BLUE RIVER WASTEWATER TREATMENT PLANT ......2020/01/24 · BLUE RIVER WASTEWATER TREATMENT PLANT CLIENT PROJECT/CONTRACT NO. 081000821/1595 TECHNICAL SPECIFICATIONS DRAFT JANUARY

903 E. 104TH STREET, SUITE 230 • KANSAS CITY, MISSOURI 64131 • P. 816.942.5027 • F. 816.326.6701 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/00001

KC WATER CITY OF KANSAS CITY, MISSOURI

BLUE RIVER WASTEWATER TREATMENT PLANT

CLIENT PROJECT/CONTRACT NO. 081000821/1595

TECHNICAL SPECIFICATIONS

DRAFT

JANUARY 2020

January 2020 - DRAFT TOC-1 11168A60 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/00002 (PDS)

KC WATER CITY OF KANSAS CITY, MISSOURI

BLUE RIVER WASTEWATER TREATMENT PLANT BIOSOLIDS FACILITY

CLIENT PROJECT/CONTRACT NO. 081000821/1595

TABLE OF CONTENTS

DIVISION 09 - FINISHES SECTION NO. TITLE 09960 HIGH-PERFORMANCE COATINGS

DIVISION 10 - SPECIALTIES SECTION NO. TITLE 10880 INDUSTRIAL WEIGHING SCALES

DIVISION 11 - EQUIPMENT SECTION NO. TITLE 11233 HOLDING TANK MIXING SYSTEM 11312I PROGRESSING CAVITY PUMPS 11312Z SEVERE DUTY PROGRESSIVE CAVITY PUMPS 11313J PROGRESSING CAVITY CAKE PUMPS 11334 IN-LINE GRINDER 11339 PRESSURIZED, IN-LINE, SLUDGE SCREEN 11355 THERMAL HYDROLYSIS PROCESS SYSTEM 11358 CENTRIFUGE DEWATERING EQUIPMENT 11392 SIDESTREAM DEAMMONIFICATION SYSTEM

DIVISION 14 – CONVEYING SYSTEMS SECTION NO. TITLE 14554 SCREW CONVEYORS 14558 BELT CONVEYOR SYSTEM 14593 POST-THP SLUDGE STORAGE SYSTEM 14594 PRE-THP SLUDGE STORAGE SILOS 14633 TOP RUNNING DOUBLE GIRDER BRIDGE CRANES

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DIVISION 15 - MECHANICAL SECTION NO. TITLE 15936 BUILDING AUTOMATION SYSTEM 15954 TESTING, ADJUSTING, AND BALANCING FOR HVAC

DIVISION 16 - ELECTRICAL SECTION NO. TITLE 16222 LOW VOLTAGE MOTORS UP TO 500 HORSEPOWER 16224 MEDIUM VOLTAGE MOTORS 16235 SINGLE SPARK-IGNITED GENERATOR SET 16240 BATTERY SYSTEMS 16262 VARIABLE FREQUENCY DRIVES 0.50 - 50 HORSEPOWER 16264 VARIABLE FREQUENCY DRIVES 60 - 500 HORSEPOWER 16268 UNINTERRUPTIBLE POWER SUPPLIES 10 - 30 KVA 16271 DRY TYPE MEDIUM-VOLTAGE TRANSFORMERS 16272 DRY-TYPE TRANSFORMERS 16285 SURGE PROTECTIVE DEVICES 16305 ELECTRICAL SYSTEM STUDIES 16341 5-KILOVOLT MEDIUM VOLTAGE METAL CLAD SWITCHGEAR 16342 15-KILOVOLT MEDIUM VOLTAGE METAL CLAD SWITCHGEAR 16346 5-KILOVOLT MEDIUM VOLTAGE METAL-ENCLOSED INTERRUPTER

SWITCHGEAR 16347 MEDIUM VOLTAGE AUTOMATIC TRANSFER SWITCHES 16411 DISCONNECT SWITCHES 16412 LOW VOLTAGE MOLDED CASE CIRCUIT BREAKERS 16413 LOW VOLTAGE INSULATED CASE CIRCUIT BREAKERS 16422 MOTOR STARTERS 16441 GROUP-MOUNTED CIRCUIT BREAKER SWITCHBOARDS 16444 LOW VOLTAGE MOTOR CONTROL CENTERS 16950 FIELD ELECTRICAL ACCEPTANCE TESTS

DIVISION 17 - INSTRUMENTATION AND CONTROLS SECTION NO. TITLE 17950 SCADA SYSTEM CALIBRATION, TESTING, TRAINING AND

COMMISSIONING

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SECTION 09960

HIGH-PERFORMANCE COATINGS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Coatings, including coating systems, surface preparation, application requirements, and quality control requirements.

1.02 REFERENCES

A. ASTM International (ASTM): 1. D16 - Standard Terminology for Paint, Related Coatings, Materials, and

Applications. 2. D2200 – Standard Practice for Use of Pictorial Surface Preparation Standards

and Guides for Painting Steel Surfaces. 3. D3359 - Standard Test Methods for Rating Adhesion by Tape Test. 4. D3960 - Standard Practice for Determining Volatile Organic Compound (VOC)

Content of Paints and Related Coatings. 5. D4262 - Standard Test Method for pH of Chemically Cleaned or Etched

Concrete Surfaces. 6. D4263 - Standard Test Method for Indicating Moisture in Concrete by the

Plastic Sheet Method. 7. D4285 - Standard Test Method for Indicating Oil or Water in Compressed Air. 8. D4414 - Standard Practice for Measurement of Wet Film Thickness by Notch

Gages. 9. D4417 - Standard Test Methods for Field Measurement of Surface Profile of

Blast-Cleaned Steel. 10. D4541 - Standard Test Methods for Pull-Off Strength of Coatings Using

Portable Adhesion Testers. 11. D4787 - Standard Practice for Continuity Verification of Liquid or Sheet Linings

Applied to Concrete Substrates. 12. D5162 - Standard Practice for Discontinuity (Holiday) Testing of

Nonconductive Protective Coating on Metallic Substrates. 13. D7234 - Standard Test Method for Pull-Off Adhesion Strength of Coatings on

Concrete Using Portable Pull-Off Adhesion Testers. 14. E337 - Standard Test Method for Measuring Humidity with a Psychrometer

(the Measurement of Wet- and Dry-Bulb Temperatures). 15. F1869 - Standard Test Method for Measuring Moisture Vapor Emission Rate

of Concrete Subfloor Using Anhydrous Calcium Chloride. 16. F2170 - Standard Test Method for Determining Relative Humidity in Concrete

Floor Slabs Using In-situ Probes.

B. International Concrete Repair Institute (ICRI): 1. 310.2 - Guideline for Selecting and Specifying Concrete Surface Preparation

for Sealers, Coatings, Polymer Overlays, and Concrete Repair.


C. NACE International (NACE): 1. SP0178 - Design, Fabrication, and Surface Finish Practices for Tanks and

Vessels to Be Lined for Immersion Service. 2. SP0188 - Discontinuity (Holiday) Testing of New Protective Coatings on

Conductive Substrates.

D. National Association of Pipe Fabricators (NAPF): 1. 500-03 - Surface Preparation Standard for Ductile Iron Pipe and Fittings in

Exposed Locations Receiving Special External Coatings and/or Special Internal Linings.

