product Data 1. Piping layouts in full detail. 2. Location of pipe hangers and supports. 3. Location and type of backup block or device to prevent joint separation. 4. Large scale details of wall penetrations and fabricated fittings. 5. Schedules of all pipe, fittings, special castings, couplings, expansion joints and other appurtenances. 6. Catalog cuts of joints, couplings, harnesses, expansion joints, gaskets, fasteners and other accessories. 7. Brochures and technical data on coatings and linings and proposed method for application and repair. Samples Design Data Cannon Road Lift Station Piping - General Requirements Project No. 3583 15050-1 P:\CRy cd Cartsbad-1682’T\30679-Lift StabonV Pro] Docs\7.2 Final Docs\lDo % Specs\l5050.doc E. TestReports 1. Four copies of certified shop tests showing compliance with appropriate standard. 2. Four copies of all field test reports, signed by Contractor and Engineer. F. Certificates 1. Copies of certification for all welders performing work in accordance with ANSI B3 1.1. G. Manufacturers Installation (or application) instructions. H. Statement of Qualifications I. Manufacturers Field Report J. Project Record Document K. Operation and Maintenance Data in accordance with Section 01730. L. Warranties 1.04 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) 1. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength B. American National Standards Institute (ANSI) 1. ANSI B16.5 - Pipe Flanges and Flanged Fittings 2. ANSI B3 1.1 - Power Piping C. American Welding Society (AWS) 1. AWS B2.1 - Specification for Welding Procedure and Performance Qualifications D. American Water Works Association (AWWA) 1. AWWA Manual M 1 1 - Steel Pipe - A Guide for Design and Installation E. F. Underwriters Laboratories (UL) G. Factory Mutual (FM) American Society of Mechanical Engineers (ASME) H. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. Piping - General Requirements 15050-2 Project No. 3583 Cannon Road Lift Station P:\Cily of Carlsbad-l6827W0679-~R StationV Proj DOcsV 2 Final Docs\1OO % Specs\15050 doc 1.05 A. B. C. D. E. F. G. 1.06 A. PART 2 2.01 A. B. QUALITY ASSURANCE All materials shall be new and unused. Install piping to meet requirements of local codes. Provide manufacturer's certification that materials meet or exceed minimum requirements as specified. Reference to standards such as ASTM and ANSI shall apply to those versions in effect at the time of bid opening. Coordinate dimensions and drilling of flanges with flanges for valves, pumps and other equipment to be installed in piping systems. Bolt holes in flanges to straddle vertical centerline. Reject materials contaminated with gasoline, lubricating oil, liquid or gaseous fuel, aromatic compounds, paint solvent, paint thinner and acid solder. Pipe-joint compound, for pipe carrying flammable or toxic gas, must bear approval of UL or FM. Unless otherwise specified, pressures referred to in all Piping Sections are expressed in pounds per square in gauge above atmospheric pressure, psig and all temperature are expressed in degrees Fahrenheit (F) . DELIVERY, STORAGE AND HANDLING During loading, transportation and unloading, take care tb prevent damage to pipes and coating. Carefully load and unload each pipe under control at all times. Place skids or blocks under each pipe in the shop and securely wedge pipe during transportation to ensure no injury to pipe and lining. PRODUCTS MATERIALS Specific piping materials and appurtenances are specified in the respective Piping or System Sections. General installation materials shall be as specified below. 1. Unions shall be brass or bronze unions for joining nonferrous pipe; malleable brass or bronze- seated iron or steel unions for joining ferrous pipe; PVC unions for joining PVC pipe. 2. Flanged Joints. Bolt and nuts, Grade B, ASTM A307 Type 304 stainless steel, bolt number and size same as flange standard; studs - same quality as machine bolts; 1/16-in thick rubber gaskets with cloth insertions; rust-resistant coatings. 3. Temporary Plugs shall be standard plugs or caps which are suitable for permanent service. Cannon Road Lift Station Project No. 3583 PlCity Of Carkbad-i682T\30679-~ft StalimV Prq D0~A7.2 Final Docs\lOO X Specs\l505O.dOc Piping - General Requirements 15050-3 PART 3 3.01 A. B. C. D. EXECUTION GENERAL All dirt, scale, weld splatter, water and other foreign matter shall be removed from the inside and outside of all pipe and sub-assemblies prior to installing. All pipe joints and connections to equipment shall be made in such a manner as to produce a minimum of strain at the joint. Install piping in a neat manner with lines straight and parallel or at right angles to walls or column lines and with risers plumb. Run piping so as to avoid passing through ductwork or directly under electric light outlets andor interference with other lines. All work shall be accomplished using recognized methods and procedures of pipe fabrication and in accordance with the latest revision of applicable ANSI Standards, ASME Codes and Pipe Fabrication Institute Standards. 1. 2. 3. 4. 5. 6. 7. Use full length of pipe except where cut lengths are necessary. Do not spring or deform piping to make up joints. Pipe shall be cut square, not upset, undersize or out of round. Ends shall be carefully reamed and cleaned before being installed. Bending of pipe is not permitted. Use fittings for all changes in direction. Do not use bushings except where specifically approved by the Agency's Representative. Reducers shall be eccentric to provide for drainage from all liquid-bearing lines and facilitate air removal from water lines. Verify the locations and elevations of any existing piping and manholes before proceeding with work on any system. Any discrepancies between the information shown on the Drawings and the actual conditions found in the field shall be reported at once to the Agency's Representative. No claim for extra payment will be considered if the above provision has not been complied with. , Where lines of lower service rating tie into services or equipment of higher service rating the isolation valve between the two shall conform to the higher rating. All piping interiors shall be thoroughly cleaned after installation and kept clean by approved temporary closures on all openings until the system is put in service. Closures should be suitable to withstand the hydrostatic test. Test Connections 1. Provide %-in female NPT test connection equipped with %-in brass plug on all pump discharge lines. Where indicated on the Drawings, test connections should be equipped with bar stock valve and gauge. Piping - General Requirements 15050-4 Project No. 3583 Cannon Road Lift Station P:\cily of Carisbad-16827W679-Lift Station\7 Pro] Docs\7.2 Final Docs\loO % Specs\l5050.doc 3.02 UNIONS A. Use unions to allow dismantling of pipe, valves and equipment. 3.03 WELDING A. Welding in accordance with ANSI B3 1 and AWS B3 .O. 3.04 FLANGED JOINTS A. Make flanged joints with bolts; bolt studs with nut on each end; or studs with nuts where one flange is tapped. Use number and size of bolts conforming to same ANSI Standard as flanges. Before flanges pieces are assembled, remove rust resistant coating from machined surfaces, clean gaskets and smooth all burrs and other defects. Make up flanged joints tight, care being taken to prevent undue strain upon valves or other pieces of equipment. 3.05 SLEEVE COUPLINGS A. Install tierods, pipe clamps or bridles when sleeve type couplings or fittings are used in piping system where indicated, and at changes in direction or other places as necessary, to prevent joints from pulling apart under pressure. Use bridles and tierods at least %-in in diameter, except where tierods replace flange bolts of smaller size, in which case fit with nut on each side of pair of flanges. Joint harnessing shall conform, as a minimum, to the requirements for the bolts and tie bolt lugs as set forth in AWWA Manual M11. 3.06 TESTING A. Test all pipelines for water/gas tightness as specified in the Piping or System sections. Furnish all labor, testing plugs or caps, pressure pumps, pipe connections, gauges and all other equipment required. Testing shall be performed in accordance with one or more of the testing procedures appended to ths Section as specified in each Piping or System Section. All testing shall be performed in the presence of the Agency's Representative. B. Repair faulty joints or remove defective pipe and fittings and replace as approved by the Engineer. Retest. END OF SECTION Cannon Road Lift Station Project No. 3583 P:\Ciclly of Ca~sbad-1682A30679-Lift Stahoni7 Pro) Docs\7.2 Final Docs\lOO % Specs\l5050 doc Piping - General Requirements 15050-5 Piping - General Requirements 15050-6 This page intentionally left Blank. Cannon Road Lift Station Project No. 3583 P\City of CarIsbad-l682~0679-L1fl Station\7 Proj Docs\7.2 Final Docsil W % Specs\l5050.dOC SECTION 15064 PVC PIPE AND FITTINGS PART 1 1.01 A. B. 1.02 A. B. C. D. E. 1.03 A. 1.04 A. GENERAL SCOPE OF WORK Furnish all labor, materials, equipment and incidentals required and install plastic piping and appurtenances for the chemical feed system, valve vault vent piping, and sump pump discharge as shown on the Drawings and as specified herein. Refer to Section 15050 for additional general piping requirements. RELATED WORK Influent sewer line and storm drain lines are included in Division 2 and SSPWC 2003. Concrete work is included in Division 3. Field painting is included in Section 09902. Hydraulic Specialties are included in Section 11400. Valves and appurtenances are included in Division 15. SUBMITTALS Shop drawings and product data, in accordance with SSPWC 2003, shall include the following: 1. Shop drawings, including piping layouts and schedules, shall be submitted to the Engineer and shall include dimensioning, fittings, locations of valves and appurtenances, joint details, methods and locations of supports, anchorage, grade of material, and all other pertinent technical specifications for all piping to be furnished. 2. Shop drawing submittals for piping under this Section shall include all data and information required for the complete piping systems. All dimensions shall be based on the actual equipment to be furnished. Types and locations of pipe hangers andor supports shall be shown on the piping layout for each piping submittal. REFERENCE STANDARDS American Society for Testing and Materials (ASTM). 1. ASTM D 1784 - Standard Specification for Rigd Poly(Viny1 Chloride) (PVC) Compounds and Chlorinated Poly(Viny1 Chloride) (CPVC) Compounds. 2. ASTM D1785 - Standard Specification for Poly(Viny1 Chloride) (PVC) Plastic Pipe, Schedules 40, 80 and 120. Cannon Road Lift Station Proiect No. 3583 PVC Pipe and Fittings 15064-1 P City of Carlsbad-1682i?30679-L1fl StaBon\7 Prq Das\7 2 Final DocsWJO X ~pecs\l5064 doc .__I. 3. 4. 5. 6. 7. 8. 9. ASTM D2464 - Standard Specification for Threaded PolyCVinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. ASTM D2466 - Standard Specification for Poly(Viny1 Chloride) (PVC) Plastic Pipe Fittings, Schedule 40. ASTM D2467 - Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. ASTM D2564 - Standard Specification for Solvent Cements for Poly(Viny1 Chloride) (PVC) Plastic Piping Systems. ASTM D2665 - Standard Specification for Poly(Viny1 Chloride) (PVC) Plastic Drain, Waste and Vent Pipe and Fittings. ASTM D2855 - Standard Practice for Making Solvent - Cemented Joints with Poly (Vinyl Chloride) (PVC) Pipe and Fittings. ASTM D33 11 - Standard Specification for Drain, Waste and Vent (DWV) Plastic Fittings Patterns. 10. ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws and Studs. 1 1. ASTM F594 - Standard Specification for Stainless Steel Nuts. B. Plastic Pipe Institute (PPI) 1. PPI TR3 1 - Underground Installation of Polyolefin Piping. C. American National Standard Institute 1. ANSVASME B 16.5 Pipe Flanges and Flanged Fittings. 2. ANSVASME A13.1 Scheme for Identification of Piping Systems. D. National Sanitation Foundation (NSF) E. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. 1.05 QUALITY ASSURANCE A. All plastic pipe and fittings of each type shall be furnished by a single manufacturer who is experienced in the manufacture of the items to be furnished; however, it shall not be a requirement that the pipe and fittings be manufactured by the same manufacturer, provided that the pipe and fittings are compatible in both compounding and size. The pipe and fittings shall be designed, constructed and installed in accordance with the best practices and methods and shall be suitable for the intended service. Manufacturers shall have at least five years experience fabricating plastic pipe and fittings. PVC Pipe and Fittings 15064-2 Cannon Road Lift Station Project No. 3583 P\City of Caflsbad-16827\30679-Lift StationV Prq DOcs\7.2 Final Docdl 00 % Specs\15064.doc i 1.06 A. B. 1.07 A. B. PART 2 2.01 A. SYSTEM DESCRIPTION Piping shall be installed in those locations as shown on the Drawings. The equipment and materials specified herein are intended to be standard types of plastic pipe and fittings for use in transporting wastewater, water, air and chemicals. DELIVERY, STORAGE AND HANDLING 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. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. PRODUCTS MATERIALS - PVC PIPE AND FITTINGS Poly (Vinyl Chloride) Pipe and Fittings - PVC 1. Pipe shall be manufactured from PVC compounds meeting ASTM D1785-96B. The pipe shall have a minimum hydrostatic design stress of 2,000 psi at 73 degrees F and shall be suitable for field cutting and solvent welding. Pipe shall be of the sizes as shown on the Drawings and shall be Schedule 80, Type I, Grade 1 unless otherwise shown. 2. Fittings shall conform to ASTM 1784, cell Class 12454B, Schedule 80. Socket welded fittings shall conform to ASTM D2467-960. Thread fittings shall conform to ASTM D2464-962. Fittings shall be manufactured from PVC compound meeting ASTM D1784, Class 12454-B. Fabricated fittings are not permitted. Solvent cement shall be as specified in ASTM D2564. A compatible primer shall be applied prior to cementing in accordance with the manufacturer’s recommendations. Grooved PVC pipe joints will not be accepted. 3. Pipe, fittings and solvent for use with potable water shall be certified by the National Sanitation Foundation in accordance with NSF Standard No. 14 and the seal shall be included on the pipe. 4. Gaskets a. Flanged Joints: EPDM, minimum 1/8-inch thick. Provide a filler gasket between flanges with a raised face to protect the PVC flange from the bolting moment. 5. Bolting a. Flanged Joints: Type 316 stainless steel. ASTM A193, Grade B8M hex head bolts and washers; Grade B8M hex head nuts. Flanges shall be ANSI Class 150 flanges. Schedule 80. sliD ring (van-stone) solvent weld tvDe Cannon Road Lift Station Project No. 3583 P:\Ctty of Carlsbad-16827UO679-Ltfl Station\7 Pro] Docs\7.2 Flnal Docs\100 % Specs\l5064.doc PVC Pipe and Fittings 15064-3 6. Accessories a. Flexible Couplings B. PART 3 3.01 A. B. C. 1) 2) 3) 4) 5) Manufacturer: Technova or equal. Type: Flanged with two convolution bellows and tie rods. Bellows: White Teflon with Monel reinforcing bands. Flanges: Type 3 16L stainless steel, ANSI Class 150. Couplings: Type 3 16 stainless steel tie rods, rated 150 psig at 180 OF. b. Solvent Cement 1) Manufacturer in conformance with ASTM D2564. 2) Apply a compatible primer prior to cementing in accordance with the manufacturer's recommendations. e. Thread Lubricant: Teflon tape. d. Check Valves: Check valves shall be suitable for sewage service. Poly (Vinyl Chloride) Pipe and Fittings for Drain, Waste and Vent Service (DWV). 1. Pipe shall be manufactured from PVC compounds meeting ASTM D1784, Class 12454-B in accordance with ASTM D2665. The patterns, dimensions and laying lengths of fittings including adapters shall meet the requirements of ASTM D33 1 1. Solvent cement for joining DWV pipe and fittings shall be as specified in ASTM D2564. EXECUTION INSTALLATION The installation of plastic pipe shall be strictly in accordance with the manufacturer's technical data and printed instructions. Joints for PVC pipe shall be solvent cement welded unless flanged or threaded are otherwise shown on the Drawings or are specified as other types herein. In making solvent-cemented connections, clean dirt and moisture from pipe and fittings, bevel pipe ends slightly with emery cloth to remove any shoulder or burrs created by cutting of the pipe. Solvent cement joints shall be made in accordance with ASTM D2855 except that solvent cement formulated especially for and as specified above shall be used for joining CPVC pipe and fittings. Primer shall be used whenever recommended by the pipe, fitting, or cement manufacturer and in all cases for joints on pipe systems four inches in diameter or larger. Making solvent cement joints shall not be performed and the work shall stop when the temperature, measured in the shade, is 40 degrees F and falling. Joints between PVC drain, waste and vent pipe and cast-iron soil pipe shall be made with approved mechanical compression joints designed for such use. PVC Pipe and Fittings 15064-4 Cannon Road Lift Station Project No. 3583 P \City of Carlsbad-16827W067411ft Station\7 Pro) Doc+\7.2 Final Docs\IOO % Specs\l5064 doc D. All piping shall have a sufficient number of unions to allow convenient removal of piping and shall be as approved by the Engineer. PVC pipe shall be installed with at least one expansion joint or loop near the center of each straight run of pipe which is 50 feet or longer with the maximum spacing between expansion joints or loops being 150 feet. E. Where plastic pipe passes through wall sleeves, the space between the pipe and sleeve shall be sealed with a mechanical sealing element as specified in Section 15 120. F. All plastic pipe to metal pipe connections shall be made using flanged connections. Metal piping shall not be threaded into plastic fittings, valves, or couplings nor shall plastic piping be threaded into metal valves, fittings or couplings. Only socket to thread adaptors shall be used for threaded plastic pipe connections to other threaded devices. G. Concrete inserts for hangers and supports shall be furnished and installed in the concrete as it is placed. The inserts shall be set in accordance with the requirements of the piping layout and the Contractor shall verify these locations from approved piping layout drawings and the structural drawings. Pipe hangers and supports are specified in Section 15 140. H. Preparation for Installation 1. Keep pipe clean and free of foreign material during storage and installation. Move pipe spools by hand or with slings. Do not store or drop pipe directly on concrete or ground. Cut PVC in accordance with the manufacturer’s printed instructions. 2. Gasketed Joints: Take care that the gaskets and flange faces are free of all foreign matter. Seat gaskets carefhlly and tighten bolts sequentially with a torque-limiting wrench to assure uniform gasket compression. If a gasketed joint fails a pressure test, the gasket shall be discarded and replaced with a new gasket. 3. Threaded Joints: Clean male and female threads of metallic piping with cutting oil and solvent. Lubricate male pipe threads as required in the applicable pipe specification. Tighten threaded plastic joints only with a strap wrench to prevent over-tightening. I. Pipe Installation 1. Alignment: Pipe shall be installed level, plumb and parallel or perpendicular to the major axes of the equipment, unless otherwise shown. Rotate fittings to prevent misalignment and stresses in pipe and connections to equipment. Bolts in flanges shall be located symmetrically about the vertical axis of the adjacent pipe. Where possible, locate pipe of similar diameters parallel and adjacent to one another. 2. Supports: Install pipe supports designed to transmit seismic loads to the support member or structure. Install pipe supports designed to permit thermal expansion and disconnection from connected equipment. Where possible, support multiple parallel pipes on common supports. 3. Connections: Connect pipe to equipment with connections designed to allow minor movement. Field locate union fittings as required for component installation and removal. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827\30679-Lifl Station\7 Pro] Docs\7.2 Final Docs\100 % Specs\l5064.doc PVC Pipe and Fittings 15064-5 3.02 FIELD TESTING A. All pipelines shall remain undisturbed for the minimum curing or cooling time specified for each type of pipe material but no less than 8 hours to develop full curing and complete strength at all joints. AI1 pipe systems shall be flushed clean and then subjected to a hydrostatic pressure test at a test pressure and temperature specified herein. Testing procedures shall also be as specified below and in Section 15050. Should the temperature not be attainable under hydrostatic conditions, then the test may be performed under hydro-dynamic conditions, provided that accurate measurements for loss of the test fluid can be made, or the pressure shall be proportionally increased to simulate the stresses of the higher temperature in relation to the lowest system temperature that is expected during the duration of the test. The proportionally higher test pressures shall be determined in accordance with the accepted temperature versus strength properties as published by the pipe manufacturer, Plastic Pipe Institute or other pipe material standards organization. Allowance for expansion of polyethylene pipe during the test shall be made in accordance with PPI Technical Report TR3 1. B. The test pressures and temperatures for the various pipe lines shall be as follows: 1. Ferric chloride feed piping: 2. Drain Piping: 15 psi at ambient temperature 10 psi at 65 degrees F C. The test shall be performed by slowly filling the piping system, expelling entrapped air from all high points. The fill rate shall be controlled so that the fluid velocity within the pipe system is less than two fps. Upon completion of the filling process, the system shall be brought up to the specified test temperature as applicable, holding the system pressure to less than ten percent of the test pressure. Once the system has been stabilized at the specified test temperature, the pipe should be slowly brought up to the test pressure in such a manner so as to not create shock, surge or water hammer in the pipe system. The test duration time limit shall not begin until the full pressure specified above has been reached and the system has been stabilized to within five percent of the test temperature. The system pressure and temperature shall be maintained to within one-half percent but no more than five percent of the specified value for the temperature and within five psi of the specified value for the pressure. These tolerances shall be held for the entire duration of the test. Upon completion of the test, the pressure shall be slowly removed by opening a valve or other pressure relieving device at a location remote to the location of the pressure/temperature monitoring equipment. D. The pressure test shall be monitored by a recording type pressure gage for tests not requiring temperature control or a dual pen pressure/temperature recording gage when temperature control is required. The entire test process shall be recorded, including the initial temperature stabilization and pressurization of the piping system. The record shall be continuous through the system test and shall show the final de-pressurization of the pipe system. E. All visible leaks detected during the pressure test shall be repaired and the pressure/temperature test rerun. A successful test shall be a test in which no visible leaks are detected and the pipe system pressure can be maintained within one-half percent but no more than five psi of the specified value. F. Prior to testing, the pipelines shall be supported in an approved manner to prevent movement during the tests. PVC Pipe and Fittings 'I 5064-6 Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827U0679-LIft Station\7 Pro] Don\7.2 Final Docs\100 % Speail5OM.doc 3.03 PAINTING A. All PVC pipe and fittings exposed to the direct sunlight shall be field painted to provide additional UV protection. This painting shall be required whether or not marking is required and shall be in accordance with Section 09902. END OF SECTION Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827\30679-Lifl Stabon\7 Proj Docs\7.2 Final Docs\lOO % Specs\lM.doc PVC Pipe and Fittings 15064-7 This page intentionally left Blank. PVC Pipe and Fittings 15064-8 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16B27\3067S-Lift SIation\7 Prq Don\7.2 Final Docdl00 % Specs\15064.doc SECTION 15066 DOUBLE WALL CHEMICAL PIPE SYSTEM PART 1 GENERAL 1.01 A. B. 1.02 A. B. C. D. E. 1.03 A. SCOPE OF WORK This section covers the double wall chemical containment pipe system to be installed on the chemical feed piping that is not located within the lift station building. The system shall include but is not limited to the double wall containment pipe, plexiglass enclosures, as specified herein. The Contractor shall hrnish all labor, materials, equipment and incidentals necessary and install the double wall chemical pipe system as shown on the drawings and as specified herein. RELATED WORK Chemical feed and metering pumps are included in Section 1 1260. General piping requirements are included in Section 15050. Pipe testing requirements are included in Section 15050. Control requirements are included in Division 13. Electrical requirements are included in Division 16. SUBMITTALS Shop drawings submittals shall be made in accordance with the requirements of SSPWC 2003 and Section 15050, except as modified herein. 1. 2. 