E. NSF International (NSF): 1. 61 - Drinking Water System Components - Health Effects.

F. Occupational Safety and Health Administration (OSHA).

G. Society of Protective Coatings (SSPC): 1. Glossary - SSPC Protective Coatings Glossary. 2. Guide 6 - Guide for Containing Surface Preparation Debris Generated during

Paint Removal Operations. 3. Guide 15 - Field Methods for Retrieval and Analysis of Soluble Salts on Steel

and Other Nonporous Substrates. 4. PA 1 - Shop, Field, and Maintenance Painting of Steel. 5. PA 2 - Procedure for Determining Conformance to Dry Coating Thickness

Requirements. 6. PA 9 - Measurement of Dry Coating Thickness Using Ultrasonic Gages. 7. QP 1 - Standard Procedure for Evaluating the Qualifications of

Industrial/Marine Painting Contractors. 8. SP 1 - Solvent Cleaning. 9. SP 3 - Power Tool Cleaning. 10. SP 5 - White Metal Blast Cleaning. 11. SP 10 - Near-White Metal Blast Cleaning. 12. SP 11 – Power Tools Cleaning to Bare Metal. 13. SP 13 - Surface Preparation of Concrete. 14. SP 16 - Brush-Off Blast Cleaning of Coated and Uncoated Galvanized Steel,

Stainless Steels, and Non-Ferrous Metals. 15. SP COM - Surface Preparation Commentary. 16. SP VIS 1 - Guide and Reference Photographs for Steel Surfaces Prepared by

Dry Abrasive Blast Cleaning. 17. SP WJ-1 - Waterjet Cleaning of Metals -- Clean to Bare Substrate. 18. SP WJ-2 - Waterjet Cleaning of Metals -- Very Thorough Cleaning. 19. SP WJ-3 - Waterjet Cleaning of Metals -- Thorough Cleaning. 20. SP WJ-4 - Waterjet Cleaning of Metals -- Light Cleaning.

1.03 DEFINITIONS

A. Definitions used in this Section are in accordance with definitions referenced in ASTM D16, ASTM D3960, and SSPC Glossary of Definitions.

B. Specific definitions: 1. Abrasive: Material used for blast cleaning, such as sand, grit, or shot. 2. Abrasive Blast Cleaning: Cleaning/surface preparation by abrasive propelled

at high speed.


3. Anchor Pattern: Profile or texture of prepared surface(s). 4. Biogenic Sulfide Corrosion: Corrosion caused by sulfuric acid formed when

Thiobacillus bacteria metabolizes hydrogen sulfide. 5. Bug Holes: Small cavities resulting when air bubbles are entrapped in the

surface of formed concrete during placement and consolidation. 6. System: Protective film with 1 or more coats applied in a predetermined order,

including surface preparation and quality control requirements. 7. Coating/Paint/Lining Thickness: Total thickness of primer, intermediate, and/or

finish coats after drying or curing. 8. Dew point: Temperature a given air/water vapor mixture starts to condense. 9. Drying Time: Time interval between application and material curing. 10. Dry to Recoat: Time interval between material application and its ability to

receive the next coat. 11. Dry to Touch: Time interval between material application and its ability to

tolerate a light ouch without coating damage. 12. Exposed Surface: Any indoor or outdoor surface not buried or encased. 13. Feather Edging: Reducing coating thickness at its edge to blend with existing

surrounding coating. 14. Feathering: Tapering off a wet edge with a comparatively dry brush. 15. Ferrous: Cast iron, ductile iron, wrought iron, and all steel alloys except

stainless steel. 16. Field Coat: Application of a surface coating system at the work site. 17. Finish Coat: Final coat in a paint system, including texture, color, smoothness

of surface, and other properties affecting appearance. 18. Hold Point: A defined point, specified in this Section, at which work shall be

halted for inspection. 19. Holiday: A discontinuity, skip, void, or pinhole in coating or coating system film

that exposes the substrate. 20. Honeycomb: Segregated and porous surface of hardened concrete due to

insufficient consolidation. 21. Hydroblast: High or ultra-high pressure water jet surface preparation. 22. Incompatibility: One coating's inability to overlay another coating or surface as

evidenced by bleeding, poor bonding, or lifting of old coating; inability of a coating to bond to a substrate.

23. Immersed/Immersion: A service condition in which substrate is submerged, is immediately above liquids, or is subject to frequent wetting, splashing, or washdown.

24. Laitance: A thin, weak, brittle layer of cement and aggregate fines on a concrete surface.

25. Mil: 0.001 inch. 26. Overspray: Dry spray, particularly paint bonded to an unintended surface. 27. Pinhole: A small diameter discontinuity in a coating or coating system film,

created by offgassing from a void in a concrete or masonry substrate causing a void between coats or exposing the substrate. Usually caused by coating application while temperature is rising.

28. Pot Life: Time interval after components are mixed and coating can be satisfactorily applied.

29. Prime Coat: First full paint coat applied to a surface when using a multicoat system. Primers adhere to a new substrate, protect the substrate, and promote adhesion of subsequent coats of paint. The prime coat on metal surfaces is the first full coat and does not include solvent wash, grease emulsifiers, or other pretreatment applications.


30. Resurfacer/Resurfacing Material: A layer of cementitious and/or resin-based material used to fill or otherwise restore surface continuity to worn or damaged concrete surfaces.

31. Shelf Life: Maximum storage time a material may be stored without losing its usefulness.

32. Shop Coat: 1 or more coats applied in an off-site shop or plant before shipment to work site where field or finishing coat(s) are applied.

33. Spreading Rate: Area covered by a unit volume of paint at a specific thickness. 34. Stripe Coat: A separate brush coat of paint applied to all weld seams, pits,

nuts/bolts/washers, and edges. This coat shall not be applied until previous coats have cured. Once applied, the coat shall be allowed to cure before subsequent coats are applied.

35. Tie Coat: An intermediate coat that bonds different types of paint material, improving succeeding coat adhesion.

36. Thick Film Coating System: A coating system applied with a minimum dry film thickness of 25 mils.

37. Touch-Up Painting: Application of paint on previously painted surfaces to repair marks, scratches, and deteriorated or damaged areas to restore the appearance and performance of the coating.

38. Water Blast: An alternative to air abrasive blast cleaning that can be used with or without abrasive injection. Water cleaning at pressures up to 5,000 pounds per square inch is called low-pressure water cleaning or power washing. High-pressure water cleaning uses water pressures between 5,000 and 10,000 pounds per square inch. Water jetting is water blasting with added abrasive at pressures between 10,000 and 25,000 pounds per square inch. Ultra-high-pressure water jetting is water blasting at pressures above 25,000 pounds per square inch.

39. Weld Splatter: Beads of non-structural weld metal that adhere to the surrounding surface, removed as part of surface preparation.

1.04 ABBREVIATIONS

A. CSM - Coating System Manufacturer.

B. CMU - Concrete Masonry Units.

C. CSA - Coating System Applicator. Specialty subcontractor retained by the Contractor to install the coating systems specified in this Section.

D. CTR - Coating System Manufacturer's Technical Representative.

E. DFT - Dry-Film Thickness. Thickness of cured film, usually expressed in mils (0.001 inch).

F. SSD - Surface Saturated Dry. Refers to concrete surface condition where the surface is saturated (damp) without the presence of standing water.

G. TPC - Technical Practice Committee.

H. VOC - Volatile Organic Compound. Portion of the coating that is a compound of carbon, is photochemically reactive, and evaporates during drying or curing; expressed in grams per liter (g/l) or pounds per gallon (lb/gal). VOC is determined by EPA Method 24.


I. WFT - Wet Film Thickness. Coating thickness as measured immediately after application. Usually expressed in mils (0.001 inch).

1.05 PERFORMANCE REQUIREMENTS

A. Coating materials shall be formulated for environments encountered in water and wastewater treatment processes.

B. Coating materials that come in contact with water distributed as potable water shall be certified in accordance with NSF 61.

1.06 SUBMITTALS

A. As specified in Section 01300 - Submittal Procedures, submit the following: 1. Schedule of proposed coating materials. 2. Schedule of surfaces to be coated with each coating material. 3. Dehumidification and heating plan. 4. Product data:

a. Physical properties of coatings, including the following: 1) Solids content. 2) Ingredient analysis. 3) VOC content. 4) Temperature resistance. 5) Typical exposures and limitations. 6) Manufacturer's standard color chips.

b. Compliance with regulatory requirements: 1) VOC limitations. 2) Lead compounds and polychlorinated biphenyls. 3) Abrasives and abrasive blast cleaning techniques and disposal. 4) Methods for tenting blasting areas and methods to protect existing

equipment from dust and debris. 5) NSF certification of coatings for potable water supply systems.

c. CSM's current printed recommendations and product data sheets for coating systems, including: 1) Surface preparation recommendations. 2) Primer type. 3) Maximum dry and wet-mil thickness per coat and number of coats.

a) Coating Coverage Worksheets. 4) Minimum and maximum curing time between coats, including

atmospheric conditions for each. 5) Curing time before submergence in liquid. 6) Thinner to be used for each coating. 7) Ventilation requirements. 8) Minimum and maximum atmospheric conditions during which the

paint shall be applied. 9) Allowable application methods. 10) Maximum allowable substrate moisture content. 11) Maximum shelf life. 12) Requirements for transportation and storage. 13) Mixing instructions. 14) Shelf life. 15) Material Pot life.


16) Precautions for applications free of defects. 17) Method of application. 18) Drying time of each coat, including prime coat. 19) Compatible prime coats. 20) Limits of ambient conditions during and after application. 21) Required protection from sun, wind, and other conditions. 22) Touch-up requirements and limitations. 23) Minimum adhesion of each system submitted in accordance with

ASTM D4541 and ASTM D7234. d. Samples: Include 8-inch square drawdowns or brushouts of topcoat finish

when requested. Identify each sample as to finish, formula, color name and number, sheen name, and gloss units.

e. Affidavits signed by an officer of the CSM’s corporation attesting to full compliance of each coating system component with current federal, state, and local air pollution control regulations and requirements.

f. List of cleaning and thinner solutions allowed by the CSMs. g. Storage requirements, including temperature, humidity, and ventilation for

Coating System Materials as recommended by the CSMs. h. Thick film coating systems (greater than 25 mils):

1) CSM's detailed written instructions for coating system treatment and graphic details for coating system terminations in coated structures, including pipe penetrations, metal embedments, gate frames, and other terminations encountered.

2) Include detail treatment for coating system at concrete joints. 3) Manufacturer's Representative’s (CTR) Field Reports.

5. Quality assurance submittals: a. Quality assurance plan. b. Qualifications of CSA, including:

1) List of Similar Projects. a) Name and address of project. b) Year of installation. c) Year placed in operation. d) Point of contact: Name and phone number.

2) Provide a minimum of 5 project references, each including contact name, address, and telephone number where similar coating work has been performed by their company in the past 5 years.

c. CSA Reports: 1) Written daily quality control inspection reports.

d. CTR Reports: 1) Reports on visits to project site to view and approve surface

preparation of structures to be coated. 2) Reports on visits to project site to observe and approve coating

application procedures. 3) Reports on visits to coating plants to observe and approve surface

preparation and coating application on shop-coated items.


1.07 QUALITY ASSURANCE

A. CSA qualifications: 1. Minimum of 5 years of experience applying specified type or types of coatings

under conditions similar to those of the Work: a. Provide qualifications of applicator and references listing 5 similar projects

completed in the past 5 years. 2. SSPC QP 1 certified. 3. Manufacturer-approved applicator when manufacturer has approved applicator

program or when required in these specifications.

B. CTR qualifications: 1. Certification, one of the following:

a. NACE Level 2 or 3 Certified Coating Inspector. b. SSPC Level 3 Protective Coatings Inspector.

2. Minimum of 5 years of experience evaluating application of manufacturer's coatings under conditions similar to those of the Work: a. Provide CTR qualifications and references listing 5 similar projects

completed in the past 5 years.

C. Regulatory requirements: Comply with governing agencies' regulations by using coatings conforming to their VOC limits. 1. Lead-based coatings are not permitted. 2. Do not use coal-tar epoxy in contact with drinking water or exposed to

ultraviolet radiation.

D. Certification: 1. Certify that applicable pigments resist deterioration when exposed to hydrogen

sulfide and other sewage gases. 2. Product data shall designate coating as being suitable for wastewater service.

E. Pre-installation conference: Conduct as specified in the Project Technical Requirements. 1. Coordinate Hold Point schedule.

F. Field samples: 1. Prepare and coat a minimum 100-square-foot area of each system between

corners or limits such as control or construction joints. 2. Approved field sample may be part of the Work.

G. Obtain approval before coating other surfaces. Use products by same manufacturer for prime coats, intermediate coats, and finish coats on same surface, unless specified otherwise.

H. CSM services: 1. CSA shall arrange for CTR to attend pre-installation conferences. 2. Visit the project site periodically to consult on and inspect specified surface

preparation and application Hold Points. 3. Visit coating plants to observe and approve surface preparation procedures

and coating application of items to be shop primed and coated. 4. CTR shall provide written inspection reports.


I. Quality control requirements: 1. Contractor shall be responsible for the workmanship and quality of the coating

system installation. a. Inspections by Owner, Engineer, CSA, or CTR will not relieve or limit

Contractor’s responsibilities. 2. Conform to this specification's requirements and the standards referenced in

this Section. Changes in the coating system application requirements will be allowed only with the Engineer's written acceptance.

3. Specially trained crews with experience applying the specified coating system coating are required for: a. Coating application using plural component spray equipment or other

specialty equipment. b. Coating with specialty linings for severe service conditions, including floor

coatings, and with linings for corrosive headspaces or secondary containment areas.

4. CTR shall specially train personnel for coating systems as specified in Appendix B Coating Detail Sheets. a. CSM shall approve personnel in writing applying the coating system.

5. Do not use contaminated, outdated, diluted materials, and/or materials from previously opened containers.

6. Identify inspection access points used by Owners or Engineers. 7. Provide ventilation, ingress, egress, or other means as necessary for Owner's

or Engineer’s personnel to safely access the work areas. 8. Conduct and continually inspect work so the coating system is installed as

specified. The CSM shall provide written directions to correct coating work not conforming to the specifications or is otherwise unacceptable.

9. Provide written daily reports summarizing test data, work progress, surfaces covered, ambient conditions, quality control inspection test findings, and other information pertinent to the coating system application. a. Determine relative humidity in accordance with ASTM E337. Confirm

other conditions, such as proper protective measures for surfaces not to be coated and safety requirements for personnel. 1) Measure daily at shift's beginning and end and at intervals not to

exceed 4 hours during the shift. 2) Determine the acceptability of weather and/or environmental

conditions within the structure in accordance with the CSM's requirements.

b. Monitoring surface preparation: Spot check cleanliness, surface profile, and surface pH testing at least 3 times daily. Check each surface at least once. In accordance with: 1) ASTM D4262. 2) ASTM D4263. 3) ASTM D4417. 4) ICRI 310.2 requirements. 5) SSPC Surface Preparation Standards.

c. Confirm that compressed air used for surface preparation or blow-down cleaning is free of oil and moisture.

d. Monitor surface preparation daily at shift's beginning and end and at intervals not to exceed 4 hours during the shift.

e. Do not apply coatings when environmental conditions are outside of the CSM's published limits.


f. Monitoring coatings application: Continuously inspect, measure, and record the wet film thickness and general film quality (visual inspection) for runs, sags, pinholes, holidays, etc. during coating. 1) Perform WFT measurements in accordance with ASTM D4414.

g. Post cure evaluation: Measure and inspect the overall dry film thickness on all surfaces. Conduct a DFT survey and perform adhesion testing, holiday detection, or cure testing as required in this Section and/or the CSM’s written instructions. Perform all applicable tests in accordance with ASTM D4541, ASTM D4787, ASTM D5162, ASTM D7234, SSPC-PA 1, SSPC-PA 2, SSPC-PA 9, and other pertinent standards and recommended practices.