3. Provide detailed pipe fabrication drawings for the double wall containment pipe and fittings. Identify all components in a list of materials. Detail each unique spool, identifylng all dimensions, welds, and methods of construction. Provide double-line scaled drawings showing all fittings, valves, in-line devices, chemical injectors, and supports. Identify each support and cross-reference to applicable mechanical details or manufacturer's catalog number. Identify all in-line equipment and valves by project equipment number. Provide detailed drawings of the plexiglass enclosures showing sizing for each location, weight, materials, support details, and installation instructions. Cannon Road Lift Station Double Wall Chemical Pipe System Project No. 3583 15066-1 P\Cily of Carlsbad-16B27!30679-Lifl Station\T Prq Doa\7.2 Final Oocs\lM) K Specs\l5066.doc 1.04 A. B. C. D. 1.05 A. REFERENCE STANDARDS American Society for Testing and Materials (ASTM) 1. ASTM D 1784 - Standard Specification for Rigid Poly (Vinyl Chloride)(PVC) Compounds and Chlorinated Poly (Vinyl Chloride)(CPVC) Compounds National Electric Code (NEC) National Electrical Manufacturers Association (NEMA) Other references that apply to the installation and fabrication of the double wall chemical containment pipe and fittings specified herein and referenced shall apply. QUALITY ASSURANCE Double Wall Chemical Pipe System shall be fhmished by a manufacturer who is fully qualified, experienced and reputable in the fabrication, and installation of the secondary containment specified herein. The system shall be designed constructed and installed in accordance with the best practices and methods and shall comply with these specifications as applicable. PART 2 PRODUCTS 2 .O 1 PIPE AND FITTINGS A. Double Wall Containment Piping: All chemical pump discharge piping outside of the lift station building and all injection piping shall be of double wall construction. Piping materials shall be per the individual chemical feed system subsections. B. Equipment Manufacturers: 1. Clear PVC Containment Piping System: a. Flo-Safe b. Or equal. 2.02 PLEXIGLASS ENCLOSURES A. General: 1. Where the use of double wall piping is not possible (e.g., at the injection point), plexiglass enclosures shall be provided around the equipment for personnel protection. 2. Enclosures shall be designed for easy removal and with easy access to the pump head and pump controls. 3. Enclosure components shall be furnished with integral handles, pulls, and other accessories needed to remove portions of the assembly and access shielded equipment. Double Wall Chemical Pipe System 15066-2 Project No. 3583 Cannon Road Lift Station P:\Cily of Cadsbad-16827\30679-Lifl StationV Pro] Docsi7.2 Final Docs\lOO % Spea\l5066.dcc 4. Enclosures weighing in excess of 20 lbs. shall have hinged access doors with closure latches. B. Hinges, mounting brackets, supports, latches and accessories shall be constructed of Type 3 16 stainless steel. PART 3 EXECUTION 3.01 SHIPMENT, HANDLING, AND STORAGE A. Insofar as is practical, the equipment specified herein, shall be factory assembled and ready for installation around the fabricated piping systems. The parts and assemblies that are shipped unassembled, shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. B. Weight, handling instructions, type of storage required, and instructions for protective maintenance during storage shall be included with each shipment to the project site. 3.02 INSTALLATION A. General 1. The Contractor shall be responsible for the proper installation of all double wall chemical pipe system components. Installation of system components and interconnections between system components and other plant systems shall be in accordance with the Specifications, manufacturer’s printed instructions, and approved shop drawings. B. Double Wall Containment Piping 1. Preparation for Installation a. Keep pipe clean and free of foreign material during storage and installation. b. Move pipe spools by hand or with slings. Do not store or drop pipe directly on concrete or ground. 2. Containment Pipe Installation a. Alignment: 1) Containment pipe shall be installed around the chemical feed piping system and shall match the alignment. 2) Adjust containment pipe around fittings to prevent misalignment and stresses in pipe and connections. b. Connections: 1) 2) Containment pipe shall be sealed at the ends to capture any leakage. Field locate fittings as required for component installation and removal. Cannon Road Lift Station Double Wall Chemical Pipe System Project No. 3583 15066-3 P:\City of Carlsbad-1682A30679-Lifl StaIionV Pro] Docs\7.2 Final Docs\100 K Specs\l5066.doc C. Plexiglass Enclosures 1. Installation a. The Contractor shall exercise care in installing the plexiglass enclosures around injection points, and equipment within piping. b. The plexiglass enclosures shall be installed and supported such that there are no stresses in the piping, equipment or injection points. c. Field modification of the plexiglass enclosures is not acceptable. 3.03 FIELD TESTING A. Pipe Pressure Test 1. The canier pipe system shall be tested for leaks prior to performing the pressure test on the containment piping. The carrier piping shall be tested in conformance with the 2. The containment piping shall be tested to a maximum of 5 psi with air. A pressure regulator should be used to ensure that over pressurizing and brittle fiacture of the containment piping does not occur. 3. The joints shall be soaped and visually inspected for leaks. Leaks shall be corrected and the piping retested. END OF SECTION Double Wall Chemical Pipe System 15066-4 Project No. 3583 Cannon Road Lift Station P\City of Carlsbad-I6827!30679.Lift Station\7 Pro] Docs\7 2 Final Docs\100 X Specs\15066.dOc SECTION 15 100 VALVES PART 1 1.01 A. B. 1.02 A. B. 1.03 A. B. C. GENERAL SCOPE OF WORK Furnish all labor, materials, equipment and incidentals required and install complete and ready for operation and test all non-buried valves as shown on the Drawings and as specified herein. The equipment shall include, but not be limited to, the following. 1. Valve Actuators - General 2. Knife Gate Valves 3. Plug Valves 4. Check Valves RELATED WORK Yard Piping is included in Division 2. Valves on all WAC systems, plumbing and/or chemical systems, not noted herein are included in their respective Sections of Divisions 1 1 and 15. SuBMlTTALS Submit materials required to establish compliance with this Section. Submittals shall include the following: 1. Certified drawings showing all important details of construction and dimensions. 2. Descriptive literature, bulletins and/or catalogs of the equipment. 3. The total weight of each item. 4. A complete bill of materials. 5. Additional submittal data, where noted with individual pieces of equipment. Test Reports 1. Provide certified hydrostatic test data, per manufacturers standard procedure or MSS-SPdl for all valves. Certificates 1. For each valve specified to be manufactured, tested and/or installed in accordance with AWWA and other standards, submit an affidavit of compliance with the appropriate standards, including certified results of required tests and certification of proper installation. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad.lBB27U0679-Liff Stationi7 Prq Docs\7.2 Final Docs\loO % Specs\lSlW.doc Valves 151 00-1 D. Operating and Maintenance Data 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, descriptions and other information required to instruct operating and maintenance personnel unfamiliar with such equipment. 1.04 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) 1. ASTM A48 - Standard Specification for Gray Iron Castings. 2. ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings. 3. ASTM A159 - Standard Specification for Automotive Gray Iron Castings. 4, ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes. 5. ASTM A436 - Standard Specification for Austenitic Gray Iron Castings. 6. ASTM B30 - Standard Specification for Copper-Base Alloys in Ingot Form. 7. ASTM B62 - Standard Specification for Composition Bronze or Ounce Metal Castings B. American Water Works Association (AWWA) 1. AWWA C 1 1 1 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. 2. AWWA C508 - Swing-Check Valves for Waterworks Service, 2-in (50 mm) Through 24-in (600 mm) NPS 3. AWWA C509 - Resilient Seated Gate Valves for Water Supply Service 4. AWWA C5 1 1 - Reduced-Pressure Principle Backflow Prevention Assembly 5. AWWA C550 - Protective Epoxy Interior Coatings for Valves and Hydrants 6. AWWA C800 - Underground Service Line Valves and Fittings C. American National Standards Institute (ANSI) 1. ANSI B2.1 - Specifications for Welding Procedures and Performance Qualifications 2. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings Classes 25, 125 and 250 3. ANSI B 16.10 - Face-to-Face and End-to-End Dimensions of Valves D. American Iron and Steel Institute (AISI) I Valves 151 00-2 Cannon Road Lift Station Project No. 3583 P,\City of Carlsbad-l6827\3067%Lift Station\7 Pro) Docs\7.2 Final Docs\100 % Specs\lSlW doc E. F. G. H. I. 1.05 A. B. C. D. 1.06 A. Manufacturer's Standardization Society of the Valve and Fittings Industry (MSS) 1. MSS-SP-61 - Pressure Testing of Steel Valves. 2. MSS-SP-70 - Cast Iron Gate Valves, Flanged and Threaded Ends. 3. MSS-SP-7 1 - Gray Iron Swing Check Valves, Flanged and Threaded Ends. 4. MSS-SP-78 - Cast Iron Plug Valves, Flanged and Threaded Ends. 5. MSS-SP-82 - Valve Pressure Testing Methods 6. MSS-SP-98 - Protective Coatings for the Interior of Valves, Hydrants and Fittings. National Electrical Manufacturers Association (NEMA) Underwriters Laboratories &JL) Factory Mutual (FM) Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. QUALITY ASSURANCE Qualifications 1. Valves and appurtenances shall be products of well established firms who are fully experienced, minimum 10 years, reputable and qualified in the manufacture of the particular equipment to be furnished. 2. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with this Section as applicable. 3. All units of the same type shall be the product of one manufacturer. Certifications 1. The manufacturers shall furnish an affidavit of compliance with Standards referred to herein as specified in Paragraph 1.03C above. Refer to PART 3 for testing required for certain items in addition to that required by referenced standards. Inspection of the units may also be made by the Engineer or other representative of the Agency after delivery. The equipment shall be subject to rejection at any due to failure to meet any of the specified requirements, even though submittal data may have been accepted previously. Equipment rejected after delivery shall be marked for identification and shall be removed from the job site at once. Unless otherwise noted, items specified herein shall comply with SSPWC 2003 Standards. In case of conflicts, the requirements of this Section shall govern. SYSTEM DESCRIPTION All of the equipment and materials specified herein is intended to be standard for use in controlling the flow of wastewater, air and chemicals, as noted on the Drawings. Cannon Road Lift Station Proiect No. 3583 Valves 15100-3 P \City of Carlsbad-1682A30679-Lift Station\7 Pro] Doa\7 2 Final Docs\lM) % 6pecs\15100 doc __I_.. __ B. Valves, appurtenances and miscellaneous items shall be installed as shown on the Drawings and as specified, so as to form complete workable systems. 1.07 DELIVERY, STORAGE AND HANDLING A. Reference is made to SSPWC 2003 for additional information. B. 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 Engineer. 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 and connecting piping is completed. a. All valves 3-in 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-in 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 Agency shall be removed, or the valve shall be removed and replaced. C. Storage and Protection 1. Special care shall be taken to prevent plastic and similar brittle items from being directly exposed to the sun, or exposed to extremes in temperature, to prevent deformation. See the individual piping sections and manufacturer's information for further requirements. 1.08 MAINTENANCE A. Special tools and the manufacturer's standard spare parts, if required for normal operation and maintenance, shall be supplied with the equipment in accordance with Section 01730 and where noted, as specified herein. PART 2 PRODUCTS 2.0 1 MATERIALS AND EQUIPMENT - GENERAL A. The use of a manufacturer's name and/or model or catalog number is for the purpose of establishing the standard of quality and general configuration desired. , Valves 1 5 1 00-4 Cannon Road Lift Station Project No. 3583 P\City of Carlsbad-1682A30679-tifl Slalion\7 Proj Docs\7.2 Final Docs\lM) % Specs\lBIW.doc B. Valves and appurtenances shall be of the size shown on the Drawings or as noted and as far as possible equipment of the same type shall be identical and from one manufacturer. C. 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. D. Unless otherwise noted, items shall have a minimum working pressure of 125 psi 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. E. Joints, size and material - unless otherwise noted or required by the Engineer: 1. 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. 2. Valves and appurtenances shall be of the same nominal diameter as the pipe or fittings they are connected to. 3. All valves exposed to view, or in vaults. a. 3-in and smaller - threaded ends b. 4-in and larger flanged ends. F. Provide all special adaptors as required to ensure compatibility between valves, appurtenances and adjacent pipe. G. Valves and actuators located outdoors but not within a building; within maximum 24 above liquid; in vaults; or where otherwise noted shall be especially designed for submerged service where water may completely submerge the valve and operator. All other units shall be as a minimum weather tight. 2.02 VALVE ACTUATORS - GENERAL A. The valve manufacturer shall supply and integrally, rigidly mount all actuators, including any type of manual or powered actuators, on valves at the factory. The valves and their individual actuators shall be shipped as a unit. B. Unless otherwise noted, valves shall be manually actuated; nonburied valves shall have an operating wheel, handle or lever mounted on the operator; buried valves and those with operating nuts shall have a non-rising stem with an AWWA 2-in nut. At least two tee handles shall be provided for all operating nuts. C. 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. D. Each operating device shall have cast on it the word “OPEN’ or “CLOSE” and an arrow indicating the direction of operation. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827\30679.Lift Station\7 Pro) Docs\7.2 Final DoCs\100 % Specs\l51M).doc Valves 1 51 00-5 E. Stem guides shall be of the adjustable wall bracket type, bronze bushed, with maximum spacing of 10-ft as manufactured by Clow; Rodney Hunt or equal. Extended operating nuts and/or stems shall have universal joints and pin couplings, if longer than 10-ft and a rating of at least five times the maximum operating torque. Stem adaptors shall be provided. F. Where required by the installation, or as specified, provide the following: extended stem; floor stand and handwheel; position indicator and etched or cast arrow to show direction of rotation to open the valve; resilient, moisture-resistant seal around stem penetration of slab. G. Additional valve actuators are included with the individual valve types and as noted in Paragraph 1.02 above. H. All position indication and direction of opening arrows shall be embossed, stamped, engraved, etched or raised decals. I. Unless otherwise noted, all valves larger than 3-in nominal diameter shall be provided with position indicators at the point of operation. 2.03 KNIFE GATE VALVES A. All knife gate valves shall be flanged, knife gate valves for 25 psi working pressure. Valves shall be marked for direction of flow and round bar wedges and gate guides shall be installed in the liner body to force the gate against the seat. The gate shall be a beveled knife edge. Valves shall have metal to metal seating, with a raised seat face with a relief groove to allow the gate to push solid particles aside to prevent material packing in the seat area. All wetted surfaces shall be Type 304 stainless steel with cast iron body and stainless steel trim. Paclung gland bolts shall be Type 304 stainless steel with plated, self-locking nuts. Seats shall be solid stainless steel. The valves shall have 111 port straight-through opening. Flanges shall be drilled and threaded to match connecting piping as shown on Drawings. Knife gate valves shall be Series L as manufactured by DeZurik Inc. or similar model as manufactured by ITT; Red Valve Co. or equal. B. 2.04 PLUG VALVES A. Plug valves shall be of the offset disc type, 1/4 turn, non-lubricated, serviceable (able to be repacked) under full line pressure and capable of sealing in both directions at the rated pressure. The disc shall be completely out of the flow path when open. Plug valves specified herein shall be by DeZurik; Keystone or equal. All manufacturers, named or otherwise, must comply completely with this Section. 1. For clean liquid or screened sewage, all size plug valves shall have a minimum port area of 80 percent. Valves 1 51 00-6 2. All plug valves for whatever service, shall be capable of passing "pigging" cleaning equipment (using a Girard or similar cleaning pig of full nominal pipeline diameter) in either direction and manufacturer shall so certify that this may be done without the use of special equipment. I Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827U0679-Lift Station\7 Prq Doa\7.2 Final Docs\lMI 46 SpeCS\15100.dOC B. Valves shall be rated at minimum 175 psi WOG (Water, Oil and Gas) working pressure for sizes 4- in to 12-in inclusive and at minimum 150 psi WOG working pressure for sizes 14-in and larger. 1. All plug valves under this Paragraph shall be performance, leakage and hydrostatically tested in accordance with AWWA C504, except as modified herein. 2. At the above rated minimum working pressures, the valves shall be certified by the manufacturer as permitting zero leakage for a period of at least 1/2 hour with pressure applied to the seating face. 3. At the direction of the Engineer, the valve manufacturer may be requested to perform a valve seat leakage test, witnessed by the Engineer to prove compliance with this Section. C. Valve bodies shall be of cast iron, 30,000 psi tensile strength, ASTM A126, Grade B, or of ductile iron, ASTM A536 and of the top entry, bolted bonnet design, cast with integral flanges conforming to the connecting piping. All exposed bolts, nuts and washers shall be zinc or cadmium-plated, except for buried or submerged valves, which shall have Type 3 16 stainless steel hardware. D. The valve disc shall: 1. Be cast iron ASTM A126, Grade B, or ductile iron, ASTh4 A536, Grade 65-45-12. 2. Be removable without removing the valve from the line. 3. Have an integral upper and lower shaft which shall have seals on the upper and lower journals to prevent entrance of solids into the journals. 4. Be one piece for valves up to 14-in. E. Shaft bearings shall be permanently lubricated, rigidly backed TFE, stainless steel or bronze at both upper and lower stem journals. The operator shaft shall have easily replaceable seals, which shall be externally adjustable and repackable without removing the bonnet from the valve, or shall have self adjusting packing. F. The valve seating surface shall provide full 360 degree seating by contact of a resilient seating material on the disc mating with welded-in high nickel content overlay seating surface in the body. 1. The seating design shall be resilient and of the continuous interface type having consistent opening and closing torques and shall be non-jamming in the closed position. Screw-in seats shall not be acceptable. 2. Discs shall have a full resilient facing of neoprene or Buna-N. G. The methods of mounting the actuator to the valve shall provide an air gap between the two. Actuator shall clearly indicate valve position and an adjustable stop shall be provided. Construction of actuator housing shall be semi-steel. Hardware on actuators shall be of the same materials as the valves. H. Plug valves shall be installed so that the direction of flow through the valve and the shaft orientation is in accordance with the manufacturer’s recommendations. Cannon Road Lift Station Project No. 3583 P:\city of Carlsbad-l682T\30679-Lift Slation\? Praj Docs\7.2 Final Docs\lM) X Specs\151W.doc Valves 151 00-7 2.05 CHECK VALVES A. Check valves for metallic lines of 2-in to 24-in diameter shall be swing type suitable for sewage service and shall meet the requirements of AWWA C508. The valves shall be iron body, bronze mounted, single disc, 150 psi working water pressure, nonshock and hydrostatically tested at 300 psi. 1. When there is no flow through the line, the disc shall hang lightly against its seat in practically a vertical position. When open, the disc shall swing clear of the waterway. 2. Check valves shall have bronze seat and body rings, extended bronze hinge pins and bronze nuts on the bolts of bolted covers. 3. Valves shall be so constructed that disc and body seat may easily be removed and replaced without removing the valve from the line. Valves shall be fitted with an extended hinge arm with outside lever and weight. The position of the weight shall be adjustable. Various weights shall be provided and installation approved by the Engineer. Lever shall be installed to the horizontal in the closed position, for both horizontal and vertical pipeline installations. 4. The submersible pump discharge check valves shall have two weighted arms, one located at each end of the pivot arm. Each arm shall be equally weighted. The valve shall be for heavy duty service that requires very rapid closure. In addition, these valves shall incorporate a hydro-viscous damping system to cushion the final closure of the valve. The damper(s) shall be installed either on each valve arm or internally adjacent to the valve seating surface. 5. Check valves shall be by Apco Valve and Primer Corporation; American-Darling; M&H; Golden Anderson; Clow; Mueller or equal. Valves 151 00-8 END OF SECTION I Cannon Road Lift Station Project No. 3583 P:\City ofCadsbad-16827U0679-Lifl Sla!ion\l Pro] Docs\7.2 Final Docs\lOO X Specs\l5lOO.doc SECTION 15400 PLUMBING - GENERAL PROVISIONS PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor, materials, equipment, services and incidentals required and install and test a complete plumbing system as specified and shown on the following: 1. 154 10 - Plumbing - Piping Systems 2. 15440 - Plumbing Fixtures and Trim 3. 15450 - Plumbing Equipment B. The work of these Sections is based on the following: 1. Drawing Number P- 1 Plumbing Legendschedule P-2 Plumbing Floor PladDetails C. More specifically the work shall include, but shall not be limited to the following: 1. All items included under the Scope of Work of other Plumbing Sections. 2. Cutting, coring and rough patching in accordance with Division 01. 3. All parts necessary to make a complete Plumbing System ready for continuous operation. 4. The absence of pipe supports and details on the Drawings shall not relieve the Contractor of the responsibility for providing them. 1.02 RELATED WORK A. The following work related to, but not covered under the plumbing work will be done under other related Sections. 1. All piping systems in the building other than the plumbing work specified in the Plumbing Sections. 2. Yard piping for sanitary beyond 5-ft-0-in outside the building unless otherwise indicated. 3. Potable water beyond 5-fi-0-in outside the building unless otherwise indicated. 4. Electrical work is included under Division 16. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827\30679-Lifl SlationV Proj Docs\7.2 Final Docs\100 % Specs\l5400.doc Plumbing - General Provisions 15400-1 1.03 SUBMITTALS A. Inspection by the Engineer's representative or failure to inspect shall not relieve the Contractor of responsibility to provide materials and perform the work in accordance with the documents. B. Submit shop drawings and product data to establish compliance with this Section. Submittals shall include the following: 1. Shop drawings and technical literature covering details of all equipment, fixtures and accessories being furnished under this Section prior to fabrication, assembly or shipment. 2. For units that will be shipped exposed, provide a description of the protective packaging that will be used during transit. 3. All submittals shall contain a statement that Section 15400 and all other referenced Sections have been read and complied with. The certification statement shall be made by all of the following that are applicable; the Contractor, sub-contractor and the vendor. The statement shall be an individual statement for each party involved, and shall be included with every submittal and resubmittal. C. Operation and Maintenance Data I. Operating and maintenance manuals shall be hished to the Agency. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc, that are required to assist operation and'~maintenance personnel unfamiliar with such equipment. 