J. Inspection at Hold Points: 1. Conduct inspections at Hold Points during the coating system application and

record the results. 2. Coordinate Hold Points with the Engineer so the Engineer can observe

Contractor’s inspections on a scheduled basis. 3. Provide the Engineer a minimum of 24 hours of notice before conducting Hold

Point Inspections. 4. Hold Points shall be as follows:

a. Conditions before surface preparation: Before starting surface preparation, observe, record, and confirm that oil, grease, and/or soluble salts are gone from the surface.

b. Post surface preparation: After completing surface preparation, measure and inspect for cleanliness and proper surface profile as specified in this Section and in the CSM’s written instructions.

c. Coatings application: At the beginning of any coating system application, measure, record, and confirm acceptability of surface and ambient air temperature and humidity. Inspect applicator's equipment for serviceability and suitability for coatings application.

d. Post application inspection: Identify defects in application work on all surfaces, including pinholes, holidays, excessive runs or sags, inadequate or excessive film thickness, and other problems.

e. Follow-up corrective actions and final inspection: Measure and re-inspect corrective coating work performed to repair defects at prior Hold Points, and repeat until the surface condition is acceptable. Conduct final visual inspection with follow-up tests, such as holiday detection, adhesion tests, and DFT surveys.

f. Coatings application: At the beginning of coating system application, measure, record, and confirm acceptability of surface and ambient air temperature and humidity. Inspect applicator's equipment for serviceability and suitability for coatings application. 1) Observe conditions during the Pre-application Meeting.

1.08 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle products as specified in Section 01600 - Product Requirements.

B. Immediately remove unspecified and unapproved coatings from Project site.


C. Deliver new labeled, unopened containers: 1. Do not deliver materials after manufacturer's expiration date or over 12 months

from manufacturing date, whichever is more stringent. Store materials in well-ventilated enclosed structures and protect from weather and excessive heat or cold in accordance with the CSM’s recommendations. a. Store flammable materials in accordance with federal, state, and local

requirements. b. Store rags and cleanup materials appropriately to prevent fire and

spontaneous combustion. 2. Store and dispose of hazardous waste in accordance with federal, state, and

local requirements. This requirement specifically applies to waste solvents and coatings.

3. Container labels shall show the following: a. Brand name or product title. b. CSM's batch number. c. CSM's manufacture date. d. CSM's name. e. Generic material type. f. Application and mixing instructions. g. Hazardous material identification label. h. Shelf life expiration date. i. Color. j. Mixing and reducing instructions.

4. Clearly mark containers to indicate safety hazards associated with the use of or exposure to materials.

1.09 PROJECT CONDITIONS

A. Apply coatings to dry surfaces. 1. Surface moisture: Comply with manufacturer's requirements or as specified in

this Section. a. Plaster and gypsum wallboard: 12 percent. b. Masonry and concrete block: 12 percent. c. Interior located wood: 15 percent. d. Concrete floors: Moisture vapor transmission rate of no more than

3.0 pounds per 1,000 square feet per 24 hours in accordance with ASTM F1869 or relative humidity no greater than 80 percent if tested in accordance with ASTM F2170 unless the CSM's recommendations are more restrictive.

e. Concrete structures: Negative results from Plastic Sheet Test in accordance with ASTM D4263, and maximum of 80 percent relative humidity in accordance with ASTM F2170.

B. Do not apply coatings when the following conditions exist. If such conditions exist, provide containment, covers, environmental controls, and other necessary measures. 1. During rainy, misty, or damp weather, or to surfaces with frost or

condensation. 2. When the surface temperature is below 10 degrees Fahrenheit above the dew

point.


3. When ambient or surface temperature: a. Is less than 55 degrees Fahrenheit unless manufacturer allows a lower

temperature. b. Is less than 65 degrees Fahrenheit for clear finishes, unless manufacturer

allows a lower temperature. c. Exceeds 90 degrees Fahrenheit, unless manufacturer allows a higher

temperature. d. Exceeds manufacturer's recommendation.

4. When relative humidity is higher than 85 percent. 5. Under dusty or adverse environmental conditions. 6. When light on surfaces measures less than 15 foot-candles. 7. When wind speed exceeds 15 miles per hour.

C. Apply coating only under evaporation conditions rather than condensation. 1. Use dehumidification equipment, fans, and/or heaters inside enclosed areas to

maintain required atmospheric and surface temperature requirements for proper coating application and cure.

2. Measure and record relative humidity and air and surface temperatures at the start and end of each shift to confirm proper humidity and temperature levels inside the work area. a. Submit test results.

D. Continuously ventilate, dehumidify, and heat enclosed spaces with high humidity during surface preparation, coating application, and curing. 1. Maintain minimum air temperature of 55 degrees Fahrenheit and 10 degrees

Fahrenheit above the dew point. 2. Maintain dew point of at least 10 degrees Fahrenheit less than the

temperature of the coldest part of the structure where work is performed. 3. Reduce dew point temperature in conditioned space by at least 10 degrees

Fahrenheit within 20 minutes. 4. Seal work areas and maintain positive pressure per dehumidification

equipment supplier's recommendations. 5. Maintain these conditions before, during, and after application to ensure

proper adhesion and cure of coatings for no less than: a. Entire curing period. b. 8 hours after coating.

E. Systems: 1. Site electrical power availability as specified in Section 01500 - Temporary

Facilities and Controls. 2. Internal combustion engine generators may be used.

a. Obtain required permits and provide air pollution and noise control devices on equipment as required by permitting agencies require.

b. Comply with state, federal, and local fire and explosion protection measures when locating and operating generator.

c. Locate engine generator outside hazardous classified areas per NFPA 820.

d. Provide daily fuel service for generator for duration of use. 3. Dehumidification:

a. Provide desiccant or refrigeration drying. b. Use only desiccant types with a rotary desiccant wheel capable of

continuous operation.


c. Liquid, granular, or loose lithium chloride drying systems are not acceptable.

4. Heating: a. Use electric, indirect combustion, or steam coil. b. Direct-fired combustion heaters are not acceptable heat sources during

abrasive blasting, coating application, or coating cure. 5. Filters:

a. Use a filtration system for dust removal designed to not interfere with dehumidification equipment’s ability to control dew point and relative humidity inside the reservoir.

b. Do not allow air from the working area or dust filtration equipment to recirculate through thein dehumidifier during coating application or when solvent vapors are present.

6. Design and submittals: a. Prepare and submit dehumidification and heating plan, including all

equipment and operating procedures. b. Suppliers of services and equipment shall have at least 3 years of

experience in similar applications.

F. Provide containment and ventilation system components in accordance with SSPC-Guide 6, Level 3 and as required for hazardous materials.

1.10 MAINTENANCE

A. Provide table of products applied organized by surface type. List coating manufacturer, color, color formulation, distributor name, telephone number, and address.

B. Provide extra materials: 1. Minimum 1 gallon of each type and color of coating applied or provide

additional quantities if specified in the Contract Documents: 2. Deliver unopened factory-labeled cans when manufacturer packages material

in gallon cans. 3. Deliver material in new gallon containers, properly sealed and identified with

permanently affixed, durable, printed labels indicating brand, type, and color, when manufacturer does not package material in gallon cans, deliver.

1.11 CTR RESPONSIBILITIES

A. General: 1. Attend pre-installation conference. 2. Perform onsite application training. 3. Periodically inspect coating system application.

B. Coating system installation training: 1. Provide a minimum of 8 hours of classroom and off-site training for application

personnel and supervisory personnel in one of the following ways: a. Train a minimum of 2 supervisory personnel and 2 application personnel. b. Submit a letter from the CSM stating that CSM approves the supervisory

and application personnel, listed by name and responsibility, and no additional training is required.

2. CTR can train up to 14 application personnel and 3 supervisory personnel at a time.


3. Minimum training requirements: a. Explain in detail the mixing, application, curing, and termination

requirements. b. Provide hands-on demonstration of coating system mixing. c. Explain in detail the ambient condition requirements for temperature and

humidity. d. Explain in detail the surface preparation requirements. e. Explain in detail the re-coat times, cure times, and related ambient

condition requirements. f. Write a letter stating that training was satisfactorily completed by the

personnel, listed by name and responsibility. 4. Provide special training as specified in the Coating Detail Sheets.

C. Coating system inspection: 1. CTR inspection is in addition to the CSA's inspection as specified in this

Section. 2. Be on-site to oversee:

a. Coating application at least once a week. b. End of surface preparation. c. During coating application. d. Post-cure inspection.

3. Routinely inspect and verify in writing that application personnel have successfully performed surface preparation, filler/surfacer application, coating system application, and Quality Control Inspection in accordance with this Section and to warrantable quality.

4. Perform the following activities to confirm conformance with the specifications: a. Inspect ambient conditions during coating system installation at Hold

Points for conformance with the specified requirements. b. Inspect each coated surface type and coating system applied to verify the

following: 1) Cleanliness. 2) Surface pH for concrete substrates. 3) Confirm surface preparation of substrates where coating system will

terminate or will be applied for conformance to the specified application criteria.

c. Verify surface profile of substrates by completing the following: 1) Inspect preparation and application of coating detail treatment at

terminations, transitions, metal embedments in concrete, and joints and cracks in substrates.

2) Inspect application of filler/surfacer materials for concrete and masonry substrates.

3) Verify proper mixing of coating materials. 4) Inspect application of primers and finish coats, including wet and dry

film thickness. 5) Inspect coating systems for proper cure times and conditions.

d. Review adhesion testing of cured coating systems. e. Review coating system continuity testing. f. Inspect and record representative-localized repairs. g. Conduct final review of completed coating system installation. h. Prepare and submit site visit reports after each site visit to document that

the coating work is in accordance with the CSM’s Recommendations.


D. Final report: 1. Prepare a final report, after coating work ends, summarizing each day's test

data, observations, drawings, and photographs. Include substrate conditions, ambient conditions, and application procedures observed during the CTR's site visits. Include a statement that completed work was performed in accordance with the requirements of the CSM’s recommendations.

PART 2 PRODUCTS

2.01 MATERIALS

A. General: 1. Product requirements as specified in Section 01600 - Product Requirements.

2.02 COATING SYSTEMS IDENTIFICATION

A. Naming Conventions: Coating Systems Identifications contain the elements defined in Table 1.

Table 1 Coating System Identification Elements

First Element - Second Element

- Third Element - Fourth Element (optional)

3 or 4 alpha characters

1-3 alpha characters

1 number 3 or 4 alpha characters

Coating Type Substrate System Number Additional Substrate or Special Condition

Example: EPX - C - 6 - BSC

1) First element identifies the coating type using the following abbreviations: a) ACR: acrylic. b) CTE: coal tar epoxy. c) ELA: elastomeric acrylic. d) EPU: epoxy-polyurethane. e) EPX: epoxy. f) POL: polyurethane. g) SIL: silicone. h) SILX: siloxane or silane. i) VE: vinyl ester.

2) Second element identifies the substrate using the following abbreviations: a) C: concrete or masonry. b) F: concrete flooring. c) FRP: fiber-reinforced plastic. d) GM: galvanized metal. e) M: metal. f) PVC: polyvinyl chloride, chlorinated polyvinyl chloride.

3) Third element identifies the sequential system number. a) For example, EPX-C-2 is the second standard epoxy coating system for

concrete substrates.


4) Fourth element is optional and identifies the additional substrate or special condition with the following abbreviations: a) PWS: Potable water service applications (NSF-61 approved). b) BSC: Biogenic sulfide corrosion-resistant applications in wastewater. c) BG: Below grade or buried. d) OZ: Organic zinc primer, epoxy polyurethane system. e) SC: Secondary containment.

2.03 PRODUCTS FOR COATING SYSTEMS

A. Products: As specified in Appendix B Coating Detail Sheets.

B. Cleaning solvents: 1. Requirements for solvent wash, solvent wipe, or cleaner used, including, but

not limited to, those used for surface preparation in accordance with SSPC-SP 1: a. Emulsifying type. b. Containing no phosphates. c. Biodegradable. d. Does not damage zinc. e. Compatible with the specified primer. f. Complying with applicable air-quality control board requirements.

2. Use clean white cloths and clean fluids in solvent cleaning.

PART 3 EXECUTION

3.01 GENERAL PROTECTION REQUIREMENTS

A. Protect adjacent coated surfaces from coatings and damage associated with coating work. Repair damage resulting from inadequate or unsuitable protection.

B. Use drop cloths and other coverings to protect adjacent surfaces not to be coated against spatter and droppings.

C. Mask off surfaces of items not to be coated or remove items from area.

D. Furnish and deploy sufficient drop cloths, shields, and protective equipment to prevent spray or droppings from fouling surfaces not being coated and, in particular, surfaces within storage and preparation areas.

E. Place coating waste, cloths, and material that may pose a fire hazard in closed metal containers and remove daily from site.

F. Remove electrical plates, surface hardware, fittings, and fasteners before coating application. Carefully store, clean, and replace items after completing coating in each area. Do not use solvent or degreasers to clean hardware that may remove permanent lacquer finishes.

G. Erect and maintain protective enclosures in accordance with SSPC- Guide 6.


H. Protect the following surfaces from abrasive blasting by masking or by other means: 1. Threaded portions of valve and gate stems, grease fittings, and identification

plates. 2. Machined surfaces for sliding contact. 3. Surfaces to be assembled against gaskets. 4. Surfaces of shafting where sprockets will be fit. 5. Surfaces of shafting where bearings will be fit. 6. Machined bronze surfaces, including slide gates. 7. Cadmium-plated items, except cadmium-plated, zinc-plated, or sherardized

fasteners used to assemble equipment requiring abrasive blasting. 8. Galvanized items, unless scheduled to be coated.

I. Protect installed equipment, mechanical drives, and adjacent coated equipment from abrasive blasting to prevent damage caused by spent abrasive blast media, dust, or dirt entering such equipment.

J. Schedule cleaning and coating to keep dust and spray from the cleaning process from falling on wet, newly coated surfaces. 1. Whenever possible, coordinate with other trades and complete surface

preparation and coating work before installing hardware, hardware accessories, nameplates, data tags, electrical fixtures, and similar uncoated items that will be in contact with coated surfaces. Mask machined surfaces, sprinkler heads, and other small items that will not be coated.

2. After completing coating, reinstall removed items. 3. Disconnect and move equipment adjacent to walls to clean and coat

equipment and walls. Replace and reconnect equipment after coating.

3.02 GENERAL SURFACE PREPARATION REQUIREMENTS

A. Prepare surfaces in accordance with CSM's instructions unless more stringent requirements are specified in this Section.

B. Coating detail sheets in Appendix B include additional surface preparation requirements.

C. Follow more stringent requirement if information conflicts.

D. Where required by the Owner’s representative, a NACE International certified coatings inspector, provided by the Owner, will inspect and approve surfaces to be coated before applying a coating. 1. CSA shall coordinate coating inspections.

a. Identify coating inspection Hold Points during the pre-installation conference.

b. Provide at least 2 days notice before inspection. 2. Contractor shall correct surface defects identified by the inspector at no

additional cost to Owner.

3.03 MECHANICAL AND ELECTRICAL EQUIPMENT PREPARATION

A. Identify equipment, ducting, piping, and conduit as specified in the Project Technical Requirements.


B. Remove grilles, covers, and access panels for mechanical and electrical system and coat separately.

C. Prepare and finish coat equipment primed by the manufacturer using specified intermediate and top coats, as applicable, and color selected by the Owner.

D. Prepare, prime, and coat both insulated and bare pipes, conduits, boxes, insulated and bare ducts, hangers, brackets, collars, and supports, except where items are covered with material not requiring coating, or with a prefinished coating.