2. A representative of the manufacturer who has complete knowledge of proper operation and maintenance shall be provided for the number of 8 hour days as listed below to instruct representatives of The Agency and the Engineer on proper operation and maintenance. With The Agency's permission, this work may be conducted in conjunction with the inspection and the installation and test run as provided under PART 3. If there are difficulties in operation of the equipment due to the manufacturer's design or fabrication, additional service shall be provided at no additional cost to The Agency. D. In general, corrections or comments or lack there of, made relative to submittals during review shall not relieve the Contractor fiom compliance with the requirements of the drawings and specifications. Submittals are for review of general conformance with the design concepts of the project and general compliance with the contract documents. The Contractor is responsible for the final design conforming and correlating all quantities and dimensions, selecting fabrication processes and techniques of construction, coordinating the work of all trades, and performing the work in a safe and satisfactory manner. 1.04 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) B. American National Standards Institute (ANSI) C. American Water Works Association (AWWA) Plumbing - General Provisions 15400-2 Project No. 3583 Cannon Road Lift Station P:\City of Carlsbad-16827U0679-Lift Station\7 Pq Docs\7 2 Final Docs\lOO K Specs\15400.doc D. E. F. G. H. I. J. K. 1.05 A. B. C. D. E. F. G. H. National Fire Protection Association (NFPA) National Electrical Manufacturers Association (NEMA) Plumbing and Drainage Institute (PDI) Cast Iron Soil Pipe Institute (CISP) Underwriters Laboratories (UL) Factory Mutual (FM) American Society of Plumbing Engineers Data Book way be used as a design guide.) Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. QUALITY ASSURANCE The Contractor shall be fully responsible for the proper execution and performance of the work described herein. It shall be their responsibility to inspect all installation conditions and bring to the attention of the Engineer any conditions which may affect their work adversely. They shall report to the Engineer, prior to commencing any portion of this work, any conditions unsuitable for the installation of their portion of the work. Mention herein or indication on the Drawings of equipment, materials, operation or methods shall require that each item mentioned or indicated be provided to make a complete. system of plumbing ready for continuous operation. The location of all equipment, fixtures and piping shall be considered as approximate only and the right is reserved by the Engineer to change at any time, before the work is installed, the position of such equipment and piping to meet structural conditions and to provide proper headroom clearance or for other sufficient causes and such changes shall be made without additional expense to the Agency. Attention is called to the necessity for elimination of transmission of vibration from mechanical equipment to building structures. All equipment, therefore, shall be carefully selected and installed to meet this condition and isolators and water hammer arrestors shall be provided where required. Instruct such persons as designated by the Agency in the care and use of all plumbing equipment and piping systems installed. Comply with all the laws, ordinances, codes, rules and regulations of the State, local or other authorities having jurisdiction over any of the work specified herein. Obtain all required permits and pay all legal fees for the same and in general take complete charge and responsibility for all legal requirements pertaining to this Section of the work. Requirements set forth in this Section and indicated on the Drawings shall be followed when in excess of the required or minimum regulations. Cannon Road Lift Station Plumbing - General Provisions Proiect No. 3583 15400-3 PCity of Carlsbad-16827U0679-Lif! Station\7 Pro) Docs\7.2 Final DOn\lOO X 'specs\154OO.doc I. J. K. L. M. N. 0. 1.06 A. B. 1.07 A. B. If any work is performed and subsequent changes are necessary to conform to the regulations, such change shall be made as part of this work at no additional cost to the Agency. All work shown on the Drawings is intended to be approximately correct to scale, but figured dimensions and detailed drawings shall be followed in every case. The Drawings shall be taken in a sense as diagrammatic. Size of pipes and general method of running them are shown, but it is not intended to show every offset and fitting nor every structural difficulty that may be encountered. To carry out the true intent and purpose of the Drawings all necessary parts to make complete working systems ready for use shall be furnished without extra charge. Refer to the Structural and Architectural Drawings which indicate the type of construction in which the work shall be installed. Locations shown on the Plumbing Drawings shall be checked against the general and detailed drawings of the construction proper. All measurements must be taken at the building. All equipment of a given type included in this Section shall be furnished by or through a single manufacturer or as specified on the schedules Inspection by the Engineer’s representative or failure to inspect shall not relieve the Contractor of responsibility to provide materials and perform the work in accordance with the documents. The piping manufacturer shall furnish an affidavit of compliance certifjmg that all materials used and work performed complies with the specified requirements. The Contractor shall provide copies of mill test confirming the type of material used in the various components. The Agency and Engineer reserve the right to sample and test any materials after delivery and to reject all components represented by a sample that fails to comply with the specified requirements. SERVICE AND UTILITY CONNECTIONS Sanitary and Storm Water 1. The sanitary waste and drainage systems shall terminate at the sump pits or at points 54-0411 outside the building or as otherwise shown on the Drawings. Water Service 1. The water meter and backflow preventer units shall be furnished and installed complete with all components. The water connections shall be made to these units as shown and from these points furnish and install all water to the building, equipment, fixtures and apparatus, as shown on the Drawings. DELIVERY, STORAGE AND HANDLING Refer to requirements of Division 01. All materials shall be inspected for size, quality and quantity against approved shop drawings upon delivery. Plumbing - General Provisions 15400-4 Project No. 3583 Cannon Road Lift Station P.\City of CarIsbad-16827U0679-LiH Station\7 Proj Docs\7.2 Final Docs\100 % Specs\15200.doc C. D. E. F. G. 1.08 A. B. C. D. 1.09 A. B. C. Delivery schedule of all equipment shall be coordinated with the Contractor. Equipment ready for shipment prior to the agreed on shipping date shall be stored without cost to the Agency by the manufacturer. All materials shall be suitably packed for shipment and long term storage. Each package shall labeled to indicate the project and the contents of each package. Where applicable, equipment numbers shall be marked on the container. All equipment shipped that is exposed such as on a flat bed truck shall be protected during transit. The equipment shall be protected from moisture, road salt, dirt and stones or other materials thrown up from other vehicles. Electrical components shall be protected as above, but with special attention to moisture. The method of shipment protection shall be defined in the submittals. Instructions for the servicing and startup of equipment in long term or prolonged storage shall accompany each item. All materials shall be stored in a covered dry location off of the ground. When required to protect the materials they shall be stored in a temperature-controlled location. COORDINATION The Drawings indicate the extent and general arrangement of the systems. If any departures from the drawings or specifications are deemed necessary, details of such departures and the reasons therefore shall be submitted as soon as practical for review. No such departures shall be made without the prior written concurrence of the Engineer. The Contractor shall coordinate the location and placement of all concrete inserts and welding attachments with the structural engmeer. The Contractor shall assume full responsibility for coordination of the Plumbing systems, including; scheduling, and verification that all structures, piping and the mounting of equipment are compatible. The Contractor shall start up each piece of equipment and system and shall make all adjustments so that the system is placed in proper operating condition. ELECTRICAL EQUIPMENT Electric motors in NEMA frame sizes shall conform to the requirements in Division 0 1, unless otherwise specified herein. Electrical equipment which is furnished under this Section shall meet the requirements specified in Division 16: 1. Disconnect switches, motor starters, combination motor starters (starters with disconnecting means and short circuit protection), wires, and cables shall be as specified in Division 16. Electrical enclosures, panels and components shall be suitable for the environment and electrical classification for the space they are located in. The type of enclosure for the various spaces shall be as specified in Division 16. Refer to the electrical drawings for the space classifications. Cannon Road Lift Station Plumbing - General Provisions Project No. 3583 15400-5 P'\City of Carisbad-16B2A30679L1fl Station\T Pro) Docs\7 2 Final Docs\lOO % Specs\15400 doc ~- ~-__ 1.10 A. 1.1 1 A. B. C. D. PART 2 PART 3 3.01 A. B. C. D. 3.02 A. SUPPORTS All components shall be provided with lugs, brackets or field supplied devices to allow the components to be firmly attached to the structure. The lugs, brackets or field supplied devices shall be sized to withstand the seismic loads for the area and type of application. SEISMIC RESTRAINTS Seismic restraints shall be provided for all piping and equipment as required by applicable codes. All seismic criteria and design shall comply with the latest SMACNA SEISMIC RFSTRAMT GUIDE. Materials of construction for seismic supports shall be the same as those specified for equipment supports and hangers, and pipe hangers. All bolts shall be stainless steel regardless of the specified support material. Where the seismic criteria and size of piping are within the limits of the latest edition of the SMACNA Seismic Restraint Manual, the restraints as defined in the manual can be used. Restraints shall be selected from Tables for Seismic Hazard Level SHL A. Provide design of bracing for all piping that exceeds the limitations of the SMACNA Seismic Restraint Manual. PRODUCTS (NOT USED) EXECUTION INSTALLATION All the items specified in Sections 15410,15440, and 15450 under PART 2 shall be installed according to the applicable manufacturer's recommendations, the details shown on the Drawings and as specified herein and in other related Sections. The Contractor shall start up each piece of equipment and system and shall make all adjustments so the system is placed in proper operating condition. The Contractor shall not install any equipment or materials until the Agency and Engineer have approved all submittals. If any equipment or materials are installed prior to approval of the submittals, it shall be at the Contractor's risk. All work shall be installed in accordance with the manufacturer's printed instructions and shall be rigid, plumb and true to line, with all parts in perfect working order. Maintain protective covers on all units until final cleanup time and at that time remove covers and clean and polish all surfaces. PROTECTION Materials, fixtures and equipment shall be properly protected at all times and all pipe openings shall be temporarily closed so as to prevent obstruction and damage. Plumbing - General Provisions 15400-6 Project No. 3583 Cannon Road Lift Station P:\City of Carisbad-l682T\30679-Lifl Stabon\T Pro] Docs\7.2 Final Docs\IOO X Specs\15400 doc 3.03 COORDINATION SKETCHES A. It shall be the responsibility of the subcontractor to have employed a competent coordinator of mechanical systems and as such to provide all coordination of drawings or sketches as may be required or deemed necessary by the Engineer to obtain the required ceiling heights and eliminate conflicts with all piping, ducts and electrical installation. END OF SECTION Cannon Road Lift Station Plumbing - General Provisions Project No. 3583 15400-7 P.\Cily of Carlsbad-16827\30679-L1fl SlalionV Prof Docs\7.2 Final Docs\100 K Specs\l5400.doc This page intentionally left Blank. Plumbing - General Provisions 15400-8 Cannon Road Lift Station Project No. 3583 P:\Ciiy of CarIsbad-1682A30679-Ltfl StatlonV Pro1 Dccs\7.2 Final Docs\lOO k S!x?CS\15400.dW SECTION 154 10 PLUMBING - PIPING SYSTEMS PART 1 GENERAL 1.01 SCOPE OF WORK A. The areas where work is to be accomplished are specified and shown in the following: 1. Specification Sections 15400 Plumbing General Provisions 15450 Plumbing Equipment 15440 Plumbing Fixtures and Trim 2. Drawing Number P-1 Plumbing Legendschedule P-2 Plumbing Floor PladDetails B. This Section specifies the basic Plumbing Systems of Piping and the materials of each system, including valves. Specific uses and applications are specified in other related Sections. C. Furnish all labor, materials, equipment, services and incidentals required and install complete interior Plumbing Piping Systems as shown on the Drawings and as specified herein. 1. Sanitary - Waste and Vent Systems 2. Potable Hot and Cold Water Systems 3. Furnishing and installing all pipe, fittings, valves, floor drains, cleanouts, sleeves, hangers and insulation in conjunction with the above listed piping systems. 4. All piping, and equipment shown on the Drawings is intended to be approximately correct to scale, but figured dimensions and detailed drawings of the actual equipment fiunished shall be followed in every case. The Drawings shall be taken in a sense as diagrammatic. Size of piping is shown, but it is not the intent to show every offset or fitting, nor every hanger or support, or structural difficulty that may be encountered. To carry out the intent and purpose of the Drawings all necessary parts to make a complete worlung system ready for use shall be furnished without extra charge. The Contractor shall be responsible to coordinate the system installation and routing with the work of all trades. 1.02 RELATED WORK A. Refer to Section 15400. Cannon Road Lift Station Project No. 3583 P:\Cily of CarIsbad-16827W0679-Lifl Stalion\7 Proj Don\7.2 Final Docs\lOO X Spen\l54lO.dix Plumbing - Piping Systems 1541 0-1 1.03 sUBmALs A. Submit, in accordance with Sections 15400, shop drawings and technical literature covering details of all plumbing-piping systems being furnished under this Section prior to fabrication, assembly or shipment . B. For units that will be shipped exposed, provide a description of the protective packaging that will be used during transit C. All submittals shall contain a statement that Sections 15400, 154 10, 15440, 15450 and all other referenced Sections have been read and complied with. The certification statement shall be made by all of the following that are applicable; the Contractor, sub-contractor and the vendor. The statement shall be an individual statement for each party involved, and shall be included with every submittal and resubmittal. D. Provide manufacturers catalogs, literature, and engineering data on all hangers and supports. Load ratings, materials, and installation shall be in accordance with the recommendations of MSS SP-58 and MSS SP-69. 1.04 REFERENCE STANDARDS A. Refer to Section 15400. 1.05 SERVICE AND UTILITY CONNECTIONS A. Refer to Section 15400. 1.06 QUALITY ASSURANCE A. Inspection by the Engineer’s representative or failure to inspect shall not relieve the Contractor of responsibility to provide materials and perform the work in accordance with the documents. B. The piping manufacturer shall furnish an affidavit of compliance certifying that all materials provide copies of mill test confirming the type of material used in the various components. 1.07 DELIVERY, STORAGE AND HANDLING A. All materials shall be inspected for size, quality and quantity against approved shop drawings upon delivery. B. Delivery schedule of all equipment shall be coordinated with the Contractor. Equipment ready for shipment prior to the agreed on shipping date shall be stored without cost to the Agency by the manufacturer. C. All materials shall be suitably packed for shipment and long-term storage. Each package shall labeled to indicate the project and the contents of each package. Where applicable, equipment numbers shall be marked on the container. Plumbing - Piping Systems 1 541 0-2 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-1662A30679-Lifl Station\7 Proj Dm\7.2 Final Daa\lDo % Specs\lMlO.doc D. E. 1.08 A. B. C. 1.09 A. PART 2 2.01 A. All equipment shipped that is exposed such as on a flat bed truck shall be protected during transit. The equipment shall be protected fiom moisture, road salt, dirt and stones or other materials thrown up from other vehicles. Electrical components shall be protected as above, but with special attention to moisture. The method of shipment protection shall be defined in the submittals. All materials shall be stored in a covered dry location off of the ground. When required to protect the materials they shall be stored in a temperature-controlled location. COORDINATION The Drawings indicate the extent and general arrangement of the systems. If any departures fiom the drawings or specifications are deemed necessary, details of such departures and the reasons therefore shall be submitted as soon as practical for review. No such departures shall be made without the prior written concurrence of the Engineer. The Contractor shall coordinate the location and placement of all concrete inserts and welding attachments with the structural engineer. The Contractor shall assume full responsibility for coordination of the Plumbing systems, including; scheduling, and verification that all structures, piping and the mounting of equipment are compatible. SEISMIC RESTRAINTS Refer to Section 15400. PRODUCTS PIPING SYSTEM MATERIALS Sanitary 1. 2. 3. 4. 5. The pipe and fittings shall be SV (Service) hub and spigot cast iron soil pipe and fittings conforming to ASTM A74 and ANSI A1 12.5.1 tarred inside and out at the foundry. Joints shall be made up using lead and oakum. Caulking lead shall conform to U.S. Department of Commerce CS-94 and Fed Spec QQ-L-156. As an option to lead and oakum, resilient gasketed compression joints conforming to ASTM C564 may be used. If optional gaskets are used, provide additional supports and hangers as required to provide piping system rigidity equal to that of leaded joints. Piping above grade shall be of the above mentioned hub and spigot type or of the No-Hub type conforming to the Cast Iron Soil Pipe Institute Standards 301. The No-Hub coupling shall be Anaheim Foundry Co. Husky SD4000, Clamp-All 125 or by MG Coupling Co. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-l6827\30679-Lifl StattonV Proj Docs\7.2 Final Docs\l W 41 Specs\l5410.doc Plumbing - Piping Systems 1 541 0-3 6. Steel pipe and cast iron fittings may be used for sanitary vents in sizes 2-in and smaller, except where vents pass through roof or are buried in earth. Pipe shall be standard weight, Schedule 40, galvanized steel, conforming to ASTM A53. Fittings shall be black cast iron, threaded type conforming to ANSI B16.4. 7. Copper piping may be used for sanitary waste and vent in sizes 2-in and smaller. Pipe shall be Type "L" used with either cast or wrought DW fittings. Solder Alloy 95TA (95 percent Tin, 5 percent Antimony), ASTM B32. No solder containing lead shall be utilized on the project. B. Water Systems (Potable) 1. Piping shall be Type "L" copper with cast bronze or wrought copper, solder type fittings for above grade and Type "K for where buried or shall be flanged end, ductile iron. Solder Alloy 95TA (95 percent Tin, 5 percent Antimony), ASTM B32. No solder containing lead shall be utilized on the project. 2. All copper piping 2-1/2-in and larger and all buried copper piping shall be Type S-2 brazed. Brazing filler metal classified as BCu4 or BCu5, with minimum melting point of 1300 degrees F. Use wrought fittings for brazing. 3. Piping larger than 4-in shall be flanged end, ductile iron or Type L copper tubing utilizing a grooved joint system as provided by the Victaulic Co. or equal. 2.02 VALVES A. General 1. It is the intention of the Plumbing Drawings and this Section to require control valves at the bottom of all potable and protected hot and cold water service risers and as shown on the Drawings. 2. Install drawoff valves on the house side of main control valves, at the bottom of all risers, at all low points and where shown on the Drawings. Drawoffs shall consist of a hose end valve as hereinafter described. 3. Group and locate control valves in all locations so they may be easily operated, through access panels, doors, or adjacent to equipment. 4. Valves, in general, shall be of the same manufacture throughout unless noted otherwise. All valves, except as noted otherwise, shall be made for 125 lb steam working pressure and shall have round iron wheel handles. B. Water Valves 1. All water valves 2-in and smaller shall be full port ball type similar to Watts 830 1/83 1 1 ; Apollo 77-100 or equal. 2. All water valves 2-1/2-in and 3-in unless otherwise noted, shall be brass body gates and shall be Nibco Inc. S-113; Stockham B-112 or Hammond 1B-647. Plumbing - Piping Systems 1541 0-4 Project No. 3583 Cannon Road Lift Station P:\City of Carlsbad-16827W0679-Lifl Stabon\7 Pro] DOEs\7 2 Final Docs\lOO % Specs\l5410.doc 2.03 DRAINS A. For the purpose of explanation and description only, the following drain catalog numbers are taken from the catalogs of Zum Industries, Inc. unless otherwise noted. Those drains as manufactured by J.R. Smith Mfg. Co. or Josam Mfg. Co. and determined by the Engineer to be equal in every respect to those specified will be acceptable for installation. All drains shall be of sizes, shown on the Drawings. B. Floor Drains (FD) 1. All floor drains and open ended drains shall be fitted with a deep seal cast iron "P'l type or "running" type trap to suit drain outlet. Traps shall be acid resisting material where noted. 2. Floor drains shown on the Drawings as (AW) and installed in corrosive resistant piping systems shall be of same material as the acid resisting pipe and fittings described above. 3. All floor drains shall have cast iron or acid resisting drainage flange, seepage control, clamping collar and inside caulk outlet unless noted otherwise to be IPS outlet. 4. Schedule of Floor Drains Cat. No. Remarks "A" 2-525 Medium duty drain 2.04 CLEANOUTS A. For the purpose of explanation and description only, the following cleanout catalog numbers are taken from the catalogs of Zum Industries, Inc. unless otherwise noted. Those drains manufactured by J.R. Smith Mfg. Co. or Josam Mfg. Co. as and determined by the Engineer to be equal in every respect to those specified will be acceptable for installation. All cleanouts shall be of size shown on the Drawings. B. In cast iron bell and spigot pipe, cleanouts shall consist of a cast iron ferrule and extra heavy brass tapered screw cleanout plug with square or hexagonal nuts. C. In threaded pipe, (galvanized steel with recessed drainage pattern fittings) cleanouts shall consist of standard iron pipe size (IPS) brass plugs screwed into drainage fittings. D. Wall Cleanouts 1. Wall cleanouts (WCO) shall be equal to Zurn 2-1441 or 2-1443 with stainless steel shallow cover and screw. 2. Cleanout tees shall be equal to Zurn 2-1446 or 2-1447 Cannon Road Lift Station Project No. 3583 P\City of Ca1tsbad-1682A30679-L1ft StationV Pro! DOC5\7.2 Final Docs'i100 % Specs\lMlO.doc Plumbing - Piping Systems 1 54 1 0-5 2.05 A. B. 2.06 A. B. C. D. E. F. SLEEVES AND CASTINGS Sleeves 1. Sleeve all piping through walls, beams and partitions. All wall sleeves shall finish flush with the finish line. 2. Sleeve all piping passing through floor slabs. All sleeves shall extend 2-in above the finish floor slab. 3. All sleeves for exterior emergency shower eye wash units shall be packed with insulation. 4. Materials and installation conforming to the requirements of Division 0 1 shall be hmished under this Section. 5. Refer to "Typical Detail Sheets" for additional information. Castings 1. Provide waterproof castings on each plumbing pipe penetrating walls of wet wells, tanks or pits. Castings shall be of size and length to suit pipe and wall thickness. 