E. Replace identification markings on mechanical or electrical equipment when coated over or spattered.

F. Prepare and coat interior surfaces of air ducts and convector and baseboard heating cabinets visible through grilles and louvers with 1 coat of flat black paint to limit of sight line.

G. Prepare and coat dampers exposed immediately behind louvers, grilles, and convector and baseboard heating cabinets to match face panels.

H. Prepare and coat exposed conduit and appurtenances occurring in finished areas with color and texture to match adjacent surfaces.

I. Prepare and coat sides' front, back, and edges of plywood backboards for electrical equipment before installing backboards and mounting equipment on them.

J. Color code equipment, piping, conduit, and exposed ductwork and apply color banding and identification, such as flow arrows, naming, and numbering, in accordance with the Contract Documents.

3.04 CLEANING OF NEW AND PREVIOUSLY COATED OR NEW SURFACES

A. Utilize cleaning agent to remove soluble salts, such as chlorides, from concrete and metal surfaces: 1. Cleaning agent: Biodegradable non-flammable and containing no VOC. 2. Manufacturers: The following or equal:

a. CHLOR*RID International, Inc. 1) Complete soluble salt removal with steam or warm water cleaning.

3. Steam clean and degrease surfaces to be coated to remove oils and grease. 4. Clean surfaces with decontamination agent in conjunction with abrasive blast

cleaning, steam cleaning, high-pressure washing, or hand washing, as approved by the CTR and the Engineer.

5. Test cleaned surfaces to ensure removal of soluble salts. Carry out additional cleaning as needed.

6. Complete final surface preparation before applying new coating system in strict accordance with CSM's printed instructions.

3.05 BLAST CLEANING

A. Surface preparation requirements: 1. Do not reuse spent blast abrasive. 2. Ensure that filter compressed air used for blast cleaning is free of condensed

water and oil. Clean moisture traps at least once every 4 hours or more


frequently, as required, to prevent moisture from entering the abrasive blasting equipment air supply. Check blast air for moisture and oil after each cleaning in accordance with ASTM D4285.

3. Install oil separators just downstream of compressor discharge valves and at the discharge point of blast pot discharges. Check separators on the same frequency as the moisture traps.

4. Keep regulators, gauges, filters, and separators on compressor air lines to blasting nozzles operational at all times.

5. Install an air dryer or desiccant filter drying unit to dry the compressed air before blast pot connections. Use and maintain the dryer throughout surface preparation work.

6. Use a venturi-type, or other high velocity-type, abrasive blast nozzles supplied with at least 100 pounds per square inch gauge air pressure at the nozzle and enough volume to obtain appropriate blast cleaning production rates and surface cleanliness.

7. Provide airborne particulate evacuation and filtering that meets OSHA safety standards. Maintain optimal visibility both to clean and provide the specified surface profile and to allow inspection of the substrate during surface preparation work.

8. If prepared and cleaned metallic substrates become contaminated between final surface preparation work and coating system application, or if the prepared substrate darkens or changes color, re-clean by water blasting, or abrasive blast cleaning as appropriate until the specified degree of cleanliness is restored.

B. Water jetting or water blasting: 1. Use water jetting or water blasting for recoating or relining where an adequate

surface profile exists. 2. Perform water jetting or water blasting in accordance with SP 13 and SSPC-

WJ-1, WJ-2, WJ-3, WJ-4.

3.06 PREPARATION REQUIREMENTS FOR CONCRETE SURFACES

A. Cure for at least 28 days before coating.

B. Remove degraded concrete using abrasive blast cleaning or high or ultrahigh pressure water jetting, chipping, or other abrading tools until achieving a sound, clean substrate. Remove all bruised or cracked concrete.

C. Prepare substrate cracks and areas requiring resurfacing; perform detail treatment, including, but not limited to, terminating edges per the CSM's recommendations and as indicated on the Drawings. 1. Prepare concrete surfaces in accordance with SSPC-SP 13.

D. Prepare concrete surfaces in accordance with SSPC-SP 13. 1. Inspect concrete surfaces to select appropriate surface preparation method to

provide a suitable substrate for the specified coating system. 2. Use blast cleaning or other means to expose the complete perimeter of air

voids or bug holes. Do not leave shelled over, hidden air voids beneath the exposed concrete surface.

3. Repair concrete defects and physical damage.


4. Clean concrete surfaces of dust, mortar, formwork, fins, loose concrete particles, form release materials, oil, and grease.

5. Fill voids to provide surface as specified in the Project Technical Requirements.

E. Provide clean substrate visually free of calcium sulfate, loose, coarse, or fine aggregate, laitance, loose hydrated cement paste, and otherwise harmful substances. 1. Confirm concrete surface minimum pH of 9.0 with surface pH testing. 2. If after surface preparation the surface pH remains below 9.0, perform

additional water blasting, cleaning, or abrasive blast cleaning until additional pH testing indicates an acceptable pH level.

F. Prepare concrete surface for coating in accordance with SSPC-SP 13. 1. Provide ICRI 310.2 minimum No. 3 concrete surface profile (CSP) or as

specified on Coating Detail Sheets. 2. Evaluate profile of the prepared concrete using ICRI 310.2 surface profile

replicas.

G. Blast clean cementitious repair mortars or grouts to the same profile and degree of cleanliness requirements required for concrete substrates.

H. Blast clean polymer-based surfacers or waterborne modified cementitious surfaces only if they have exceeded the CSM's recommended recoat time.

I. Vacuum all concrete surfaces before coating application, leaving a dust free, sound concrete substrate. 1. Thoroughly clean concrete surfaces to be coated to remove loose dirt and

spent abrasive. 2. Remove debris produced by blast cleaning from the structures to be coated,

and legally dispose of it off-site.

J. Test moisture content of concrete to be coated: 1. Conduct ASTM D4263 plastic sheet test at least once for every 500 square

feet of surface area to be coated. a. Any moisture on plastic sheet after test period constitutes a

non-acceptable test, and the concrete must be dried further. 2. Conduct ASTM F1869 test at least once for every 1,000 square feet of

concrete floor surface area to be coated. 3. Conduct ASTM F2170 one relative humidity moisture test at least once for

each 500 square feet of non-floor concrete surface area where the opposite side is exposed to soil or water. a. Waterproof surfaces exposed to soil or water where specified in the

Project Technical Requirements. 4. Comply with specified minimum moisture content and CSM’s written

recommendations for moisture vapor transmission rates or relative humidity values.

K. Masonry surfaces: 1. Cure for at least 28 days before coating. 2. Prepare masonry surfaces to remove chalk, laitance, loose dirt, dried mortar

splatter, dust, peeling, or loose existing coatings, or otherwise deleterious substances to leave a clean, sound substrate.


3. Wash and scrub masonry surfaces with clear water. Do not use muriatic acid. 4. Seal or fill masonry surfaces with a sealer or block filler compatible with the

specified primer after cleaning. 5. Confirm that masonry surfaces are dry before coating application.

a. If using pressure washing or low-pressure water blast cleaning for preparation, allow the masonry to dry for at least 5 days under dry weather conditions or until the minimum ambient temperature is 70 degrees Fahrenheit before coating.

3.07 GENERAL PREPARATION REQUIREMENTS FOR METALLIC SURFACES

A. Remove rust, scale, and welding slag and spatter. 1. Remove and grind smooth all excessive weld material and weld spatter on

metal surfaces before blast cleaning in accordance with NACE SP0178, Appendix C, Level C.

2. Grind sharp edges on metal substrate to approximately 1/16-inch radius before abrasive blast cleaning.

B. Prepare metallic surfaces in accordance with applicable portions of surface preparation specifications of the SSPC specified for each coating system. 1. Remove grease and oil in accordance with SSPC-SP 1. 2. Use solvent as recommended by the CSM. 3. Measure profile depth of the surface to be coated in accordance with Method

C of ASTM D4417. Contractor shall select blast particle size and gradation to produce the specified surface profile.

4. Constantly monitor and maintain ambient environmental conditions to ensure cleanliness and that no “rust back” occurs before coating material application.

C. Prepare metallic surfaces by blast cleaning in accordance with SSPC-VIS 1 (ASTM D2200). Prepare abrasive blast representative areas for the Owner's representative to inspect on the first day of cleaning.

D. Unless otherwise specified, the requirements for blast cleaning steel, ductile iron, and stainless steel substrates are as follows: 1. Ferrous metal surfaces not to be submerged: Abrasive blast in accordance

with SSPC-SP 10 unless blasting may damage adjacent surfaces, is prohibited, or is specified otherwise. Where abrasive blasting is not possible, clean surfaces to bare metal with power tools in accordance with SSPC-SP 11.

2. Ferrous metal surfaces to be submerged: Abrasive blast in accordance with SSPC-SP 5, unless specified otherwise, to clean and provide roughened surface profile with a depth between 2 and 4 mils.

3. Remove traces of grit, dust, dirt, rust scale, friable material, loose corrosion products, or embedded abrasive from substrate before coating application.

4. When abrasive blasted surfaces rust or discolor before coating, abrasive blast clean surfaces again.

E. Field preparation of shop-primed surfaces: 1. Smooth welds and prominences with power tools before applying field-applied

coatings. 2. Clean and dry shop-primed ferrous metal surfaces and fabricated assemblies

before applying field coats.


3. Prepare shop epoxy primed surfaces with light abrasive blasting or abrading and then vacuum before applying finish coats. a. Follow CSM instructions for surface preparation when the primer recoat

limit has been exceeded. 4. Non-immersion service: Clean in accordance with SSPC-SP 2 (Hand Tool

Cleaning) or SSPC-SP 3 (Power Tool Cleaning) and uniformly roughen. 5. Immersion, BSC, and SC service: Remove shop primer in accordance with

SSPC-SP 5 (Near-White Blast Cleaning).

F. Damaged shop primer or rust bleeding: 1. Ferrous metals: Clean in accordance with SSPC-SP 1 (Solvent Cleaning) and

spot blast in accordance with SSPC-SP 10 (Near-White Metal Blast Cleaning) to achieve a uniform surface profile between 2.0 and 2.5 mils before recoating.

2. Reject galvanized steel with rust bleeding.

G. Damaged coating: Repair by abrasive blast cleaning surfaces as specified for the coating system; feather to a smooth transition before touching up.

3.08 PREPARATION REQUIREMENTS BY SURFACE TYPE

A. Galvanized steel and non-ferrous metal surfaces: 1. Degrease or solvent clean (SSPC-SP 1) to remove oily residue. 2. Abrasive blast clean in accordance with SSPC-SP 16.

a. If abrasive blast cannot be performed, abrade in accordance with SSPC-SP 3 (Power Tool Cleaning).

3. Apply metal pretreatment within 24 hours before coating galvanized surfaces that cannot be thoroughly abraded, such as bolts, nuts, or preformed channels.

4. Test surface for contaminants using copper sulfate solution.

B. Stainless-steel surfaces: 1. Abrasive blast clean in accordance with SSPC-SP 16 to leave a clean, uniform

appearance with surface profile between 1.5 and 2.5 mils.

C. Ductile iron pipe and fittings to be lined or coated: Abrasive blast clean in accordance with NAPF 500-03.

D. Sherardized, aluminum, copper, and bronze surfaces: 1. Abrasive blast clean in accordance with SSPC-SP 16. 2. Prepare in accordance with CSM's instructions.

E. Cadmium-plated, zinc-plated, or sherardized fasteners: 1. Abrasive blast in the same manner as uncoated metal when assembling

equipment designated for abrasive blasting.

F. PVC and FRP surfaces: 1. Lightly sand surfaces to be coated.

a. Sand to remove gloss and establish uniform surface profile. 2. Vacuum to remove loose dust, dirt, and other materials. 3. Solvent clean with clean white rags and allow solvent to evaporate completely

before applying coating materials.


3.09 APPLICATION REQUIREMENTS

A. Apply coatings in accordance with manufacturer's instructions.

B. Empty aboveground piping to be coated of contents when applying coatings.

C. Mechanical equipment shop primed by the manufacturer. 1. Pumps and valves: Shop coat with manufacturer's highest quality coating

system meeting the project specifications. a. Contractor shall provide CTR shop coating reports.

2. Non-immersed equipment: Touch up shop primer, and coat in the field with specified coating system after installation. a. If project requires equipment removal and reinstallation, complete touch-

up coating after final installation. 3. Immersed equipment not shop coated: Remove shop primer before surface

preparation and field apply coating.

D. Verify surface preparation immediately before applying coating in accordance with SSPC SP COM and the SSPC visual standard for the specified surface preparation method.

E. Allow surfaces to dry, except where coating manufacturer requires surface wetting before coating.

F. Wash coat and prime sherardized, aluminum, copper, and bronze surfaces, or prime with manufacturer's recommended special primer.

G. Do not apply coatings to a surface until it has been prepared as specified.

H. Use equipment designed to apply materials specified. 1. Use compressors with moisture traps and filters that remove water and oils

from the air. a. Perform a paper blotter test at the Engineer's request to verify air is

sufficiently free of oil and moisture. Do not allow the amount of oil and moisture to exceed CSM-recommended amount.

2. Equip spray equipment with properly sized mechanical agitators, pressure gauges, pressure regulators, and spray nozzles.

I. Where 2 or more coats are required, tint prime coat intermediate coats as necessary to distinguish each coating and to help indicate coverage. 1. Do not use color additives with chromium, lead or lead compounds that

hydrogen sulfide, other corrosive gases, might destroy or alter. Apply the specified number of coats.

J. Apply coating by brush, roller, trowel, or spray unless a specific application method is required by coating manufacturer's instructions or these Specifications. 1. Apply primer or first coat by brush to power tool cleaned ferrous surfaces. 2. Brush or spray-apply coats for blast-cleaned ferrous surfaces and subsequent

coats for non-blast cleaned ferrous surfaces. 3. After prime coat dries, mark, repair, and retest pinholes and holidays before

intermediate or top coats are applied.


K. Spray application: 1. With a brush, stripe coat edges, welds, corners, nuts, bolts, and difficult-to-

reach areas, as necessary, before spray application to ensure specified coating thickness along edges.

2. When using spray application, apply each coat to thickness no greater than recommended in coating manufacturer's instructions.

3. Use airless spray method unless air spray method is required by CSM's instruction or these Specifications.

4. Conduct spray coating under controlled conditions. Protect adjacent construction and property from coating mist, fumes, or overspray.

L. Lightly sand and thoroughly clean surfaces to receive high-gloss finishes unless CSM instructs otherwise.

M. Remove all dust on coatings between coats.

N. Shop and field coats: 1. Prime coat: Shop-apply or field-apply prime coats as specified. Use shop-

applied primer compatible with the specified field coating system and apply at the minimum dry film thickness recommended by the finish coat CSM. a. Provide data sheets identifying the shop primer to on-site coating

application personnel. b. Perform adhesion tests on the shop primer. c. Remove and recoat damaged, deteriorated, and poorly applied shop

coatings. d. If shop primer coat meets this Section's requirements, spot prime exposed

metal of shop-primed surfaces before spray applying primer over the entire surface.

2. Field coats: Apply field coats with 1 or more prime coats and finish coats to build up coating to dry film thickness specified for the coating system. a. Do not apply finish coats until other work in the area is complete and

previous coats are inspected. 3. Adhesion confirmation: Perform adhesion tests after proper coating cure in

accordance with ASTM D3359. Demonstrate that: a. Prime coat adheres to the substrate. b. Coatings adhere to the prime and intermediate coats.