2. Materials and installation conforming to the requirements of Division 01 shall be furnished under this Section. HANGERS, SUPPORTS AND ANCHORS Piping support systems shall include restraints as required by the applicable building codes to withstand seismic loading. Design shall be provided by a professional engineer hired by the Contractor as specified in other Sections. The absence of pipe supports and details on the drawings shall not relieve the Contractor of the responsibility for providing them. In certain locations, pipe supports, anchors, guides, and expansion joints may be indicated on the drawings. The Contractor shall be responsible to provide a complete system of supports, expansion joints, and anchors. Additional supports may be required adjacent to expansion joints, couplings, and valves. Hangers supporting the vertical stacks of soil, waste, drain, vent and rainwater leaders shall be heavy friction clamps at each floor and at 10-ft intervals. Supply and service vertical risers shall be supported by friction clamps on the riser which shall rest on the sleeve at each floor level and at 10- ft intervals . Hangers supporting horizontal piping at ceilings shall be of the clevis type and spaced 5-ft apart for soil, waste, drain, rainwater leaders and vent pipes; 8-ft apart for supply and service pipe 1-1/2411 diameter and larger; and 6-ft apart for pipe smaller than 1-1/2-in diameter. Horizontal piping buried in earth under lowest floor slabs or buried within the slab shall be supported with the hanger types shown on the Drawings. .Plumbing - Piping Systems 1541 0-6 Project No. 3583 Cannon Road Lift Station P\City of Carlsbad-16827\30679-Lift StahhnV Proj Docs\7.2 Final Docs\lOO % SpeCS\lWlO.doC G. H. I. 2.07 A. PART 3 3.01 A. B. C. D. All hangers shall be of a type to permit vertical adjustment after installation. Supports and hangers for cast iron soil piping shall be installed in accordance with the latest addition of the cast iron soil pipe handbook unless noted otherwise. Materials and installation shall be furnished under this Section. All hangers and supports for copper piping shall be PVC coated where in contact with copper. PIPE MARKING AND COLOR CODING Pipe marking is included in Division 9, but it shall be part of the work of this Section to assist as required by the Engineer to identify the pipe contents, direction of flow and all pertinent data required for proper marking of pipe. EXECUTION INSTALLATION Install all piping, valves, hangers and appurtenances as specified herein and in the referenced Sections above. The Contractor shall not install any equipment or materials until the Agency and Engineer have approved all submittals. If any equipment or materials are installed prior to approval of the submittals, it shall be at the Contractor's risk. In general, corrections or comments or lack there of, made relative to submittals during review shall not relieve the Contractor from compliance with the requirements of the drawings and specifications. Submittals are for review of general conformance with the design concepts of the project and general compliance with the contract documents. The Contractor is responsible for the final design conforming and correlating all quantities and dimensions, selecting fabrication processes and techniques of construction, coordinating the work of all trades, and performing the work in a safe and satisfactory manner. Valves 1. 2. 3. 4. Install control valves to all locations grouped and located to be easily operated, through access panels, doors, or adjacent to equipment. Install all final Protected Water connections to Process and HVAC equipment. Each connection shall be preceded by a ball valve directly adjacent to the unit. Install all valves in a horizontal to upright position. Valves shall not be installed in down position from the horizontal. Securely anchor pressure reducing valves and components to wall or floor at a height as directed by the Engineer. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16BZA30679-Lift Staom\7 Pro] Docs\7.2 Final Docs\IOO % Specs\lWIO.doc Plumbing - Piping Systems 1541 0-7 E. Welding 1. 2. 3. 4. 5. 6. 7. 8. 9. Welding of joints shall be by metal-arc welding process. Welding shall be by qualified welders meeting the requirements outlined in Section Dc of the ASME Boiler and Pressure Vessel Code and certified by the Hartford Steam Boiler Inspection Company. Welding shall not be done when the atmospheric temperature is less than 32 degrees F or when surfaces to be welded are wet. Surface to be welded shall be free from loose scale, slag, rust, paint, oil and other foreign material. Joint surfaces shall be smooth, uniform and free from fins, tears and other defects which might affect proper welding. Bevels shall be accurately cut by machining or by a mechanically guided cutting torch. Piping shall be carefully aligned before welding and maintained in alignment during welding. Tack welds may be used to maintain alignment. They shall be the same quality as the final welds and shall be fused thoroughly therein. Defective tack welds shall be removed before the final weld is made. The surface of the finished welds shall have a bright metallic luster after cleaning, a fairly smooth and uniform contour with regular ripples and be free from overlaps, undercuts and excessive convexity. Welds shall be sound throughout, fused thoroughly and free from gas pockets, oxide, slag inclusions and surface porosity. The inside of the pipe shall be free from globules of weld metal, spacers or other material whch would restrict the pipe area or become loose to enter the fluid stream. Defective or unsound welds shall be corrected by removing and replacing the welds. Pipe or fittings which cannot be rewelded satisfactorily shall be replaced with new pipe or fittings at the Contractor's expense. All welded joints will be visually inspected by The Agency's Representative for defects beyond those acceptable in ANSI B3 1 .l. Method of repair shall be in accordance with instructions as received from the Engineer. F. Flanged Connections 1. All flange faces shall be in perfect alignment with the holes straddling the vertical center line of the piping. 2. All bolts shall be well lubricated over the entire thread length with a heavy graphite and oil mixture prior to the tightening operation. Bolts shall be tightened with proper wrenches, care being taken to secure uniform pressure on the bolts and gasket and to avoid overstressing of the bolts, dishing of the flanges and compression of the gasket beyond its proper limits. a. Commercial grade carbon steel bolts, ASTM A307, Grade B shall be tightened to obtain approximately 15,000 psi stress based on the root area of the thread. AlIoy steel bolts, ASTM A193, Grade B7 shall be tightened to obtain a stress of 45,000 psi. Plumbing - Piping Systems 15410-8 Project No. 3583 Cannon Road Lift Station P:\City of Carlsbad-1682A30679-Lift Slation\T Pro] Docs\7.2 Final Docs\100 Yo Specs\l5410.dOC 3. All bolts shall be of sufficient length so that when fully tightened, a minimum of two full threads shall extend beyond the nut. G. Screwed Connections 1. 2. 3. 4. 5. All screwed connections shall have 111 thread of true taper, accurate to gauge and conform to ANSI. Reduction in size shall be made using reducing fittings. The use of bushings or close nipples is prohibited. Nipples shorter than 4-in in length shall be Schedule 80. Plugs shall be steel or brass with square head. Screwed joints shall be made with an approved joint compound applied to the male thread only. Caulking of screwed joints will not be allowed. H. Soldering (Copper Tubing) 1. 2. 3. 4. 5. 6. Tubing shall be cut with square ends and reamed to prevent burrs, out-of-round or improperly sized ends. After cutting, all surfaces to be soldered shall be thoroughly cleaned to a metal-bright finish, free from dirt, grease or other material before fluxing and soldering. This cleaning shall be performed by using emery cloth, sandpaper or steel wool. Clean the outside end of the tubing for a length of %-in greater than the depth of the fitting. The inside of the fittings shall be cleaned in a similar manner. Apply non-corrosive flux and assemble the joint. Acid solder or acid flux will not be allowed. The surfaces to be joined shall be heated up slowly and uniformly to the melting point of the solder. The surface being soldered shall be maintained above the melting point of the solder for sufficient time to draw the solder completely into the joint. When the solder congeals to a plastic state the excess metal shall be removed with a cloth brush, leaving a fillet around the end of the fitting. Full penetration of the solder uniformly throughout the entire socket is required. The soldered joints shall be allowed to cool in still air until only warm to the hand after which the work may be quenched. Any type of crack, pinhole, area of incomplete penetration, or similar defect will not be accepted. Peening for closing up defects shall not be permitted. Heating torches of sufficient size shall be used for heating of large fittings prior to soldering. Multiple tips or ring burners for use on combination torches may be used. Remove all external and internal loose solder and flux after joint cools. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-l6827W0679-L1fl Sfation\7 Proj DOcs17.2 Final DOcsllOO % Specs\l54lO.doc Plumbing - Piping Systems 1541 0-9 E. Grooved Joints 1. Grooved piping joints are to be made in strict accordance with the joint manufacturer’s recommendations. The depth, width and distance from the end of the pipe are to all be within the joint manufacturers tolerances. 2. Grooves are to be cut in steel piping systems. Piping shall be cut to length and squared before grooving. 3. Lubricant for the gaskets shall be supplied by the joint manufacturer. Gaskets are to be checked to be sure that they are the proper gasket for the piping system. Lubricant shall be applied to the gasket prior to installing the gasket on the pipe. 4. The gaping between the ends of the pipe being joined is to be set based on the piping systems needs to expand and contract. In general pipe expansion and contraction in grooved piping systems is to be taken up by the proper gaping of the individual joints. 5. The housing is to be assembled around the piping being sure that the housing does not pinch the gasket and that it also drops into the grooves on the two sections of piping. Bolts are to be tightened by hand uniformly. Only metal to metal contact is required between the segments of the housing. Do not over tighten the bolts.] J. Brazing 1. Cutting and cleaning of tubing shall be as specified for soldering operations. 2. Apply flux in accordance with recommendations of manufacturer of brazing filler material being used. Apply to outside of fitting and heat affected area of tubing. Avoid getting flux inside tube. Flux may be omitted when joining copper tubes to wrought copper fittings but is required for joining to cast (bronze) fittings. 3. Assemble joint by inserting tube into socket hard against stop and turning. 4. Heat parts to be joined beginning 1-in from edge of fitting, continuously moving the flame. When flux has become transparent, begin to heat the fitting at the base of the cup, still continuously moving the flame. When flux at fitting is quiet and transparent, maintain heat along joint by moving flame along axis between fitting and tubing. 5. Apply brazing material at point were tubing enters socket of fitting. Avoid putting flame on brazing material. Heated joint should melt brazing material and capillary action will draw material into the joint. When joint is properly made, a fillet of filler metal will be visible completely around the joint. Stop adding filler metal when fillet is formed. 6. After brazing material has solidified, clean off flux residue. Fittings must cool naturally. Quenching will not be allowed. 7. Any type of crack, pinhole, area of incomplete penetration, or similar defect will not be accepted. Penning for closing up defects will not be permitted. Plumbing - Piping Systems 1541 0-1 0 Cannon Road Lift Station Project No. 3583 P:\city of Carlsbad-1682A30679-Lifl Slation\7 Prq Docs\7.2 Final Docs\lOO % Specs\l54lO.doc K. Cleanouts 1. Install cleanouts as directed by applicable code, at end of each branch soil, waste and rainwater line where rainwater, waste and soil lines change direction, at the bottom of every riser either as a cleanout tee above floor or end cleanout in the horizontal below the floor. 3.02 FIELD TESTING A. Provide all air and water necessary for testing the piping systems as specified under this Section of the work. Provide all connections for testing under this Section. Remove all debris resulting from testing. Use the water in an efficient and economical manner. B. Provide all apparatus and all other supplies or materials which may be necessary for testing the systems and operating the apparatus during the period while tests of any kind are being made, or for carrying out the work of the Contract. C. The various piping systems shall be subjected to water, smoke, or air tests as noted and shall hold tight at pressures stated without extra pumping or water addition for the time intervals stated. D. All additional tests, methods or materials that may be required by the local ordinances and not specifically specified herein, shall be made as directed by the Engineer or the local inspection authority. E. Provide for all repeated tests as necessary to make system tight as required. F. Test soil, waste, drain, vent and rainwater piping as follows: 1. Test rough drainage of soil, waste, drain, vent and rainwater leader by plugging piping where it terminates in the building or where it leaves the building by filling each system completely with water to the outlets on the roof after all outlets in section have been plugged or capped, for at least 1 hour duration. 2. If it becomes necessary during the construction of the building to test a part of a section for any reason or to cover permanently any pipe before piping above the part or section has been completed, apply a water test to such part or section of the piping by maintaining a 10-fi head of water on the highest section of the piping and the test shall hold tight for 1 hour. G. Test water piping as follows: 1. Test all interior potable hot, cold and protected water piping to a water pressure of 150 psi to the lowest level and maintain this pressure without additional pumping for 2 hours. 3.03 CLEANING A. At the completion of the work, clean all piping, fixtures, equipment, apparatus and exposed trim for same included in this Section and, where required, polish ready for use. Cannon Road Lift Station Project No. 3583 P:\City of CarIsbad-16827U0679-Lift Station\7 Pro) Docs\7.2 Final Doa\lW X Specs\l54lO.doc Plumbing - Piping Systems 1541 0-1 1 B. Thoroughly disinfect the entire potable water distribution systems with a solution of not less than 50 ppm of available chlorine. Allow the disinfecting solution to remain in the system for a period of 3 hours after which time, open all valves and faucets and flush the system with clean water until the residual chlorine content is not greater than 0.2 ppm, unless otherwise directed. END OF SECTION Plumbing - Piping Systems 1541 0-1 2 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827\X1679-Lift Station\7 Proj Docs\7.2 Final Docs\lMI % Specs\15410.doc SECTION 15440 PLUMBING FIXTURES AND TRIM PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor and materials required and install Plumbing Fixtures and companion Fixture Trim complete as specified herein and as shown on the following: 1. Drawing Number P-1 Plumbing Legendschedule P-2 Plumbing Floor Plaaetails B. Furnish all labor and materials required and install the following Plumbing Fixtures and companion Fixture Trim. 1. Water closets 2. Lavatories 3. Floorsink 1.02 RELATED WORK A. Refer to Section 15400. 1.03 SUBMITTALS A. Submit shop drawings and product data, showing materials of construction and details of installation for all equipment under Division 15. 1. Specific items of Plumbing Fixtures and Trim as tabulated above under "Scope of Work". 2. For units that will be shipped exposed, provide a description of the protective packagmg that will be used during transit. 3. All submittals shall contain a statement that Sections 15400, 15440 and all other referenced Sections have been read and complied with. The certification statement shall be made by all of the following that are applicable; the Contractor, sub-contractor and the vendor. The statement shall be an individual statement for each party involved, and shall be included with every submittal and resubmittal. Cannon Road Lift Station Project No. 3583 P:\City of CarIsbad-16827W0679-Lift SlationV Prq DocsV.2 Final Dow\100 X Specs\l544O.doc Plumbing Fixtures and Trims 1 5440- I B. In general, corrections or comments or lack there of, made relative to submittals during review shall not relieve the Contractor from compliance with the requirements of the drawings and specifications. Submittals are for review of general conformance with the design concepts of the project and general compliance with the contract documents. The Contractor is responsible for the final design conforming and correlating all quantities and dimensions, selecting fabrication processes and techniques of construction, coordinating the work of all trades, and performing the work in a safe and satisfactory manner. 1.04 REFERENCE STANDARDS A. Refer to Section 15400. 1.05 QUALITY ASSURANCE A. All equipment of a given type included in this section shall be fbmished by or through a single manufacturer or as specified on the schedules B. Inspection by the Engineer's representative or failure to inspect shall not relieve the Contractor of responsibility to provide materials and perform the work in accordance with the documents. C. The Agency and Engineer reserve the right to sample and test any materials after delivery and to reject all components represented by a sample that fails to comply with the specified requirements. 1.06 DELIVERY, STORAGE AND HANDLING A. All materials shall be inspected for size, quality and quantity against approved shop drawings upon delivery. B. Delivery schedule of all equipment shall be coordinated with the Contractor. Equipment ready for shipment prior to the agreed on shipping date shall be stored without cost to the Agency by the manufacturer. C. All materials shall be suitably packed for shipment and long-term storage. Each package shall labeled to indicate the project and the contents of each package. Where applicable, equipment numbers shall be marked on the container. D. All equipment shipped that is exposed such as on a flat bed truck shall be protected during transit. The equipment shall be protected from moisture, road salt, dirt and stones or other materials thrown up from other vehicles. Electrical components shall be protected as above, but with special attention to moisture. The method of shipment protection shall be defined in the submittals. E. All materials shall be stored in a covered dry location off of the ground. When required to protect the materials they shall be stored in a temperature-controlled location. Plumbing Fixtures and Trims 15440-2 Project No. 3583 Cannon Road Lift Station P'\City of Carlsbad-16827U0679-Lifl StationV Pro] Doa\7.2 Final Docs\lOO % Specs\15440.doc PART 2 2.01 A. B. 2.02 A. B. C. D. 2.03 A. B. C. D. E. 2.04 A. B. C. PRODUCTS GENERAL The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired. Similar items of materials/equipment shall be the end products of one manufacturer in order to provide standardization for appearance, operation, maintenance, spare parts and manufacturer's service. MATERIALS Exposed fixture trim shall be brass chrome plated unless otherwise noted. Water Closet and Urinal supplies from wall shall be chrome plated at all locations. All fucture traps shall be brass chrome plated except for Water Closets, Urinals, Mop Sinks and as otherwise noted. All supply and waste nipples shall be fitted with one-piece set screw cast brass escutcheons finished in the same manner as pipes they serve. PLUMBING FIXTURES AND TRIM For the purpose of explanation and description only, plumbing fixtures and trim plate numbers are from the catalogs of Kohler Co. and Elkay Manufacturing Co. unless otherwise noted. Fixtures shall be as manufactured by the Kohler Co.; American Standard Inc.; Eljer Plumbingware; Elkay Manufacturing Co.; Just Manufacturing Co. or equal. Obtain written approval from the Engineer before purchasing all equipment and fixtures. Refer to Architectural and Structural details of partitions and floor finish before placing order for brackets and supports for fixtures. Height of rim of all fixtures from finish floor shall be as shown on the Architectural details. Chair carrier standards shall be of sufficient length to meet these requirements and handicapped fixture requirements. WATER CLOSET "C" (FLOOR OUTLET - HANDICAPPED - FLUSH VALVE) Water closet shall be vitreous china, floor outlet, elongated siphon jet bowl with 1-1/2-in top spud, Kohler K-4368-L Highcliff 1.6 gallon flush, or equal. Flush valve shall be Sloan-Royal 1 1 1 or equal, 1.6 gallon flush valve with vacuum breaker, 1-in screwdriver angle stop and chrome plated flush connection. Seat shall be white solid plastic, extended back, open front and less cover with check hinge as manufactured by Church; Bemis or equal. Cannon Road Lift Station Plumbing Fixtures and Trims Project No. 3583 15440-3 P:\City of Ca~sbad-16827\30679-L1~ StationV Pro] Docs\7 2 Final DOcs\100 K SpecsU5440 doc D. Closet flange shall be cast brass with brass closet bolts, washers, cap nuts and wax setting ring. E. Water closet shall have a height which provides a floor to top of seat height of between 17-in and 19-in. 2.05 LAVATORY (LAV) "Aff A. 20-in by 18-in vitreous china lavatory with 5-in back, rectangular basin, anti-splash rim, front overflow, two soap depressions and punched for concealed arm brackets, Kohler K-2032 Greenwich or equal. B. Self closing 0.5 gpm lavatory faucet, Symmons-Scot S-60-H or equal. C. Lavatory drain with perforated strainer, Kohler K-7717 or equal. D. Kohler K-7601, or equal, 3/8-in angle supply with loose key stops and annealed vertical tube, chrome plated with cast brass escutcheons. E. Kohler K-9010 or equal, 1 -1/2-in chrome plated cast brass P trap with cleanout plug. K-90 15 chrome plated brass waste nipple and cast brass chrome plated escutcheons. F. Concealed arm chair carrier with foot support of type suitable to meet building conditions as manufactured by J.R. Smith Co.; Zurn Industries, Inc.; Josam Manufacturing Co. or equal. 2.06 Floor Sink (FS) A. Floor sink shall be J.R. Smith 3 100-Y-03 or equal, 8-1/2-in by 8-1/2-in and 6" deep indirect waste receptor. B. Acid resisting enameled inside, painted outside with flashing flange, large loose sediment bucket with % grate. PART 3 EXECUTION 3.01 INSTALLATION A. Install all the items specified under PART 2 according to the applicable manufacturer's instructions and the details as shown on the Drawings. B. The Contractor shall not install any equipment or materials until the Agency and Engineer have approved all submittals. If any equipment or materials are installed prior to approval of the submittals, it shall be at the Contractor's risk. C. Install all fixtures and trim in accordance with the manufacturer's printed instructions and install rigd, plumb and true to line, with all parts in perfect working order. D. Installation of the plumbing fixtures and accessories shall meet the applicable requirements of the Physically Handicapped Code and shall be located as shown and detailed on the architectural drawings. Plumbing Fixtures and Trims 15440-4 Project No. 3583 Cannon Road Lift Station P\Clty of Carlsbad-1682A30679-Lift Station\7 Proj Docs\7.2 Final Docs\IOO % Specs\15440.doc 3.02 CLEANING A. Properly protect all plumbing fixtures and trim at all times and temporarily close all openings to prevent obstruction and damage. B. Maintain protective covers on all units until final clean-up time and, at that time, remove covers, clean and polish all fixtures and trim surfaces. C. At the completion of the work, clean, polish and make ready for use, all fixtures, equipment, apparatus and exposed trim included in this Section. END OF SECTION Cannon Road Lift Station Project No. 3583 P:\City of Ca~sbad-16827\X1679-L1fl Stalion\T Praj Docs\7 2 Final Docs\l 00 % Specs\l5440.dac Plumbing Fixtures and Trims 15440-5 Plumbing Fixtures and Trims 15440-6 This page intentionally left Blank. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827U0679-Lifl Slatim\7 Pro] Don\7.2 Final Docs\lOO % Specs\15440 doc SECTION 15450 PLUMBING EQUIPMENT PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor and materials required and install Plumbing Equipment complete as specified herein and as shown on the following: 1. Drawing Number P-1 Plumbing Legendschedule P-2 Plumbing Floor PladDetails B. Furnish all labor and materials required and install the following Plumbing Equipment. 1. Water Hammer Arresters 2. Electric Instantaneous Water Heaters 3. Emergency Shower and Eyemace Wash Combination 4. Water Meters 5. Reduced Pressure Zone Backflow Preventer (RPZ) 1.02 RELATED WORK A. Refer to Section 15400 1.03 SUBMITTALS A. Submit shop drawings and product data, showing materials of construction and details of installation for all equipment under division 15. 1. Specific items of plumbing equipment as tabulated above under "SCOPE OF WORK". 2. For units that will be shipped exposed, provide a description of the protective packaging that will be used during transit 3. All submittals shall contain a statement that Sections 15400, 15410, 15440 and all other referenced Sections have been read and complied with. The certification statement shall be made by all of the following that are applicable; the Contractor, sub-contractor and the vendor. The statement shall be an individual statement for each party involved, and shall be included with every submittal and resubmittal. Cannon Road Lift Station Project No. 3583 P\City of CafisbaU-16827\30679-L1ft Station\7 Pro] Docs\7.2 Final Dodl00 Oh Specs\15450.doc Plumbing Equipment 15450-1 B. Operation and Maintenance Data 1. Submit to the Engineer as provided in Division 0 1, Operating and Maintenance Manuals. The following information shall be considered a minimum. Where applicable, provide information required for specific pieces of equipment. a. Personnel familiar with the operation and maintenance of the specific information shall prepare manuals. b. Equipment shall be identified with the Engineers Equipment Numbers and Identification as shown in the Schedules and on the Drawings. c. Provide information in three ring binders. All sheets shall have reinforced punches. Tabbed dividers shall separate all sections. Drawings will be bound in the manual, or contained in envelopes bound into the manual. 2. Contents - Each volume shall contain the following minimum contents: a. Installation including instructions for unpaclung, installing, aligning, checking and testing. Foundation data, allowable piping loads, and electrical design shall be included. b. Operating Instructions to provide pre-operational checks, start up and shut down, and description of all control modes. Include emergency procedures for all fault conditions and actions to be taken for all alarms. Procedures for long-term storage shall be included. c. Maintenance shall include preventive, and corrective. Schedules for test of other functions are to be included. Provide a list of tools required to service the equipment. Trouble shooting instructions to include a trouble-shooting guide shall be included. 3. Spare Parts List a. Shop Drawing Data to include performance curves, data sheets, flow diagrams, wiring diagrams, and descriptive drawings. C. In general, corrections or comments or lack there of, made relative to submittals during review shall not relieve the Contractor from compliance with the requirements of the drawings and specifications. Submittals are for review of general conformance with the design concepts of the project and general compliance with the contract documents. The Contractor is responsible for the final design conforming and correlating all quantities and dimensions, selecting fabrication processes and techniques of construction, coordinating the work of all trades, and performing the work in a safe and satisfactory manner. 1.04 REFERENCE STANDARDS A. Refer to Section 15400. 1.05 QUALITY ASSURANCE A. All equipment of a given type included in this section shall be furnished by or through a single manufacturer or as specified on the schedules Plumbing Equipment 15450-2 Cannon Road Lift Station Project No. 3583 P:\Clty of Carlsbad-l6827\30679-Ltfl S!alion\7 Pro! Docs\72 Final DocS\lQo % Spw\15450.doc B. Inspection by the Engineer's representative or failure to inspect shall not relieve the Contractor of responsibility to provide materials and perform the work in accordance with the documents. C. The Agency and Engmeer reserve the right to sample and test any materials after delivery and to reject all components represented by a sample that fails to comply with the specified requirements. D. All rotating parts of equipment shall be statically and dynamically balanced at the factory. 1.06 DELIVERY, STORAGE AND HANDLING A. All materials shall be inspected for size, quality and quantity against approved shop drawings upon delivery. B. Delivery schedule of all equipment shall be coordinated with the Contractor. Equipment ready for shipment prior to the agreed on shipping date shall be stored without cost to the Agency by the manufacturer. C. All materials shall be suitably packed for shipment and long-term storage. Each package shall be labeled to indicate the project and the contents of each package. Where applicable, equipment numbers shall be marked on the container. D. All equipment shipped that is exposed such as on a flat bed truck shall be protected during transit. The equipment shall be protected from moisture, road salt, dirt and stones or other materials thrown up from other vehicles. Electrical components shall be protected as above, but with special attention to moisture. The method of shipment protection shall be defined in the submittals. E. Instruction for the servicing and startup of equipment in long-term or prolonged storage shall accompany each item. F. All materials shall be stored in a covered dry location off of the ground. When required to protect the materials they shall be stored in a temperature-controlled location. PART 2 PRODUCTS 2.0 1 GENERAL A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired. B. Similar items of materiaWequipment shall be the end products of one manufacturer in order to provide standardization for, appearance, operation, maintenance, spare parts and manufacturer's service. C. Attention is particularly called to the fact that written approval of all specified equipment proposed for purchase shall be received from the Engineer before purchase of any equipment or components of the equipment. Cannon Road Lift Station Project No. 3583 P:\City of CarIsbad-16827\30679-Lifl Station\7 Proj Docs\7.2 Flnal Docs\100 % Specs\15450.doc Plumbing Equipment 15450-3 2.02 A. B. 2.03 A. B. 2.04 2.05 A. B. C. D. ELECTRICAL EQUIPMENT Electrical equipment, which is furnished under this Section, shall meet the requirements specified in Division 16, except that any fire code requirements shall supersede those of Division 16: 1. Disconnect switches, motor starters and combination motor starters (starters with disconnecting means and short circuit protection) shall be as specified in Division 16. 2. Cord-connected controls for hazardous areas shall be provided with intrinsically safe relays, which shall be as specified in Division 16. 3. Raceways, boxes, fittings and supports shall be as specified in Division 16. 4. Wires and cables shall be as specified in Division 16. Electrical enclosures, panels and components shall be suitable for the environment and electrical classification for the space they are located in. The type of enclosure for the various spaces shall be as specified in Division 16. Refer to the electrical drawings for the space classifications. WATER HAMMER ARRESTERS Water hammer arresters shall be sized in accordance with manufacturer’s recommendations. Arresters shall be stainless steel bellows type as manufactured by J.R. Smith Co.; Zurn Industries Inc. or equal. ELECTRIC INSTANTANEOUS WATER HEATER (WH-1) 1. WH-1 shall be 0.75 gpm with 50 degree F rise; the heating element shall be 5500 Watts, 240 Volts, 23 Amps. 2. Unit material shall be ABS UL rated 94Vo; glass reinforced NORYL heater body and Ni Chrome element; UL Listed. 3. Unit shall be Model No. EX55 by Eemax or equal. EMERGENCY SHOWEREYE WASH UNIT (ESEWU) Furnish and install a combination emergency shower and eye wash unit where shown on the Drawings as ESEWU. Units shall have a 10-in cycolac plastic shower head and eye wash bowl, stay open ball valves and hand and foot control for eye wash. Units shall be complete with automatic flow control devices as required to limit emergency shower flow to 20 gpm and eye wash flow to 3 gpm. An emergency identification sign shall be included with each unit. Plumbing Equipment 154504 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-l6827\30679-Lift StabOn\7 Proj Docs\7.2 Final Docs\loO % Sped1 545O.doc E. F. 2.06 A. B. 2.07 A. B. C. D. E. PART 3 3.01 A. Units shall be one of the following with modifications as required to meet the requirements specified: 1. Haws - Model No. 8320 2. Guardian - Model No. G-1902-P-HFC 3. Western - Model No. 920 1 4. Bradley - Model No. S 19-3 1 OAC (Substitute yellow impact-resistant bowl) Unit shall be modified to include a 8-fl hand held recoil hose assembly with bracket for spray head and equal to: 1. Haws - Model 8906 2. Guardian - Model G- 17 16 3. Bradley - Model S 19-600 WATER METERS Water meter shall be purchased through the City and installed by the City. Meter shall be of the size shown on the Drawings and installed per district standard and specifications. REDUCED PRESSURE ZONE BACKFLOW PREVENTER (RPZ) Shall be of the size shown on the Drawings and body shall be constructed of bronze for sizes less than 2-1/2-in and epoxy coated cast iron for sizes 2-1/2-in and larger. Each unit shall be complete with two companion OS&Y gate valves for size 2-1/2”-in and larger and ball valve for size 2” and smeller. Unit shall be equipped with test connections. Valves shall be of similar material as that of the backflow device body, including epoxy coating. Unit shall have replaceable bronze seats and captured springs. Unit shall be supported on galvanized steel floor stanchions with floor flange secured to floor. Unit shall be of the manufacture that meets the approval of the authority having jurisdiction. Submittal for approval shall be accompanied by the City “acceptable device list” or alternately by their written approval. Acceptable manufacturers shall include Watts 909; Febco 825Y; Wilkins 975XL or equal. EXECUTION INSTALLATION Install all the items specified under PART 2 according to the applicable manufacturer’s instructions and the details shown on the Drawings. Cannon Road Lift Station Project No. 3583 P \Clly of Car(sbad-I6827\30679LiH Slaiion\7 Pro1 OOc5\7 2 Final Do~s\100 X Specs\15450 doc Plumbing Equipment 15450-5 B. The Contractor shall not install any equipment or materials until the Agency and Engineer have approved all submittals. If any equipment or materials are installed prior to approval of the submittals, it shall be at the Contractor's risk. C. Install water hammer arresters on all potable water lines, at top of all risers and immediately adjacent to all quick closing mechanical and electrical operating valves and on all flush valve headers. 3.02 CLEANING A. Properly protect all materials and equipment at all times to prevent obstruction and damage. Maintain protective covers on all units until final clean-up time. B. At the completion of the work, all equipment and exposed trim for the same included in this Section shall be thoroughly cleaned and, where required, polished ready for use. END OF SECTION Plumbing Equipment 15450-6 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-l6827\30674Ltfl Station\7 hoj Docs\7.2 Final Docs\100 % Spea\15450.doc SECTION 15500 HVAC GENERAL PROVISIONS PART 1 GENERAL 1.01 SCOPE OF WORK A. This Section and Drawings cover the requirements of the WAC Work to be performed and shall not void any of the requirements specified under the General Conditions or General Requirements. B. The areas where work is to be accomplished are specified and shown in the following: 1. Specification Sections 15500 HVAC - GENERAL PROVISIONS 2. Drawing Number H- 1 Legendschedule H-2 HVAC Floor Plan/Details H-3 H-4 Elevation PlaniDetails Odor Control Units Schematic Piping C. The requirements specified herein shall be modified only if specified otherwise for particular application in other Divisions. D. This HVAC specification is incomplete without the information contained on the Drawings and the Equipment Schedules specified on the drawing. E. Work included under the "Scope of Work" of this HVAC Section includes all labor, material, equipment, tools and services necessary to furnish, deliver, unload, install, test and place in satisfactory operation, the equipment, services and systems as called for under the HVAC Section including any incidental work not shown, or not specified but which can reasonably be inferred as belonging to the various system and necessary in good practice to provide complete and fully operational systems. F. The following work descriptions are not intended to in any way limit the above broad statement, but are intended as a more specific mention of the most important items included therein. The Contractor shall provide the materials and installation of the ventilation system for the pump station which include an electrical room, generator room, restroom, chemical storage room, odor control room, and connecting piping for the odor control units. G. The functions of the HVAC systems are as follows: Heat Removal Ventilation Odor Containment Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-16827\30679-L1R Stal1on\7 Proj Docs\7.2 Final Docs\100 Oh Specs\15500.doc HVAC General Provisions 15500-1 H. I. 1.02 A. B. C. D. E. F. G. H. I. J. 1.03 A. Provide equipment of the type, size, capacity and arrangement as shown on the Drawings and as scheduled. Equipment shall consist of the particular components listed in the schedules in addition to those components normally required for the type of unit. The order of component assembly will be as stated in the schedule. Particular attention must be paid to the remarks and notes in the schedules and on the Drawings. All ductwork, piping, and equipment shown on the Drawings is intended to be approximately correct to scale, but figured dimensions and detailed drawings of the actual equipment furnished shall be followed in every case. The Drawings shall be taken in a sense as diagrammatic. Size of ductwork and piping are shown, but it is not the intent to show every offset or fitting, nor every hanger or support, or structural difficulty that may be encountered, To carry out the intent and purpose of the drawings all necessary parts to make a complete working system ready for use shall be hrnished without extra charge. The Contractor shall be responsible to coordinate the system installation and routing with the work of all trades. RELATED WORK Cutting and patching is included in Division 1, except for items specified herein. Temporary heating, electric power and lighting is included in Division 1. Trenching, excavation and backfill is included in Division 2, except for items specified herein. Concrete work is included in Division 3, except for required HVAC anchor bolts, sleeves and templates which shall be furnished under this Section. Structural steel and miscellaneous metal is included in Division 5, except for supplementary steel required for HVAC hangers, equipment supports, anchors and guides, which shall be furnished under this Section. Flashing and counterflashing is included in Division 7, except for items specified herein. Painting is included in Division 9, except for factory finished HVAC equipment, HVAC shop painting and HVAC identification labeling. Exterior louvers are included in Division 10. Plumbing work is included under the Plumbing Section (Division) except for water and drain closing in connections to HVAC equipment. Electrical field wiring is included in Division 16. SUBMITTALS Submit shop drawings and product data for the following: 1. Catalog cuts and data sheets for all equipment under division 15. HVAC General Provisions 15500-2 Project No. 3583 Cannon Road Lift Station P:\City of Carkbad-16827\30679-Lifl SIationV Prq Dccs\7.2 Final DOcs\lOO % Specs\155W doc 2. Submit all data and the fan schedules. The submittal shall include fan data sheets with a description of the proposed fan, fan size, type, arrangement, materials of construction, weight, motor horsepower, motor type, power supply, and frame size. Provide catalog data and selections for vibration isolators, include materials of construction. For belt drive equipment; provide drive data indicating the sheave sizes, belts size, number and length. Each submittal shall include pertinent equipment dimensional data, fan performance (operating data 0 information, and a performance curve showing the fan operating point and range. Minimum curve size shall be 8 inches by 6 inches. Faxed copies of curves are not acceptable. A list of accessories to be furnished shall be included on each submittal. Copies of operating and maintenance manuals shall be submitted. Significant dimensional differences between the specified equipment and the proposed equipment shall be noted on the equipment submittal. The Contractor shall provide data to show the dimensionally different equipment will fit within the space and still provide suitable clearance. Where corrosion resistance is required, provide conformation of material suitability for the specified service. 3. Detailed equipment, ductwork and piping layout drawings; minimum scale %-in = 1 -ft-0-in for interior systems and equipment, dimension clear service spaces for motors and dnves, filter, coils and spacer section access doors, and ductwork access panels and doors. (Site layout drawings and roof plans showing HVAC equipment and systems may be prepared and submitted at scales smaller than %-in = 1-ft-0-in, subject to Engineer's prior approval.) 4. Standard shop and field installation details for transitions, elbows, takeoffs, discharge nozzles, turning vanes, access panels and doors, volume control and splitter dampers and extractors. 5. Piping and appurtenances, materials and joining methods. Pipe hanger materials and methods. 6. Ductwork materials, joining methods, reinforcing and material gauges. Where options are allowed by SMACNA, the proposed option shall be clearly defined. Indicate proposed materials and methods for ductwork and equipment hangers. 7. Prepare dimensional comparisons between proposed equipment and scheduled equipment when the proposed equipment is dimensionally larger than that scheduled. Do not propose dimensionally larger equipment from an alternate manufacturer for installation in confined areas, or when the installation of alternate equipment will result in reduction of service access below that recommended by the manufacturer. 8. Prepare layouts showing size, arrangement, and routing of field fabricated refrigerant piping for split-systems and air handling units with remote condensers. Include a letter from the AC system manufacturer indicating their approval of the proposed sizing and routing. 9. For units that will be shipped exposed, provide a description of the protective packaging that will be used during transit. 10. All submittals shall contain a statement that Section 15500 and all other referenced Sections have been read and complied with. The certification statement shall be made by all of the following that are applicable; the Contractor, sub-contractor and the vendor. The statement shall be an individual statement for each party involved, and shall be included with every submittal and resubmittal. 11. Submit air system testing, adjusting and balancing reports for review and approval. Cannon Road Lift Station Project No. 3583 P:\Cily of Carlsbad-l6827\30679-!Aft Slalion\7 Prq Docs\7.2 Final Dw\100 % Specs\15500.doc HVAC General Provisions 15500-3 12. Operation and Maintenance Data a. Submit to the Engineer as provided in Section 01 730, Operating and Maintenance Manuals. The following information shall be considered a minimum. Where applicable, provide information required for specific pieces of equipment. 1) Personnel familiar with the operation and maintenance of the specific information shall prepare manuals. 2) Equipment shall be identified with the Engineers Equipment Numbers and Identification as shown in the Schedules and on the Drawings. 3) Provide information in three ring binders. All sheets shall have reinforced punches. Tabbed dividers shall separate all sections. Drawings will be bound in the manual, or contained in envelopes bound into the manual. b. Contents - Each volume shall contain the following minimum contents: 1) Installation including instructions for unpacking, installing, aligning, checking and testing. Foundation data, allowable piping loads, and electrical design shall be included. 2) Operating Instructions to provide pre-operational checks, start up and shut down, and description of all control modes. Include emergency procedures for all fault conditions and actions to be taken for all alarms. Procedures for long-term storage shall be included. 3) Maintenance shall include preventive, and corrective. Schedules for test of other functions are to be included. Provide a list of tools required to service the equipment. Trouble shooting instructions to include a trouble-shooting guide shall be included. 1.04 REFERENCE STANDARDS A. These standards shall be considered as minimum requirements. This is a general list and not all standards listed are necessarily referenced elsewhere in this Section. Specific requirements of this Section and/or Drawings shall have precedence. In case of conflict between published requirements, the Engineer shall determine which is to be followed. B. Abbreviation and the title of Federal, State and industry standards, technical societies, associations and institutes and other organizations which may be used are as follows: 1. 2. 3. 4. 5. 6. 7. 8. Associated Air Balance Council (AABC) American Conference of Governmental Industrial Hygienists (ACGIH) American Bearing Manufacturers Association (ABMA) Air Movement and Control Association (AMCA) American National Standards Institute (ANSI) American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) American Society of Mechanical Engineers (ASME) American Society for Testing and Materials (ASTM) HVAC General Provisions 15500-4 Project No. 3583 Cannon Road Lift Station P\City of Carlsbad-1682A30679-bfl StationV Prq Do~s\7.2 Final Docs\100 I Specs\15500.d% 9. Institute of Electrical and Electronic Engineers (IEEE) 10. National Environmental Balancing Bureau (NEBB) 1 1. National Electrical Code (NEC) 12. National Electrical Manufacturers Association (NEMA) 13. National Fire Protection Association (NFPA) 14. Occupational Safety and Health Administration (OSHA) 15. Sheet Metal and Air Conditioning Contractors National Association (SMACNA) 16. Underwriters Laboratories (UL) C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. 1.05 QUALITY ASSURANCE A. Provide single source supplier/installer responsibility for the following systems or services: 1. Testing and Balancing 2. Power Exhaust Fans B. Provide single source supplier/installer responsibility for systems where specified in other related Sections. C. The insulation materials to be furnished under this section shall be essentially the standard products of manufactures regularly engaged in the manufacture of insulation systems. D. Several manufacturers are indicated as acceptable for each type of insulation in these specifications. The insulation sub-contractor shall be responsible for determining that all insulation supplied for the project is suitable for installation in the spaces indicated. The insulation sub-contractor shall also insure that all materials used are compatible and in compliance with applicable codes and standards. E. All equipment of a given type included in this section shall be furnished by or through a single manufacturer or as specified on the schedules F. Inspection by the Engineer’s representative or failure to inspect shall not relieve the Contractor of responsibility to provide materials and perform the work in accordance with the documents. G. The Agency and Engineer reserve the right to sample and test any materials after delivery and to reject all components represented by a sample that fails to comply with the specified requirements. H. An authorized representative of the manufacturer shall perform the initial startup of the equipment. The Agency and Engineer shall witness startup. The use of local sales representatives to perform this work is not acceptable, unless the manufacturer provides documented evidence that the sales representative has been specifically trained for this work. I. All rotating parts of equipment shall be statically and dynamically balanced at the factory. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827U0679-Llft Station\7 Prq Docs\7.2 Final Do~s\100 % Specs\l55Ml.doc HVAC General Provisions 15500-5 1.06 DELIVERY, STORAGE AND HANDLING A. All materials shall be inspected for size, quality and quantity against approved shop drawings upon delivery. B. Delivery schedule of all equipment shall be coordinated with the Contractor. Equipment ready for shipment prior to the agreed on shipping date shall be stored without cost to The Agency by the manufacturer. C. All materials shall be suitably packed for shipment and long-term storage. Each package shall labeled to indicate the project and the contents of each package. Where applicable, equipment numbers shall be marked on the container. D. All equipment shipped that is exposed such as on a flat bed truck shall be protected during transit. The equipment shall be protected from moisture, road salt, dirt and stones or other materials thrown up from other vehicles. Electrical components shall be protected as above, but with special attention to moisture. The method of shipment protection shall be defined in the submittals. E. Instruction for the servicing and startup of equipment in long-term or prolonged storage shall accompany each item. F. All materials shall be stored in a covered dry location off of the ground. When required to protect the materials they shall be stored in a temperature-controlled location. 1.07 COORDINATION A. The Drawings indicate the extent and general arrangement of the systems. If any departures from the drawings or specifications are deemed necessary, details of such departures and the reasons therefore shall be submitted as soon as practical for review. No such departures shall be made without the prior written concurrence of the Engineer. B. The Contractor shall coordinate the location and placement of all concrete inserts and welding attachments with the structural engineer. C. The Contractor shall assume full responsibility for coordination of the HVAC systems, including; scheduling, and verification that all structures, ducts, piping and the mounting of equipment are compatible. 1.08 WARRANTY A. In the event that the equipment or components fail to perform satisfactorily at any time within the Defects Liability Period, the Contractor shall replace it with one capable of operating as specified, and shall comply with the requirements in Division 1. The Contractor shall be responsible for all cost incurred in furnishing and installing the replacement equipment. HVAC General Provisions 15500-6 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827U0670Lifl StationV Pro) Docs\7.2 Final Docs\100 % SpeCs\l5500.doC 1.09 DEFINITIONS A. Particular terminology used under this Section is defined as follows: 1. Traffic Level and Personnel Level - Areas, including process areas, equipment rooms, boiler rooms and other areas where insulation may be damaged by normal activity and local personnel traffic. Area extends to 8-Et above floor, walkways, platforms and stairs, and horizontally 3-ft beyond the edge of walkways, platforms, and stairs. 2. Exposed Piping and Ductwork - Piping and ductwork visible from the floor level and includes all piping and ductwork in equipment rooms, boiler rooms, etc. 3. Concealed Piping and Ductwork - Piping and ductwork not visible from the floor level and includes piping and ductwork above hung ceilings and in shaftways. 4. Supply Air Ductwork - Ductwork carrying air from a fan or air handling unit to the space or spaces to which it will be introduced. This air may have been heated or cooled or in the case of ventilation system the air would be neither heated nor cooled. Supply air ductwork extends from the fan or air handling unit to the registers, grills or diffusers at the end of the ductwork. 5. Rekrn Air Ductwork - Ductwork carrying air from the space it was supplied to back to a fan or air handling unit. Return air ductwork extends from the regsters or grills at the end of the ductwork to the air handling unit or connection with an outdoor air intake duct. 6. Exhaust Air Ductwork - Ductwork carrying air from a space to a fan and then to be discharged to the outdoors. Exhaust air ductwork extends fiom the registers of grills at the end of the ductwork to the fan. From the fan exhaust ductwork extends to the discharge point, exhaust air damper, or exhaust air plenum, whichever comes first. 7. Ventilated Spaces - Areas supplied with outdoor air on a continuous or intermittent basis. The outdoor air may be heated and/or cooled or untreated. 8. Indoor Piping - Piping within a building that is not exposed to the weather. 9. Outdoor Piping - Piping that is not within a building and which is exposed to the weather. 10. Indoor Ductwork - Ductwork within a building that is not exposed to the weather. 1 1. Outdoor Ductwork - Ductwork that is not within a building and is exposed to the weather. 12. Flues/Stacks/Breeching - Ductwork carrying products of combustion to atmosphere. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827K30679-Ufl StaIionV Proj Docs\7.2 Final Docs\100 % Specs\l5sO0.doc HVAC General Provisions 15500-7 PART 2 PRODUCTS 2.01 ELECTRICAL EQUIPMENT A. Electric Motors 1. The motor manufacturer shall confirm that motors used to power equipment are provided with bearings that will provide a bearing life equal to the dnven equipment or better. Confirmation shall be included with shop drawing submittal. 2. Motors will be selected to be non-overloading over the entire operating range of the equipment. A safety factor of 25 percent will be added to all motors up to and including 50 horsepower. A safety factor of 15 percent will be added to all motors over 50 horsepower. Motors indicated on the schedules are to be considered a minimum. This sizing is not to limit compliance with the above requirements 3. Motors located in Class 1 Division 2 areas shall be TEFC with non-sparking contacts. B. Electrical Equipment 1. Electrical equipment which is furnished under this Section shall meet the requirements specified in Division 16: a. Disconnect switches, motor starters and combination motor starters (starters with disconnecting means and short circuit protection) shall be as specified in Division 16. b. Cord-connected controls for hazardous areas shall be provided with intrinsically safe relays, which shall be as specified in Division 16. c. Raceways, boxes, fittings and supports shall be as specified in Division 16. d. Wires and cables shall be as specified in Division 16. C. Electrical enclosures and panels to include automatic temperature control panels and components shall be suitable for the environment and electrical classification for the space they are located in. The type of enclosure for the various spaces shall be as specified in Division 16. Refer to the electrical drawings for the space classifications. D. Where noted in the HVAC equipment schedules, or when shown on the Drawings, provide fan speed control switches and integral unit thermostats. 2.02 SEISMIC RESTRAINTS A. Seismic restraints shall be provided for all piping and equipment as required by applicable codes. All seismic criteria and design shall comply with latest SMACNA SEISMIC RESTRAINT GUIDE. B. Materials of construction for seismic supports shall be the same as those specified for equipment supports and hangers, and duct and pipe hangers. All bolts shall be stainless steel regardless of the specified support material. i HVAC General Provisions 15500-8 Cannon Road Lift Station Project No. 3583 P\City of Carlsbad-1682A30679-Lift Station\7 Pro) Docs\7.2 Final Don\100 oh Spea\15500.doc C. D. E. F. 2.03 A. B. C. 2.04 A. Where the seismic criteria and size of piping and ductwork are within the limits of the latest edition of the SMACNA Seismic Restraint Manual, the restraints as defined in the manual can be used. Restraints shall be selected from Tables for Seismic Hazard Class Level SHL A. The Contractor shall retain a professional engineer to provide seismic loadings and designs of seismic restraints. This will include but not be limited to the following: 1. Provide seismic loadings to the vibration isolation supplier based on actual equipment being used to allow the proper selection of vibration isolators. 2. Provide sizing of bolts for attachment of non-vibrating equipment to the structure based on the actual equipment being used. 3. Provide design of required additional bracing for equipment when vibration isolators or bolts are not adequate to withstand seismic forces. 4. Provide design of bracing for all suspending equipment. Provide design of bracing for all piping and ductwork that exceeds the limitations of the SMACNA Seismic Restraint Manual. 1. Provide design of bracing for all piping and ductwork. 2. Where piping or ductwork are subject to thermal expansion, the loads caused by the thermal expansion and contraction shall be included in the design of the restraint bracing. Signed and sealed calculations and details shall be submitted for record purposes. FLAME AND SMOKE RATINGS All materials, including adhesives, surface coatings, sealers, assemblies of several materials, insulation, jacketing, finish, HVAC supply air, return air and exhaust air but excluding odor exhaust, etc., shall have flame spread ratings not over 25 (fire resistive), and smoke development ratings not over 50 and fuel contributed rating not over 50, as established by tests conducted in accordance with the Federal Standard 00136B, National Bureau of Standards Radiant Energy Fire Test and the National Fire Code of the NFPA. For odor exhaust duct, see Section 02623 These requirements apply to all circumstances whether the materials are field applied or applied by a manufacturer in hisher shop, or elsewhere, prior to delivery to the project. V-BELT DRIVES V-belt drives shall consist of the driver and driven sheaves and one or multiple matched V-belts. Select V-belt drives with belt horsepower ratings equal to or greater than 1.5 times the driving motor nameplate horsepower. Provide sheaves with steel, cast iron, or malleable iron split taper bushings and keyways on driven shafts of Y4-in and larger diameter.] Cannon Road Lift Station Project No. 3583 HVAC General Provisions 15500-9 P:\City of Carisbad-16827UO679-Lifl Station\7 Proj Docs\7.2 Final Docs\100 % ~pecs\l5500.doc NOISE CRITERIA 2.05 A. B. The selection of pumps, fans, air handling equipment, air conditioners, heating ventilating and air conditioning machinery and mechanical equipment and the installation of the system components such as duct work and piping shall be such as not to exceed to maximum permissible noise for non- equipment spaces as defined in Table 2, Design Guidelines for HVAC System Noise in Unoccupied Spaces contained in the 1995 edition of the ASHRAE Application Handbook. Under no conditions shall the noise created by equipment exceed the levels of permissible noise exposures of occupational areas as established by the OSHA and other Federal, State and local safety and health standards, codes and ordinances. The following sound criteria shall be met for all of the following listed equipment. Data shall be the sound pressure level. C. D. 2.06 A. B. 1. The equipment supplier shal1,provide actual data for the equipment submitted. If the space does not meet the required criteria, and the noise level of the equipment is found to be the cause, the equipment supplier shall be responsible for the modifications required to correct the condition. Bearings for all equipment in the schedule below shall have heavy-duty grease lubricated ball or roller bearings. Bearings shall have ample thrust provision to prevent end play during the normal life of the bearing. Unless specifically noted otherwise, all fans and pumps shall have bearings for both the equipment and motors with the following ABMA L-10 life. 1. Fans over 3000 cfm - 40,000 hours. 2. Pumps over 500 cfm - 40,000 hours. 3. Continuous duty fans or pumps with motors over 25 horse power 100,000 hours. 4. All fans or pumps with motors over 50 horse power 100,000 hours. For systems with bearings requiring L-10 lives of 100,000 hours or greater, the equipment supplier shall provide calculations for both the equipment bearings and the motor bearings to confirm the bearing selections. For belt drives, the calculations shall include the effect of the sheave size, number of belts, the sheave location on the shaft, and the location of the motor to the driven sheave. BEARINGS General - Furnish equipment bearings suitable for the intended equipment service.' Furnish bearings designed to carry both thrust and radial loads for equipment designed for all angle operation. Provide extended lube lines with pressure relief equipped grease fittings for all bearings which are not readily accessible from outside the equipment. HVAC General Provisions 15500-1 0 Project No. 3583 Cannon Road Lift Station P:\City ol Carisbad-16827\30679-Lifl Station\? Pro] Docs\?.2 Final Docs\100 46 Specs\15500 doc C. BeIt driven fans, shall be equipped with self aligning single row ball bearings, double row tapered or spherical roller bearings. 1. Furnish bearings to give 100,000 average life hours (ABMA-LSO) for the following services: a. b. Intermittent duty. Fan impellers greater than 10-in diameter. 2. Furnish 200,000 average life hours bearings for the following services: a. Continuous duty applications. b. Class 111 and Class IV construction. D. Provide seals for bearings installed in airstreams, exposed outdoors, and for applications in corrosive or dusty atmosphere. E. Provide bearings suitable for high temperature service where heat fan construction is required. 2.07 HANGERS, SUPPORTS AND ANCHORS A. General 1. Furnish supports, hangers and other devices necessary to support firmly and substantially the piping, equipment and ductwork described in this Section. Piping and duct support systems shall include restraints as required by the applicable building codes to withstand seismic loading. Design shall be provided by a professional engineer hired by the Contractor as specified in other sections of the specifications. 2. All equipment shall be provided with lugs or brackets to allow the equipment to be firmly fastened to the structure. The lugs and brackets shall be sized to withstand the expected seismic loads for the area and type of application. Location of the attachments shall be based on the equipment being hung or base mounted as shown on the Drawings and the schedules. 3. Furnish and install all metalwork in accordance with Division 5 requirements. 4. Provide galvanized steel hanger rods, hangers, supplementary steel, anchors and guides in areas classified as corrosive, wet, and in outdoor exposed applications. 5. Where C-clamp type hangers are used, furnish with a retainer strap. 6. Hangers shall not be supported from roof decking or bulb tees. Where required, provide supplemental steel to span between the building structure. B. Piping 1. All piping supported at a maximum of IO-ft-0-in intervals. Hangers or rings, sized to fit outside the insulation. 2. All piping 2-in diameter and smaller supported by pipe rings or bands with one 3/8-in adjustable steel rod hanger and one concrete insert. Cannon Road Lift Station Project No. 3583 P\City of Carlsbad-l6627\30679-Lift Statton\7 Pmj Docs17.2 Final Docs\lOO % Specs\15500.doc HVAC General Provisions 15500-1 1 3. Anchor piping mains where indicated or wherever necessary to limit pipe expansion and to prevent vibration. Furnish anchors constructed of steel securely bolted to masonry and welded to pipes. C. Ductwork 1. Rectangular, Round and Flat-Oval Ductwork - Spacing and size of hangers shall be as called for in the SMACNA standards, except as detailed below: a. Rectangular ductwork 48-in wide and larger shall be supported by adjustable threaded rod. b. Round ductwork 37-in and larger shall be supported by two adjustable threaded rods. c. The following methods of hanger attachment to the building structure are NOT allowed. The numbers and letters refer to hanger methods shown in Figure 4-1,4-2 and 4-3 of the 1985 edition of the HVAC Duct Construction Standards Metal and Flexible as published by SMACNA. "T" wrap around straps of open web joist. "W" bent over band on open web joist. "14" Friction clamps "17" Bent wire in metal deck. 2. Perforated band iron or wire for supporting ducts shall not be permitted. 3. Support flexible duct by band hangers, 1-in wide minimum, attached so as not to crush the ductwork. The use of wire to hang flexible ductwork shall not be permitted. 4. Duct supports at flexible connections shall be adjustable. D. Design of hangers shall include the effect of all loads applied to the duct as well as the load of the duct. These loads include, but are not limited to wind, snow and internal dirt or liquid buildup. E. Odor exhaust piping shall be high density polyethylene schedule 40 piping per Section 02623. F. Vertical stack through roof shall be 3 16 stainless steel sheet metal schedule 10 per plan. G. Engine exhaust shall be schedule 10 black steel. Flexible connection shall be 3 16 stainless steel welded flange and bolt. HVAC General Provisions 1 5500- 1 2 Cannon Road Lift Station Project No. 3583 P:\City d Carlsbad-16827U0679-Lifl Sta!ion\7 Pro] Docs\7.2 Final Docs\100 % Specs\l5500.dOC 2.08 PAINTING AND COATINGS A. Unless otherwise specified, all machinery and factory finished equipment such as fans and other items of manufacture shall be hot dipped galvanized or will have a factory applied finish, color as standard with the manufacturer. Components fabricated from stainless steel do not require a coating finish unless otherwise specified. All tanks, supporting steel, hangers, rods and all other uncoated or non galvanized steel other than standard piping and fittings shall have a shop coat consisting of a suitable primer and finish coat. If not factory applied, the prime coat shall be as specified in Division 9. All items not factory or shop primed prior to installation shall be suitably cleaned of rust and mill scale by wire brushing, sanding, or other means and prime painted, immediately after installation. B. The Contractor shall be responsible for the repair of all defects, blemishes, holidays and the like apparent in manufactures coatings and shall ensure that the materials used for such repair shall match and be compatible with the manufacturer’s standard color, coatings and practices. Surfaces to be repaired or recoated are to be prepared as recommended by the paint or coating supplier. Care shall be taken not to paint over name plates. C. Furnish touch up paint for the various types of equipment hmished and deliver unopened paint to The Agency at completion of the project. The amount of touch-up paint supplied shall be sufficient to cover 15 percent of the applicable painted surfaces or one pint, whichever is greater. D. Where specified, or called for on the following schedule, special corrosion resistadprotective coatings shall be provided. Whenever a protective coating is specified, the equipment shall be coated both inside and out. Whenever necessary to provide full coverage of the equipment, the equipment shall be completely disassembled to allow proper preparation and coating application. Any component that would block the coating process shall be removed. Equipment provided with gaskets or liners shall be coated before the application of the gasketing or liner. The equipment Vendor shall test rotating equipment after coating to confirm dynamic balance. If work needs to be done to correct the equipment balance, the integrity of the coating must be corrected after such work. E. All items to be provided with a protective coating shall have the following data on the coating included with the unit submittal. Submittal shall include vendor data sheets on the specific coating being used, corrosion resistance data sheets, detailed application data sheets to include surface preparation procedures. For baked coatings submit a letter from the coating manufacturer, that the company doing the actual coating operation is an approved coating company. Any holidays, runs, sags, blisters, or inclusions in the coating are unacceptable and will be corrected. With the approval of the engineer, small areas no more than 4-in by 4-in may be corrected in the field. Larger faults shall be returned to the coater to be repaired. The faulty material shall be removed by sanding and in the case of blisters, the edges feathered. The material used for recoating shall be manufactured by the same manufacturer as the original coating and shall be suitable for field repairs. The touch up material shall have the same corrosion resistance as the original coating, and if the original coating required an ultraviolet protection, the same protection will be provided as part of the repair. The final mil thickness of the repaired coating shall be equal to the origmally specified thickness. Where baked coatings have been damaged, the repair shall be made with heat applied to the repaired surface to cure the coating. After curing a solvent test as recommended by the manufacturer shall be used to confirm that the coating is cured. F. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827U0679-Lifl Station\7 Pro] Docs\7.2 Fmal Doa\lM) ?A Specs\15500.doc HVAC General Provisions 15500-1 3 G. 2.09 A. B. 2.10 A. The coating manufacturer shall supply direct to the engineer, a set of coupons showing the final appearance of the cured coatings. Any coating that does not match the supplied coupons will be rejected. TESTING, ADJUSTING AND BALANCING Furnish the services of an AAl3C certified agency for the testing, adjusting and balancing of all HVAC air systems installed under this Section. The testing, adjusting and balancing agency shall be independent of all suppliers, installers and contractors on the project. FANS General 1. 2. 3. 4. 5. 6. 7. 8. 9. Fans shall be factory assembled, complete with fan wheel, fan housing or cabinet, bearings, drives, drive guard, motor, motor base, unit base, vibration isolators and bird screens, unless otherwise specified. All fans shall be statically and dynamically balanced before shipment. Where belt drives are used, motors shall be provided with adjustable slide bases with jack screws. All fans shall be AMCA rated for sound and air performance per AMCA 210-85 and 330-86. Where shown on the Drawings and Schedules, fans shall be of spark resistant construction. Bearings shall not be placed in the air stream. Construction shall conform to AMCA 99-0401- 82 Classifications. All electrical components shall be explosion proof. a. b. c. TYPE A - All parts in contact with the gas stream shall be non-ferrous material. TYPE B - Aluminum wheel and non-ferrous ring around shaft openings. TYPE C - Non-ferrous ring on inlet bell and shaft opening. Inlet and/or discharge screens shall be provided for fans that are not directly duct connected. Unless sparkproof construction or other materials of construction are scheduled fans shall be of steel construction. Electric motors and electrical disconnects shall be provided as specified elsewhere in this Section. Fans shall be UL listed when noted in the schedules or when code required for the specific application. HVAC General Provisions 1 5500-1 4 Cannon Road Lift Station Project No. 3583 ’ P\Cily of Carlsbad-16827UO679-Lifl Slalion\7 Pro] Docs\7.2 Final Docs\lOO X Specs\1550O.do~ B. Inline centrifbgal fans shall have flanged inlet and discharge, wheel inspection door and variable belt drive. Belt drive shall have a shroud over the belt in the air stream. Wheel shall be backward inclined aluminum whell or backward curved air foil type as scheduled. Integral duct connection flanges, corrosion resistant fasteners, and inlet guard. Provide spring hanging isolator and brackets, nema 1 switch, and 0.5 in. insulation fan housing. GreenHeck or equal. C. Propeller Wall Exhaust Fans - fans shall have cast aluminum, aluminum wheels, corrosion resistant fasteners, aluminum propeller, gravity operated damper, nema 1 switch, wall collar kit, and damper/motor guard. Plastic fan wheels are not acceptable. Manufacturers shall be Acme Eng. & Mfg. Corp.; Aerovent, Inc.; American Fan Co.; Buffalo Forge Co.; Hartzell Propeller Fan Co.; New York Blower Co.; H.K. Porter Co., Inc.; GreenHeck or equal. D. Tube and vane axial fan shall have aluminum housing, inlet and outlet flanges with mounting holes, aluminum rub ring, and meet AMCA type B spark resistance. Structural steel parts are phosphatized and coated with Permatector. Heavy duty, self-aligning ball bearings with extended lubrication lines, polished solid steel shafts and backward inclined aluminum wheel. Fan shall have capacitor start motor, motor cover, UL/cUL-705-"Power Ventilators", CSA labeled motor, easy access, inlet guard, coat entire fan with Hi-Pro Polyester-Ivory, Nema-1 switch heavy duty field mounted, neoprene base isolators, mounting rails, and motor with thermal overloads. Manufacturer shall be Greenheck or equal. 2.11 INSULATION A. Thermal Blanket Type 1. Blanket construction shall be a stapled construction. Outer and inner jacket materials will be stainless steel Type 304 knitted wire mesh .011" Dia. @ 16 sf./lb. 2. Insulation material - Both silencer and pipe shall be fiberglass needled mat, minimum density of 11 lb.B.3 and a maximum operating temperature at 1000 degrees F, as manufactured by Shannon Inc. or equal. 2.12 DUCTWORK A. Sheet metal ductwork shall be constructed of the materials specified using the gauges or thicknesses and reinforcing called for by SMACNA for the material specified. Unless otherwise specified, all components of duct systems shall be constructed of the same material as the ductwork. This is to include braces and turning vanes. 1. Galvanized steel ductwork shall be constructed of hot-dip galvanized sheet steel, per ASTM, A525 and A527. 2. Aluminum ductwork shall be constructed of 3003H-14 alloy B&S Gauges. 3. Stainless steel ductwork shall be constructed of Type 3 16 stainless steel. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16627W0679-Lift Station\7 Prq Docs\7.2 Final Docs\lM) % Specs\l55OO.doc HVAC General Provisions 15500-1 5 B. Ductwork shall be constructed of the following materials and to the following standards: Abbreviations M&F JRD - SMACNA Round Industrial Duct Construction Standards IRT - SMACNA Rectangular Industrial Duct Construction Standards - SMACNA WAC Duct Construction Standards - 1st Ed. - Metal & Flexible * except where listed otherwise in this table AL = Aluminum GS = Galvanized Steel SS = Stainless Steel C. Design of ductwork shall include all loads applied to the ductwork, in addition to the load of the duct. These loads include but are not limited to wind, snow and internal dirt or liquid buildup. D. Construction 1. All ductwork shall be substantially built with joints and seams smooth on the inside and gven a neat appearance on the outside. Inside surfaces and joints shall be smooth and free from pockets, burrs and projections. All joints shall be substantially air tight with laps made in the direction of air flow and no flanges projecting into the air stream. All changes in direction and duct transitions shall be shaped to permit the easiest possible air flow. 2. Pressure Classes a. Pressure classes for determination of sheet metal gauge and reinforcing shall be as defined by the latest issue of the SMACNA standards for duct construction. b. For ductwork with a static pressure higher than 2-in water gauge, pressure class shall be as shown on the Drawings. For ductwork with a static pressure 2-in water gauge or less pressure class shall be equal to the maximum pressure indicated for the fans or air handling units on the Schedules and the pressure class shall be the same for the entire length, including branches, of the specific duct system. 3. Rectangular Ductwork a. Ductwork shall be constructed as shown on the Drawings in accordance with the specified SMACNA Construction Standard, latest edition. b. Cross-breaking shall conform to SMACNA Standard. Cross-breaking shall be applied to the sheet metal between the standing seams or reinforcing angles. The center of the cross- break shall be of the required height to assure rigidity for each panel. c. All square elbows for rectangular ductwork shall be provided with turning vanes unless otherwise noted on the Drawings. Turning vanes shall be as detailed in the SMACNA Manual and or as shown on the Drawings. HVAC General Provisions 15500-1 6 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827W067Q-Lift Station\7 Proj Docs\7.2 Final Docs\100 % Specs\l5500.doc d. Alternate Construction (Rectangular Only) - Factory-fabricated joint systems may be offered as an alternate form of construction. The system offered shall meet all requirements of SMACNA. Alternate joint systems shall be "Ductmate System" as manufactured by Ductmate Industries, Inc., installed in accordance with the manufacturer's recommendations. The system shall be sealed for zero leakage and angle attachment to the main duct section shall be by tack welding. The use of screws is not allowed. 4. Round Ductwork a. Ductwork shall be constructed as shown on the Drawings in accordance with the specified SMACNA Construction Standard latest edition. b. Round Ductwork 1. Round ductwork shall be either lock type, welded longitudinal seam construction or spiral ductwork. 2. Gauges of ductwork and fittings shall be as specified in SMACNA. Draw bands will not be permitted. Slip joint shall be used on ductwork up to 36-in in diameter and the "loose flange" or Vanstone joint shall be used on ducts over 36-in in diameter. 3. All seam and joints shall be continuously welded. 4. Round ductwork shall be manufactured by United Sheet Metal; SEMCO or equal. 5. Round Ductwork Fittings a. All 90 degree turns shall be made of five piece mitered welded construction made by the manufacturer of the conduit. Fittings less than 90 degrees in the riser shall be made of multiple pieced mitered welded construction. b. All fittings in the round duct system shall be of the male and female type and in compound on the joint. Also, on the outside of the duct apply this synthetic rubber sealing compound in order to further make these joints air tight. Mechanically fasten the conduits together using sheet metal screws not less than four per fitting 6-in on centers maximum and equally spaced around the circumference of fitting. c. Round duct fittings shall be manufactured by United Sheet Metal; SEMCO or equal. Cannon Road Lift Station Project No. 3583 PWty of Ca~sbad-16e27\30679-L~fl Station\7 Pro] Do&7 2 Fmai D~\100 Yo Specs\155oO.doc HVAC General Provisions 15500-1 7 6. Access Doors a. Access doors shall be 24-in by 24-in minimum, except where the duct size is less than 26- in, where the largest door that will fit the duct will be used. Unhinged access panels are not acceptable, except where shown on the Drawings. Access doors shall be of the same material as the duct, pan type construction for metal ductwork, with smooth edges and fitted seals, constructed and installed for air-tight fit with ease of opening and closing. Doors shall be substantially butt hinged, with heavy sash locks and substantial door pulls. Door openings and door frames shall be reinforced with bar stock or angle. Where ductwork is installed with duct liner or exterior duct insulation, the access door shall be of the insulated type. Access doors may be factory fabricated. Where ductwork is constructed of aluminum or stainless steel, access door hardware shall be of similar material. 7. Fasteners a. Sheet metal screws, drive cleats, cinch bands and other fasteners shall be fabricated from materials with an equal of greater corrosion resistance than the ductwork in which they are installed. Where a material other than the duct material is used, it shall be approved by the Engineer before installation. 2.13 BUTTERFLY VALVES (ODOR EXHAUST PIPING) A. General Requirements 1. Butterfly valves shall be Class 150B where the valve is not listed in a schedule or where the class is not shown. All butterfly valves shall have bolted flanged ends full face neoprene, gasket, lug type and be short body unless otherwise shown on the Drawings or othenvise specified. 2. All valves shall be provided with manual actuators in addition to any other actuator specified. All manual actuators shall be provided with a 2-in operating nut, handwheel, and position indicator. In-plant valves position more that 6-ft above the operating floor shall be equipped with chainwheels unless otherwise noted. Manual valve actuators shall be capable of holding the disc in any position without creeping or fluttering. Manual actuators shall be serviceable without removal from the valve. Valve disc stops and a shaft seal shall be incorporated between the manual actuator and the valve. Flow stops in the valve flow stream will not be allowed. 3. Unless otherwise specified, all valves shall be left hand to open (counterclockse). Each valve body or actuator shall have cast thereon the word "OPEN" and an arrow indicating the direction to open. 4. All ferrous metal surfaces of valves and accessories, both interior and exterior, shall be factory expoxy coated for corrosion protection. All butterfly valves shall have an interior epoxy coating in compliance with AWWA C550. 5. Handwheel diameters shall be at least 8-in but not more than 24-in. HVAC General Provisions 15500-1 8 Cannon Road Lift Station Project No. 3583 P\City of Carlsbad-1682A30679-Lfi StationV Prq Docs\7.2 Final Docs\lOO % Specs\15500.doc 6. Valve seats shall be of Neoprene unless otherwise noted and recessed into the body. Where required, stainless steel hardware shall be used to restrain the seats fiom any movement at the maximum rated flow in either direction. As an alternate, corrosion resistant material (epoxy) shall be used to mechanically secure the seat except for butterfly valves for ozone, ozone off gas, or oxygen gas service. 7. Valve shafts shall be turned, ground, and polished and shall be constructed of Type 416 stainless steel. On valves larger than 20-in, and all Class 250 valves, the disc shall be secured to the shafts with pins. These pins shall be of the same material as the shaft and pass completely through the disc and shaft. Pins shall be tightly secured with lockwashers and nuts to ensure line vibrations cannot loosen the connection. On Class 150 butterfly valves smaller than 20411, stainless steel Type 3 16 pressure fit pins may be used. 8. Valve bearings shall be sleeve type, corrosion resistant, and self-lubricating. Bearing load shall not exceed 20 percent of the compressible strength of the bearing or shaft materials, and shall be secured in the trunion by a machined ledge. Ferrous bearings in the flow stream shall not be allowed. 9. Shaft seals shall be of the chevron or O-ring type. 10. Cartridge retained seats in the valve body are not acceptable. 1 1. After each valve is completely assembled, including the actuator, it shall be operated shop tested and certified for leakage with the disc in the horizontal plane, in accordance with AWWA C504. B. Butterfly valves 20-in and smaller shall have cast iron bodies (ASTM A126, Class B or A48, Class 40). Discs shall be Type 3 16 stainless steel seating edges. C. Valves %in and larger, as well as all buried OT submerged valves, shall be equipped with gear actuators. Such actuators shall be lubricated and sealed to prevent the entry of dirt or liquids into the actuator. D. Butterfly valves shall be as currently manufactured by Henry Pratt Company; Clow-Kennedy-M&H Valve Company; DeZurik; Crane, or equal. 2.14 SEQUENCE OF CONTROLS A. Control Sequence for Exhaust Fans 1. ElectricaVGenerator Room: EF-1, EF-2 a. When the manual selector switch is in the off position, the fan shall be off and the gravity exhaust damper shall be closed. b. When the manual selector switch is in the on position, the fan shall run and the gravity exhaust damper shall be open. c. Provide thermostatic control of exhaust fan for electrical room, per electrical plan. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16627U0679-Lift StationV Proj Docs\7.2 Final Docs\lOO X Specs\l55OO.doc HVAC General Provisions 15500-1 9 2. Restroom: EF-3 a. When the manual light switch is in the off position, the light and exhaust fan shall be off. b. When the manual light switch is in the on position, the light shall be on and the exhaust fan shall run. 3. Chemical Storage Room: EF-4 a. b. When the manual selector switch is in the off position, the fan shall be off. When the manual selector switch is in the on position, the fan shall run. 4. Odor Control System: PHX-1, PHX-2, DF-1 a. Refer to sheet H-03 FOR valve position under various operating mode. b. Dilution fan DF-1 shall operate at all times and a manual on-off switch shall be provided per electrical plan. 5. Valve Vault Fan: EF-1A a. Vault fan EF-1 A shall operate at all times and a manual on-off switch shall be provided per electrical plan. PART3 EXECUTION 3.01 INSTALLATION A. The Contractor shall start up each piece of equipment and system and shall make all adjustments so that the system is placed in proper operating condition. B. The Contractor shall not install any equipment or materials until the Agency and Engineer have approved all submittals. If any equipment or materials are installed prior to approval of the submittals, it shall be at the Contractor's risk. C. Equipment 1. Install equipment in accordance with manufacturer's recommendation. Provide piping and ductwork connections in accordance with the requirements as specified elsewhere in this Section. I). Insulation - General 1. Do not apply insulation prior to testing and acceptance of piping, ductwork and/or equipment. Clean dust, dirt, grease and moisture fiom surfaces of pipe and duct before applying insulation. Install all insulation in a neat and workmanlike manner. Nameplates and equipment certification and data tags affixed to any piece of apparatus must remain exposed to view. HVAC General Provisions 15500-20 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827U0679-Lifl StalionV Pmj Docs\7.2 Final Docs\100 % Specs\l5500.dOC 2. The recommendations and instructions of the manufacturers of products used in the work are hereby make part of this Section except as they may be superseded by other requirements of this Section. E. Installation of Ductwork 1. Fabricate and erect all ductwork where shown on the Drawings, as specified herein and in accordance with SMACNA requirements. Rigdly support and secure ductwork in an approved manner. Install hangers plumb and securely suspended from supplementary steel or inserts in concrete slabs. Sufficiently thread lower ends of hanger rods to allow for adequate vertical adjustment. Do not use building siding and metal decking to hang ductwork. 2. Wherever ducts are divided, maintain the cross-sectional area. All such changes must be approved and installed as directed by the Engineer or as approved on shop or erection drawings. 3. During installation, close the open ends of ducts to prevent debris and dirt from entering. Install work in accordance with the overall approved progress schedule and in cooperation with all other trades so there will be no delay to other trades. 4. Provide the unused portion of external louvers (where it is not used as a fresh air intake or exhaust) with a blank-off constructed of 0.0625-in aluminum. Provide blank-off panels with aluminum reinforcing angles to prevent buckling and secured to the exterior wall with aluminum angles and rustproof fasteners on not more than 12-in centers. Provide caulking completely around the outside edge of the angle and the aluminum. 5. Install automatic dampers when supplied by other trades. 6. Cross-break sheet metal in accordance with SMACNA duct construction standard. Apply cross- breaking to the sheet metal between the standing seams or reinforcing angles. The center of the cross-break shall be of the required height to assure each panel section being rigid. 7. Cross-break steamlined ducts on top only and adequately brace internally. 8. Beading as specified in SMACNA will be acceptable in lieu of cross-brealung. 9. The Drawings of the air ducts and air risers show the general location for installation of the ducts and risers. Should additional offsets or changes in direction be made, these changes must be considered in the original bid and shall be installed at no additional cost to the Agency. 10. All necessary allowances and provisions shall be made in the installation of the ducts for the structural conditions of the building. Ducts shall be transformed or divided as may be required. Wherever this is necessary, maintain the cross-sectional area. All of these changes, however, must be approved and ducts installed as directed by the Engineer or as approved on shop or erection drawings. 1 1. The taper of all transformations shall be not more than 15 degrees. 12. Secure casing to curbs according to SMACNA Duct Construction Standards. Cannon Road Lift Station Project No. 3583 P \City of Carisbad-16827U0679-Lfl StationV Pro] Docs\7.2 Final Docs\l OD K Specs\15500.doc HVAC General Provisions 15500-21 13. Provide baffle plates as required to prevent stratification and to provide proper operation of controls. 14. Where ducts are constructed of materials other than galvanized steel the reinforcing members shall be of the same material as the ductwork. 15. For PVC ductwork where reinforcing members of material other than PVC are required, totally encase the reinforcing member in PVC. 16. The use of button punching or snap locks on ductwork constructed of aluminum shall not be permitted. F. Hangers 1. The use of wire to hang flexible ductwork shall not be permitted. 2. Ductwork shall not come in contact with any of the ceiling construction or any other equipment in the ceiling cavity. G. Sealing of Ductwork 1. General - Unless otherwise indicated, seal all ductwork joints and seams using sealant in accordance with the instructions of the sealant manufacturer and this Section. All transverse seams, joints and fitting connections, both shop and field assembled, shall be sealed in accordance with this Specification. Not more than one longitudinal seam shall be unsealed in each section of duct. 2. Application of Sealant - Thoroughly clean all seams, joints, etc, of dirt, oil, grease, or other coatings which might interfere with the adhesion of the duct sealant before the sealant is applied. 3. Uncured sealant may be forced into the slotted side of the seam or joint before shop or field assembly, and the joint or seam compIeted while the sealant is still uncured. Excess sealant shall be removed fiom both the inside and outside of the duct before it sets. 4. Duct Tape - The use of duct tape alone for sealing ductwork is prohibited. Duct tape may be used primarily for the purpose of retaining the uncured duct sealant in seams and joints until it has cured. Duct tape shall not be applied to the inside of any duct nor shall it be applied to standing type joints at any time. All duct tape used shall be compatible with the sealant. 5. Sealant shall be either in liquid form or a mastic with a maximum flame spread of 25 and a maximum rate of fuel contributed and smoke developed of 50 when tested in accordance with ASTM E84, NFPA 255 and UL 723. 6. Sealing systems shall be suitable for the environment. The following schedule is to be used to select the sealant. a. Indoor, dry galvanized round and rectangular duct is to be sealed with Iron Grip 60 1 or equal. HVAC General Provisions 15500-22 Project No. 3583 Cannon Road Lift Station P:!CiIy of Carlsbad-16827\30679-Lifl StationV Proj Docs\7.2 Final D0cs\100 % Specs\l550O.doc b. Indoor, dry, stainless steel, aluminum and PVC coated is to be sealed with FTA 20 adhesive and DT-Tape gypsum or equal. c. All other areas unless otherwise noted are to be sealed with FTA 50 adhesive and DT-Tape gypsum or equal. d. All sealers listed or manufactured by Hardcast Inc. and are to define the type of sealer. Other equal sealants are acceptable. H. Ductwork Fittings and Accessory Items 1. Duct Elbows - For rectangular ductwork where full radius elbows cannot be installed, provide abrupt elbows equipped with shop-installed hollow, air foil turning vanes. 2. Flexible Connectors a. Install flexible connectors at all duct connections to fans, fan units or blowers, air handling units and air condltioning units. Make connections substantially air tight at all seams and joints. b. Where the construction of the flexible connection or vibration isolator results in a cross sectional area of the connection which is less than 90 percent of the adjacent ductwork, the size of the connection shall be increased to provide a cross sectional area equal to or greater than 90 percent of the adjacent duct. c. Provide flexible duct connections at both the intake and discharge connections for all fans and air handling units except as noted below: 1) Wall and roof fans that have integral motorlfan wheel isolation. 2) Air handling units where the fan is isolated from the intake and discharge connections by internal flexible connections or separations, and the unit is mounted without vibration isolators between the unit and the support structure. 3. Dampers a. Install manual volume control dampers wherever it may be necessary to regulate air volume for system air balancing and where shown on the Drawings. b. Install splitter dampers, where shown on the Drawings, to regulate air volume for system air balancing. Splitter dampers shall be single blade, end pivoted type, manual adjustment and position locking arrangement. c. Factory-fabricated volume extractors shall be used at all supply air diffusers. d. An access door, of ample size to permit maintenance and resetting of damper blades, shall be installed at each opposed blade damper, splitter damper and volume extractor so located for easy access to the damper blades. Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-I6B27\30674Lifl Station\7 Pmj Docs\7.2 Final DOa\lOO X Specs\l55M).doc HVAC General Provisions 15500-23 I. J. K. L. Duct Supports Through Floors 1. Where vertical ducts pass through floor openings, rigidly attach supporting angles to the ducts and anchor with expansion bolts to the floor or curb. Angles shall be of the same material as the duct for metal duct and stainless steel for non metallic ducts, placed on the two long sides of the duct extending 3-in over edge of opening, and shall not be less than the sizes recommended by SMACNA. Remaining open areas shall be filled in with a plate of the same material as the angles. Ductwork at Masonry 1. Where ducts connect to, or terminate at masonry openings, or along the edges of floors where concrete curbs are not being provided, place a continuous 2-U2-h by 2-1/2411 by 311 6-in galvanized angle of the same material as the duct around the ductwork. Then bolt the angle to the construction and make airtight to same by applying caulking compound on the angle before it is drawn down tight to construction. 2. Fasten plenums to concrete curbs with 3-in by 3-in by %-in thick continuous angle. Concrete curbs will be provided under another Division, This angle shall sit on a continuous bead of caulking compound and be anchored to the curb at 16-in centers. Terminate the sheet metal at the curb and bolt to the angle. Seal the sheet metal to the curb with a continuous bead of caulking compound. 3. When exposed ducts pass through finished floors, walls or ceilings, provide angle collars completely covering space around duct. Quality of Ductwork Installation 1. All ductwork shall be free from pulsation, chatter, vibration or objectionable noise. After system is in operation, should these defects appear, correct by removing, replacing or reinforcing the work. Sound levels shall not exceed the minimum requirement as specified in ASHRAE 1980 Systems Volume, page 35.16, Table 23. No discreet tones will be allowed. 2. The maximum allowable leakage of low pressure system shall be 5 percent of air volume. Plenums 1. Seal fresh air inlet and exhaust air plenums at louvers or otherwise subject to weather entrainment watertight at all bottom joints and seams and up all vertical seam for a minimum of 12-in. After application, remove excess sealant before it sets hard. Where possible, pitch fresh air inlet and exhaust air plenums down towards the louver. Where it is not possible to pitch the denum. wovide a 1 -in CaDDed drain connection at the low Doint of the denum. HVAC General Provisions 15500-24 Cannon Road Lift Station Project No. 3583 PCity of Cadsbad-16827U0679-Lift StalionV Pro] Docs\7.2 Final Docs\lOO % Specs\15500.doc 3.02 FIELD TESTING A. Testing and Balancing 1. General - Test, adjust and balance all HVAC systems. If required by the Engineer, tests shall be made during the progress of the work to demonstrate the strength, durability and fitness of the installation. Furnish all instruments, ladders, lubricants, test equipment and personnel required for the tests; including manufacturer's representatives for testing and start-up of all Contractor supplied equipment. Before testing and balancing, all systems shall be cleaned as specified. Submit four copies of records of all tests, measurements, settings of throttling devices and nameplate data to the Engineer. 2. Final Tests - Perform tests of all systems as required by the Engineer prior to final acceptance of the systems for the purpose of demonstrating satisfactory functional and operating efficiency as well as adjustment. During this period, check the setting of all automatic controls and take sufficient measurements to ensure that conditions are correct and that capacities are adequate to meet the specified requirements. Systems will not be considered complete until all tests have been concluded to the satisfaction of the Engineer and all other parties having jurisdxtion. In event of leakage or defects, repeat tests until all faults are corrected. Perform the general operating tests under as near design conditions as possible. 3. Perform all testing, adjusting and balancing under the supervision of a qualified heating, ventilating and air conditioning engineer employed by the air balance and testing agency. Reporting forms for testing and balancing shall be as recommended by the AABC. 4. Coordination of the test shall be the responsibility of the balancing sub-contractor. Access to the site, availability of service representatives, and tenant acquiescence will be considered in the determination of both the testing schedule and the witnessed recheck of the balancing. 3.03 ADJUSTMENT A. Start-up and Temporary Operation 1. Properly maintain and service all equipment and systems until the particular equipment or the system has been accepted by the Agency. B . Balancing of Rotating Equipment 1. All machines shall be balanced both statically and dynamically by the manufacturer within the limits of best commercial practices. The term machine, as used above, is to be considered as any piece of equipment which contains rotating components. All machines furnished shall have operating speed not exceeding 80 percent of the first critical speed. C. Painting 1. Repair of all defects, blemishes, holidays and the like apparent in manufacturer's coatings and ensure that materials used for such repair shall match or be compatible with the manufacturer's standard color, coatings and practices. Do not paint over nameplates. Cannon Road Lift Station Project No. 3583 Picity of Carlsbad-16827\30679-Lift Stabon\7 Proj DoiA7.2 Final Doa\100 46 Specs\l5590.doc HVAC General Provisions 15500-25 2. Faint black the louver side of all louver blank off panels and the interiors of unlined plenums and ductwork where connected to louvers. 3.04 CLEANING A. Leave all piping, ductwork and equipment in a thoroughly cleaned condition. Thoroughly flush all piping to remove all foreign materials prior to any cleaning procedure. All flushing and cleaning shall be to the satisfaction of the Engineer. Furnish, install and remove all temporary piping and equipment used in the cleaning and flushing operations. B. Maintain all ductwork, fans, air filters, outlets and other parts of the ductwork systems in a clean condition during installation, C. Clean complete ductwork systems prior to testing and air balancing. Secure cheesecloth over all openings of the ductwork system for entrapment of dirt during the cleaning operation. END OF SECTION HVAC General Provisions 15500-26 Cannon Road Lift Station Project No. 3583 P:\City of Carlsbad-16827W0679-Lifl Station\? Pro1 Docs\7.2 Final Docs\100 % Specs\15500.doc SECTION 155 10 STAINLESS STEEL PIPE AND FITTINGS (ODOR EXHAUST) PART 1 GENERAZ, 1.01 RELATED DOCUMENTS A. Drawings and general provisions of contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to work of this Section. B. Division 15 Basic Mechanical Materials and Methods Sections apply to work of this Section. 1.02 RELATED WORK A. Extent of coated duct is indicated on drawings and in schedules, and by requirements of this section. 1.03 QUALITY ASSURANCE A. Manufacturer's Qualifications: Firms regularly engaged in the manufacture of Stainless Steel Duct coated with Teflon@ products of types, materials, and sizes required. Manufacturer shall perform their own sheet metal fabrication and coating processes. Manufacturers whose Stainless Steel Duct coated with Teflon@ shall have been in satisfactory use for not less than five (5) years. The Agency andor his representatives shall have the right to tour the manufacturer's plant anytime that fabrication is being performed on duct intended for this project. 1. Codes and Standards: a. Ducts shall be listed for use without the necessity for internal fire protection sprinklers or any devices relied on to cut off air flow in the event of fire by Factory Mutual Research Standard 4922. 1. Duct shall have a flame spread of less than 25 and a smoke generation rate of less than 50. 2. Duct shall be Factory Mutual approved for use without sprinklers for an unlimited vertical height. b. SMACNA Standards: Comply with SMACNA's "WAC Duct Construction Standards, Metal and Flexible" for fabrication and installation of metal duct and SMACNA's "Round Industrial Duct Construction Standards" intended for use by designers of industrial ventilation systems. Cannon Road Lift Station Project No. 3583 P:Gity of Carlsbad-16827\30379-Lift StationV Pro1 Docs\7.2 Final Docs\100 % Specs\l5510.doc Stainless Steel Pipe and Fittings (Odor Exhaust) 1551 0-1 B. 1.04 A. B. 1.05 A. B. C. PART 2 2.0 1 A. Installer Qualifications: Installation contractors shall have at least 5 years of successful experience on duct projects, specifically industrial exhaust systems. 1. Codes and Standards: a. ASHR4E Standards: Comply with ASHRAE handbook, Equipment Volume, Chapter 1 "Duct Construction", for fabrication and installation of metal duct. b. Ventilating Systems", NFPA 90B "Standard for the Installation of Warm Air Heating and Air Conditioning Systems" and NFPA 91 "Standard for the Installation of Blower and Exhaust Systems." c. Field Reference Manual: Have available for reference at project field office, copy of SMACNA "Round Industrial Duct Construction Standards." SUBMITTALS Submit manufacturer's technical product data and installation instructions for Stainless Steel Duct coated with Teflon@. Shop Drawings: Submit scaled layout drawings of coated duct and fittings including, but not limited to, duct sizes, locations, elevations, and slopes of horizontal runs, walls and floor penetrations, and connections. Show interface and spatial relationships between coated duct and adjacent equipment. Show modifications of indicated requirements and how those modifications ensure that free area, materials, and rigidity are not reduced. DELIVERY , STORAGE, AND HANDLING Protect coated duct from damage due to normal handling during shipment and storage. Protection shall be applied to ends of duct to prevent dirt and moisture from entering ducts and fittings. Consignee must inspect shipment upon delivery and note any and all damages and discrepancies on bill of lading and notify manufacturer within 24 hours. Coated duct should not be stored in an area where it will have a chance to be damaged from traffic and debris. All coated duct should be stored on cardboard, Styrofoam or similar materials. Where possible, store inside and protect from dirt and debris. Where necessary to store outside, store above grade and enclose with waterproof wrapping to protect from dirt and debris. 1. If coating is scratched during shipping or handling it must be inspected using the methods described in Section 2 "Products", Subsection 2 "Duct Construction Materials", Subsection A3. Contact the manufacturer for approved repair procedures. PRODUCTS ACCEPTABLE MANUFACTURERS Stainless Steel Exhaust Duct and Fittings coated with Teflon@: PSPB & PSP-EZTM (Permashield Pipe) as manufactured by: Fab-Tech, Incorporated. Stainless Steel Pipe and Fittings (Odor Exhaust) 1551 0-2 Project No. 3583 Cannon Road Lift Station P\clty of Carlsbad-l6827\30679Lift StationV Pro] Docs\7.2 Final Docs\lOO % Spec~\lSSlO.d% B. Kern-Tuff WAR-ECTFE@ Fluoropolymer coated stainless steel duct as manufactured by: GDS Manufacturing; Williston, Vermont. 2.02 DUCT CONSTRUCTION MATEFULS A. Stainless Steel Duct coated with Teflon@ shall be constructed in full accordance with the specifications below: 1. Base metal shall be AIS1 304 stainless steel, constructed to a duct gauge and reinforcing system in accordance with "SMACNA Round Industrial Duct Construction Standards" with a Class 1, - 6" WG schedule. Longtudinal seams shall be fusion welded. Transverse seams shall be butt welded, no dissimilar filler materials allowed. 2. The coating shall be a Teflon@ ETFE thermoplastic resin. The average coating thickness shall be 10 mils (.010 inch). Complete and uniform coating coverage is required. 3. The manufacturer shall perform dielectric testing of the coating on all pieces of duct. All coated surfaces will be subjected to 2500 volts DC with no failures (sparks or audible alarms) indicated. 4. Duct Joints: a. Companion (Van Stone) Flange is the preferred method for connecting coated duct 20" diameter and larger. b. PSP-EZTM clamp (V-ring Insert Band Clamps) is the preferred method for connecting duct smaller than 20" diameter. 1. Gasket: Form-in-place, fully expanded 100% PTFE. 2.03 MISCELLANEOUS DUCT CONSTRUCTION MATERIALS A. General: Provide miscellaneous materials and products of types and sizes indicated and, where not otherwise indicated, provide type and size required to comply with duct system requirements including proper connection of duct and equipment. Support materials in contact with the duct shall be fabricated of compatible materials unless otherwise specified. 1. Duct Fittings: a. Factory fabricated duct fittings to match adjoining ducts, and to comply with the contracted duct requirements. Unless otherwise specified, fabricate elbows with centerline radius equal to one and one half (1-1/2) times the duct diameter. Unless otherwise specified, use 45 degree laterals and 45 degree elbows for branch take-off connections. Limit angular tapers to 30 degrees for contracting tapers and 20 degrees for expanding tapers. b. Predetermine location of duct drains prior to manufacturer's fabrication. Drains are to be located in the bottom of all main and branch ducts which are P-trapped and/or as shown on the drawings to allow removal of condensate. c. Factory fabricate duct and fittings with predetermined location of test holes for monitors. Stainless Steel Pipe and Fittings (Odor Exhaust) Cannon Road Lift Station Project No. 3583 1 55 1 0-3 P,\city of Carkbad-l6827U0679-L1fl StahonV P~OJ Docs\7.2 Flnal Docs\lOO Y. Specs\l5510.doc 2. Duct Joints: PART 3 3.01 A. a. General: Duct joints may be either Van Stone (Companion Angle Ring Bolted Flanges) or PSP-EZTM (V-ring Insert Band Clamps). 1. Van Stone Flange 4" diameter to 120" diameter i. 11. iii. iv. Construction shall be generally roll formed or pressed sheet stock. Materials shall be ANSI 304 Stainless Steel. Bolt holes shall be elongated. Hardware shall be SAE Grade 5 Plated steel alloy. Grade 5 Hardware shall be tightened to the following values: Bolt Diameter Torque (pounds x foot) 5/16" 22 318" 36 Gasket shall be Gore-Tex@ Joint Sealant: 4" diameter to 11" diameter = 3/16" x 1/8" 12" diameter to 24" diameter = 1/4" x 1/8" 25" diameter & up = 1/4" x 3/16" 2. PSP-EZTM Joints i. Construction shall be generally roll and press formed stainless steel sheet goods. ii. Duct flanges will be backed with a trapezoidal shaped loose metallic ring shaped to work with the formed profile of the clamp band. One circumferential bolt with one locknut is used to tighten the clamp to the duct. iii. Gasket shall be a self adhesive Gore-TexB Tape .010 x .75" on each end of duct (4" diameter to 18" diameter) or a singular die cut Gore-Tex@ gasket (2" diameter to 3" diameter) as specified by the manufacturer. Clamp bolt shall be tightened to the following values: Clamp Bolt Diameter Torque (pounds x inch) 1/4" 75 5/16" 120 3. EXECUTION INSTALLATION Examine areas and conditions under which coated duct are to be installed. Do not proceed with work until unsatisfactory conditions have been corrected in manner acceptable to installer. Stainless Steel Pipe and Fittings (Odor Exhaust) 15510-4 Project No. 3583 Cannon Road Lift Station P.\City of Carlsbad-16627U0679-Lift StationV Pro] Docs\7.2 Final Docs\lw) % Specs\15510.doc B. Assemble and install coated stainless steel duct while using extreme care not to scratch surface of coating (if scratched, immediately contact manufacturer for repair instructions) and in accordance with recognized industry practices which will achieve air-tight, under 1% leakage. Install each run with a minimum number of joints. Align duct accurately at connections, with internal surfaces smooth. Support ducts rigidly with suitable ties, braces, hangers and anchors of type, which will hold in accordance with SMACNA “Industrial Duct Construction Standards.” 1. Coating must not be penetrated during installation. No fastening devices such as Tek-style screws, rivets, etc. are to be used on any part of a coated duct application. Test holes and slots for monitoring must be predetermined before fabrication and coating unless using approved Fab- Tech Field Modification Kits. Install coated stainless steel duct as shown on drawings and described herein, following applicable state and city codes, and per SMACNA HVAC Duct Construction Standards. 2. Routing: Locate coated stainless steel duct runs, except as otherwise indicated, vertically and horizontally and avoid diagonal runs wherever possible. Locate runs as indicated by diagrams, details and notations or, if not otherwise indicated, run duct in the shortest route that does not obstruct usable space or block access for servicing building and its equipment. Hold ducts close to walls, overhead construction, columns, and other structural and permanent enclosure elements of building. Wherever possible in finished and occupied spaces, conceal duct from view, by locating in mechanical shafts, hollow wall construction, or above suspended ceilings. Do not encase horizontal runs in solid partitions, except as specifically shown. Coordinate layout with suspended ceiling and lighting layouts and similar finish work. 3. Electric Equipment Spaces: do not route duct through transformer vaults and their electrical equipment spaces and enclosures. 4. Penetrations: Where ducts pass through interior partitions and exterior walls, and are exposed to view, conceal space between construction openings and duct with sheet metal flanges of same gauge as duct. Overlap opening on 4 sides by at least 1-1/2”. END OF SECTION Cannon Road Lift Station Project No. 3583 P:Cily of Carlsbad-l6827iX)679-L1ft Statlon\7 Pro] Docs\7.2 Final Docs\lOO 46 Specs\l55lO.doc Stainless Steel Pipe and Fittings (Odor Exhaust) 1 551 0-5 This page intentionally left Blank. Stainless Steel Pipe and Fittings (Odor Exhaust) 15510-6 Project No. 3583 Cannon Road Lift Station P:City of Carlsbad-l6827!30679-L1H StationV Pmj Docs\7.2 Final Docs\100 % Specs\l55lO.d0~ PART 1 1.01 A. B. C. 1.02 A. B. C. D. E. 1.03 A. B. C. D. E. F. G. H. I. J. SECTION 15995 ODOR CONTROL SYSTEM (ACTIVATED CARBON) GENERAL SECTION INCLUDES Hardware Activated Carbon Canisters Manufacturer’s Services RELATED SECTIONS Yard piping, valves and appurtenances are included in Division 2. Concrete work is included in Division 3. Field painting, except as specified herein, is included in Section 09902. Mechanical piping, valves, pipe hangers and supports are included in the respective sections of Division 15. Electrical work, except as specified herein, is included in Division 16. DEFINlTIONS FRP: PP: PVC: CPVC: H2S : PPm: NEMA: NFPA-70: UL: ASTM: fiber reinforced plastic polypropylene polyvinyl chloride chlorinated polyvinyl chloride hydrogen sulfide gas parts per million by volume National Electrical Manufacturer’s Association The National Electrical Code Underwriter’s Laboratory American Society for Testing and Materials Cannon Road Lift Station Project No. 3583 P:CHy 01 Caflsbad-16827W67~Litt Station\7 Pro) Docs\7.2 Find Docs\lOO % Speco\l5995~.doc Odor Control System (Activated Carbon) 15995-1 K. NBS: National Bureau of Standards System Quantity of CFM per Canisters per Fan HP Designation Reactors Reactor Reactor (maximum) L. IEC: International Electrotechnical Commission Fan Static Pressure (maximum) M. AMCA: Air Movement and Control Association P2000 1.04 SYSTEM DESCRIPTION 2 2000 10 10 12” W.C. A. The Contractor shall furnish and install the odor control systems described herein. Each system includes the following: 1. Reactor Vessel 2. Activated Carbon Canisters 3. Fan and Motor Assembly 4. Interconnecting Ductwork 5. Accessories as shown below 6. Manufacturer’s Services B. The vessel, fan, and carbon canisters function as a system and shall be the end products of the odor control system supplier to achieve standardization for appearance, operation, maintenance, spare parts, and manufacturer’s services. C. There will be 2 reaction systems required, as delineated below: D. The each adsorption system will receive 2000 cfm air flow from the lift station wetwell. The design inlet H2S concentration shall be 10 ppm. The design outlet concentration shall be 0.05 ppm. A ninety-nine percent (99%) removal of the inlet H2S concentrations shall be achieved. E. Power supply and associated conduit for fan and optional control panel shall be provided by others. 1.05 SUBMETALS A. Submit the following items at the same time under one cover: 1. Documentation to demonstrate that the reaction system is the standard product of the supplier. 2. Documentation to demonstrate that the manufacturer has been regularly engaged in fabricating odor control systems for at least 5 years. 3. Certified shop and erection drawings, showing all important details of construction, dimensions and anchor bolt locations. , Odor Control System (Activated Carbon) 15995-2 Cannon Road Lift Station Project No. 3583 PCi d Carlsbad-16827\30879.Lin Staticm\7 ProJ Docs\7.2 Final Docs\lW % Specs\l5995-r.doc B. 1.06 A. B. C. 1.07 A. B. C. 4. Equipment Performance Bond for 100% of the material and labor costs, for all equipment supplied by the odor control manufacturer. The bond shall guarantee that all defects or failures will be corrected within the guarantee period of one year and shall remain in force for that period commencing upon final acceptance of the construction contract. Submit also the following: 1. Installation Instructions 2. Operation and Maintenance Instructions 3. Certified Fan Drawings 4. A Complete Total Bill of Materials of all Equipment 5. A list of manufacturers’ recommended spare parts, to be supplied in addition to those specified in Paragraph 1.07. DELIVERY, STORAGE AND HANDLING All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation. All equipment and parts must be properly protected against any damage a prolonged period at site. Each box or package shall be properly marked to show its net weight. MAINTENANCE Maintenance Service 1. System supplier shall supply a quarterly analysis of the activated carbon to be reported as odor capacity. Manufacturer shall furnish this service for 1 year from start-up of the system. Spare Parts 1. Furnish a complete set of recommended spare parts necessary for 1 year of operation of the system. Additional spare parts to the be furnished, where required, are listed in the respective Paragraphs of PART 2. 2. Spare parts shall be properly bound and labeled for easy identification, without opening the packaging and suitably protected for long term storage. Tools 1. Provide all special tools required for normal maintenance. Tools shall be packaged in a steel case, clearly and indelibly marked on the exterior to indicate equipment for which tools are intended. Cannon Road Lift Station Project No. 3583 !?\city of C~~bad-1682~~Ut Statlon\7 pml Docs\7.2 Final Docs\lOO % Specs\l5995~.doc Odor Control System (Activated Carbon) 15995-3 1.08 A. 1.09 A. B. C. D. PART 2 2.01 A. 2.02 A. B. C. D. WARRANTY All equipment supplied under this Section shall be warranted for a period of 1 year by the system supplier, manufacturer and the Contractor. Warranty period shall commence on the date of Agency acceptance as outlined in Division 1. SUBSTITUTIONS If a substitution to the designated odor control system is proposed by the Contractor, then the Contractor is totally responsible for furnishing all necessary designs, layouts, drawings, submittals, air quality modeling, and inspections necessary to demonstrate the proposed substitution is equal to that specified and is acceptable to the Agency. Due to prior approvals by jurisdictional agencies, the outside dimensions of the building cannot increase or be substantially different than those dimensions shown on the contract drawings. Interior dimensions, floor plan layout may be changed if found acceptable by the Agency. The Agency shall be the sole judge as to the comparative quality, performance, and suitability of the proposed substitute, and their decision shall be final. Any proposed substitute shall be submitted within 30 days after receipt of the Agency's Notice to Proceed. Any proposed substitute after this 30-day period will not be considered by the Agency. PRODUCTS GENERAIA The Contract Documents indicate specific required features of the equipment, but do not purport to cover all details of design and construction. REACTOR VESSEL( S) The reactor vessel shall be a PHOENIXm P-2OOO System, as supplied by Calgon Carbon Corporation. The carbon canister media contained within the reactor vessel shall be capable of being water regenerated while the system remains on-line for continuous odor treatment during normal operation. Any system which must be taken off-line for media regeneration shall not be acceptable. The reactor vessel shall be manufactured of W resistant Polypropylene, black in color. POLYPROPYLENE (PPL): The PPL reactor housing material used shall be manufactured to withstand a maximum loading of 15 inches Water Column of positive pressure. FEATURES: The following features shall be provided with the vessel: 1. Single point water drain 2. Single point water connection 3. Flanged air inlet and outlet connections 4. External sidewall canister access - for removal and replacement of canisters Odor Control System (Activated Carbon) 15995-4 Cannon Road Lift Station Project No. 3583 P:UXy of CarIsbad-1~~7SLKi Statlon\7 Pw Docs\7.2 Final DoCs\100 % SpecsU5995-r.doc 2.03 ACTIVATED CARBON CANISTERS A. The activated carbon utilized by the reactor vessel shall be provided in the form of replaceable carbon-filled canisters. B. CANISTERS: Canisters shall be of porous polyethylene construction. Canisters shall be able to be removed and replaced from the adsorber vessel exterior sidewall without requiring removal of any vessel appurtenances. C. CARBON: Each canister shall be provided with Calgon Carbon Corporation CENTAUR-HP type catalytic activated carbon. Activated carbons that cannot be regenerated in-place shall not be acceptable. The activated carbon supplied shall be of a type that does not require chemicals to be regenerated in-place. Activated carbons, which require hydroxide, permanganate, chlorine, organic, or any solutions other than clean water (see Table I) to regenerate the material will not be accepted. The activated carbon shall have the following properties: 1. Iodine Number, mg/g (min): 950 2. Ash Content, % by wt. (max): 8 3. Apparent Density, g/cc (min): 0.44 4. H2S Capacity (g/cc): 0.15* * The determination of H2S breakthrough capacity will be made by passing a moist ( 85% R.H. ) air stream containing 1% H2S at a rate of 1,450 cc/min. through a 1 inch diameter by 9 inch deep bed of uniformly packed activated carbon and monitored to 50 ppm breakthrough. Results are expressed in grams H2S removed per cc of carbon. 2.04 FAN AND MOTOR ASSEMBLY A. FAN: The fan shall be a centrifugal industrial FRP fan that is AMCA certified and licensed to bear the AMCA seal. All parts of the fan that are exposed to the airstream shall be encapsulated in FXP to insure corrosion resistance. 1. All fans shall be equipped with the following features and accessories a. b. d. e. f. €5 h. C. Flanged outlet / slip-on inlet Drain Shaft seals, Viton Inspection port Safety belt guard Lifting eyes Epoxy coated heavy-gauge all-welded steel base Constant-speed V-belt drive 2. Fan shall be as manufactured by New York Blower, or equal. B. MOTOR: The motor shall be a TEFC (totally enclosed fan cooled) unit, with a 1 .O service factor, with the following ratings: 3 phase / 60 Hertz / 230-460 Volt. Cannon Road Lift Station Project No. 3583 P:\city of ~1lsbad-16B27W87SLtH StalJon\7 Pmj Docs\7.2 Final Docs\lOO % Specs\l5995-r.doC Odor Control System (Activated Carbon) 15995-5 C. FAN OPTIONS: The following fan options shall be provided: Option 1: Class I, Div I Hazardous Area: TEXP (Totally Enclosed Explosion proof), squirrel cage induction motor with 1.0 SF and the following ratings: 3 phase / 60 Hertz / 230-460 Volt, and graphite impregnation of FRP fan body. 2.05 INTERCONNECTING PPL DUCTWORK A. .Ductwork between the reactor vessel and the exhaust fan shall be provided by the odor control manufacturer. B. Ductwork assembly and design shall be compatible with the fan and vessel. C. An expansion joint shall be included in the ductwork and installed at the outlet of the exhaust fan. The expansion joint shall dampen axial, lateral, and vibrational duct movement. The expansion joint shall be resistant to ultraviolet degradation and to the corrosive gases being processed. The expansion joint shall be of a flanged design. 2.06 STANDARD SYSTEM ACCESSORIES A. AUTOMATED REGENERATION PACKAGE - Class I, Div I, Hazardous Location: The Phoenix system shall be provided with an automatic water regeneration package. This package shall permit cyclical regeneration of the Phoenix system while the system remains on-line. This package shall consist of: 1. One (1) NEMA Type 7 bolted enclosure control panel mounted to the Phoenix vessel or skid. The control panel shall contain: One (1) Allen Bradley programmable logic controller with programmable HMI, one (1) control relay, two (2) selector switches, short circuit protection for PLC and valves, and terminal blocks for all external connections with 20% spare terminal blocks. 2. ASCO Brass Body solenoid valves with stainless internals and with NEMA type 7 solenoid. 3. One (1) Hayward CPVC ball valve with Hayward NEMA type 7 electric actuator. 4. Rigid Metallic Conduit with fittings approved for use in Class I, Div I areas. Conductors for 120 VAC service shall be stranded, type TFFN or MTW, #16 AWG B. FLOW CONTROL DAMPER: A round F" butterfly damper shall be supplied to regulate airflow through the reactor vessel. The damper shall ship loose and be ready for installation into the reactor system supply ductwork. The damper shall be furnished by the manufacturer of the odor control system. C. FLOW MONITORING EQUIPMENT: Each reactor vessel shall include a manometer sufficient to give a direct read-out of differential pressure in inches water column across the system. The manometer shall be a Dwyer Series 1230-16 or equal. Odor Control System (Activated Carbon) 15995-6 Cannon Road Lift Station Project No. 3583 PUty ol C.sdsbad-1682~79-Lttt sts6m\7 pmi Docs\7.2 Final Docs\lOO% Specs\lS-r.doc D. 2.07 A. B. C. D. GREASE FILTERS / MIST ELIMINATOR: A grease filter / mist eliminator shall be. supplied. This unit shall consist of a 304L stainless steel pad for grease filtration in front of a PPL pad with 3 16 stainless steel grid for mist elimination, housed inside an FRP enclosure. The pads shall be removable for cleaning and the housing shall have a door, or drop-out flange, to allow removal and replacement of the filter pads. A Dwyer Series 2000 Magnehelic differential pressure gage shall be installed on the housing to indicate pressure drop through the unit. This unit shall ship loose and be ready for installation into the reactor system supply ductwork. (CAUTION! The GF/ME dimensions may prohibit direct attachment to a system fan inlet connection.) The FRP housing shall be flanged and drilled per NBS PS 15-69 and come complete with gaskets, ready for installation. The filter / eliminator unit shall be manufactured by Diamond Fiberglass Fabricators, Inc., or equal. SYSTEM ACCESSORIES FAN MOTOR CONTROL - Hazardous Location: 1. A NEMA style combination motor starter with a NEMA Type 7 bolted enclosure shall be provided to operate the system fan. a. The panel shall include a circuit breaker disconnect, control transformer, contactor, solid- state overload relay assembly, start and stop pushbuttons, reset pushbutton, and a red "ON? transformer type pilot light. b. Pushbuttons and pilot light shall be door and/or flange mounted and be NEMA Type 7. c. Combination starter shall be Allen-Bradley 5 13, or equal. FAN MOTOR CONTROLLER MOUNTING STAND A free standing fan control panel mounting stand shall be provided. The stand shall be constructed of structural steel type ASTM-A36 and shall be epoxy-coated, black. FAN SOUND ATTENUATION PACKAGE: The system shall be provided with a fan sound attenuation package. This package shall consist of a rigid acoustical enclosure which is placed over the fan and motor assembly. The panels shall be fabricated with outer skins of 18 gauge 304 stainless steel and inner skins of 22 gauge perforated 304 stainless steel. Panels shall be stiffened with 18 gauge 304 stainless steel channels. Sound absorption is provided by 2.5 pcf fiber mineral wool or glass. Standard panels shall be 2" thick and rated at STC 37 and NRC 0.95. The fan sound attenuation package shall be capable of reducing the sound level by 25 dB at a minimum. This enclosure shall have hinged door(s) for operator access to the fan and motor assembly for maintenance. All doors shall be equipped with heavy duty hardware and with seals to minimize noise leakage. Stainless steel sheet flashing shall be provided to enclose the penetrations in the enclosure for the fan inlet and outlet ducting. The enclosure shall be fitted with a louvered vent(s) for heat dissipatiordventilation. The sound enclosure shall be Vibron model STL or equal. SKID MOUNTING: The system shall be mounted on an epoxy-coated carbon steel skid. The system shall be capable of being lifted and moved as required while mounted on the skid. Cannon Road Lift Station Proiect No. 3583 Odor Control System (Activated Carbon) 15995-7 PCity ol Car(sba616B2A30678Lifl Statim\7 Proj Docs\7.2 Final Docs\100 % i-\15995-r& PART 3 EXECUTION 3.01 MANUFACTURER'S SERVICES A. A manufacturer's trained specialist, experienced in the installation of odor control systems, and with at least five (5) years of field experience shall be present at the job - site and / or classroom designated by the AgencyKontractor for a maximum of three (3) mandays for the following services: 1. Inspection of the installed equipment 2. Start-up assistance 3. Trouble shooting 4. Operator training 3.02 QUALITY ASSURANCE A. The Engineer may provide and direct inspectors to inspect the equipment at the place of manufacture or upon arrival at the job site. The manufacturer shall furnish all reasonable assistance, if required by the Engineer or inspector, for the proper inspection of the work. Inspection shall not relieve the manufacturer from any obligation to perform the work strictly in accordance with this specification. Work not so performed shall be replaced by the manufacturer at his own expense. END OF SECTION Odor Control System (Activated Carbon) 15995-8 Cannon Road Lift Station Project No. 3583 P\city ol Ca1Isbsd-1682~i'S~ SlaUon\7 Pro] Docs\7.2 Final DocsUDo X Specs\l5995-r.doc