1) Coating 5 mils or more DFT: Achieve adhesion test result of 5A on immersed surfaces and 4A or better on other surfaces.

2) Coating less than 5 mils DFT: Achieve adhesion test results of 5B on immersed surfaces and 4B or better on other surfaces.

O. Brush, roll, trowel, or spray and back roll coats for concrete and masonry.

P. Plural component coating application: 1. Premix contents of component drums if required by the CSM each day. 2. Before starting application:

a. Verify gauges are working properly. b. Complete ratio checks. c. Sample the mix on plastic sheeting to ensure set time is appropriate and

complete. d. Label and retain all spray samples. Submit to Engineer when requested.


Q. Drying and recoating: 1. Provide fans, heating devices, or other means to prevent condensate or dew

on substrate surface or between coats and during curing after applying the last coat.

2. Allow each coat to cure or dry thoroughly, in accordance with if required in CSM’s printed instructions, before recoating.

3. Use CSM's printed instructions and the requirements specified in this Section to determine minimum required drying time. a. Do not allow excessive drying time or exposure, which may impair bond

between coats. b. Recoat all coatings within time limits recommended by CSM. c. If time limits are exceeded, abrasive blast clean and de-gloss clean before

applying another coat. 4. If limitations on time between abrasive blasting and coating are not met before

attaching components to surfaces that cannot be abrasive blasted, coat components before attachment.

5. Ensure primer and intermediate coats of coating are unscarred and completely integral when applying each succeeding coat.

6. Touch up suction spots between coats and apply additional coats where required to produce finished surface of solid, even color, free of defects.

7. Leave no holidays. Repair all holidays in accordance with the requirements on pertinent Coating Detail Sheets or as recommended by the CSM.

8. Sand and feather in to a smooth transition and recoat scratched, contaminated, or otherwise damaged coating surfaces so repairs are invisible to the naked eye.

9. For submerged service or highly corrosive headspace service, provide a letter to the Engineer stating that the lining system is fully cured and ready to be placed into service.

R. Workmanship: 1. Ensure that coated surfaces are free from runs, drips, ridges, waves, laps, and

brush marks. Coats shall be applied to produce a smooth, even film of uniform thickness completely coating corners and crevices.

2. Coat surfaces without drops, overspray, dry spray, excessive runs, ridges, waves, holidays, laps, or brush marks.

3. Remove splatter and droppings after coating work is completed. 4. Evenly apply each coat of material and sharply cut to a line created with

masking tape or other suitable materials. 5. Avoid over spraying or spattering paint on surfaces not to be coated. Protect

glass, hardware, floors, roofs, vehicles, and other adjacent areas and installations by taping, drop cloths, or other suitable measures.

6. When coating complex steel shapes, stripe coat welds, edges of structural steel shapes, metal cut-outs, pits in steel surfaces, or rough surfaces with the primer before overall coating system application. a. Brush apply stripe coat to ensure proper coverage. b. Do not stripe coat with spray or roller.

7. Ensure that finish coat, including repairs, has a uniform color and gloss.

S. Coating properties, mixing, and thinning: 1. Thin prime coat and apply as recommended by the CSM. Thinned coating

must comply with prevailing air pollution control regulations.


2. If maximum recoat time is exceeded, prepare surface with solvent washing, light abrasive blasting, or other procedures per CSM’s instructions.

3. Allow adequate drying time between coats as instructed by the CSM, adjusted as necessary for the site conditions.

4. Ensure that coatings, when applied, provide a satisfactory film and a smooth even surface. Lightly sand glossy undercoats to provide a surface suitable for proper application and adhesion of subsequent coats. Thoroughly stir and strain coating materials during application and maintain uniform consistency.

5. Mix coatings with 2 or more components in accordance with CSM’s instructions.

6. Where necessary to suit conditions of the surface, temperature, weather and method of application, thin the coating per CSM's recommendations. a. Ensure that volatile organic content (VOC) of the thinned coating complies

with prevailing air pollution control regulations. b. Thin coatings to only what is necessary to obtain proper application

characteristics. c. Use a thinner recommended by the CSM.

T. Film thickness and continuity: 1. Apply coating to the specified thicknesses.

a. Apply additional coats when necessary to achieve specified thicknesses, especially at edges and corners.

2. Verify WFT of the coating system first coat and after applying each subsequent coat.

3. Do not allow the minimum thickness at any point to deviate more than 25 percent from the required average.

4. Do not allow the surface area covered per gallon of coating for various types of surfaces to exceed those recommended by the CSM. a. Provide coating coverage worksheets listing the maximum and minimum

coverage for each unit volume of coating for concrete surfaces. 5. Apply additional coats to achieve the specified dry film thickness if brush or

roller application methods cannot achieve the specified film thicknesses per coat.

U. Protecting coated surfaces: 1. Do not handle, work on, or otherwise disturb coated items until the coating is

completely dry and hard. 2. After installation, recoat shop-coated surfaces with specified coating system as

necessary to match surrounding surfaces, and to coordinate with the specified color identification requirements.

V. Special requirements: 1. Before erection, apply all but the final finish coat to interior surfaces of roof

plates, roof rafters and supports, pipe hangers, piping in contact with hangers, and contact surfaces inaccessible after assembly. Apply final coat after erection.

2. Coat structural slip-critical connections and high strength bolts and nuts after erection.

3. Areas damaged during erection: a. Prepare surface for spot repairs as specified for the coating system. b. Recoat with prime coat before applying subsequent coats. c. Touch up surfaces after installation.


d. Clean and dry surfaces to be coated at time of application. 4. Coat underside of equipment bases and supports not galvanized with at least

2 coats of primer specified before setting the equipment in place. 5. Coat aluminum in contact with concrete.

3.10 APPLICATION REQUIREMENTS FOR CONCRETE COATING SYSTEMS

A. Apply filler/surfacer as recommended by CSM to fill bug holes and air voids in concrete or block texture in CMU, leaving a uniformly filled surface that does not produce blowholes or outgassing causing the coating system to pinhole. 1. Allow filler/surfacers to cure sufficiently before applying prime coat as required

by the CSM. Use the CSM-recommended drying time between coats.

B. Apply surfacer or filler and let dry before coating application. 1. Use the drying time between filler/surfacer and coating system specified by the

CSM for the site conditions. a. Let concrete substrate dry before applying filler/surfacers or coating

system materials. 2. If the maximum recoat time is exceeded, prepare surfaces by solvent washing,

light abrasive blasting, and other procedures per CSM's instructions. 3. Apply a complete parge coat of the specified filler/surfacer material over the

entire substrate before applying the coating system. a. Scrub filler/surfacer into the substrate to completely fill open air voids and

bug holes. b. Completely cover the substrate, unless otherwise specified, above such

filled voids by 1/8 inch of thickness. c. Provide relatively flat, uniformly even surface before coating application.

4. Secondary containment: Place surfacer or filler 1/16 inch thick above concrete plane to create a monolithic surface free of pinholes. a. Floor surfaces: Broadcast with aggregate to create a non-slip surface

texture. b. Remove excess aggregates and apply base coat to encapsulate

embedded non-slip aggregate.

C. Concrete substrate temperatures: 1. Apply filler/surfacers and the coating system when temperatures are falling,

typically late afternoon or evening. a. Do not coat concrete with rising concrete substrate surface temperatures

or substrates in direct sunlight, to minimize outgassing from the substrate and formation of pinholes, and/or blistering.

2. Should bubbles, pinholes, or other discontinuities form in the applied coating system material, they shall be repaired. a. Should discontinuities develop in the filler/surfacer material or in the first

coat of the coating material, repair them before the next coat. b. When discontinuities occur, open the air void behind or beneath the

discontinuities and completely fill with specified coating material. Then, abrade the coated area around the discontinuities repair reapply coating over that area.

D. Perform application detail work in accordance with these Specifications, the CSM’s current written recommendations, and drawings, whichever is stricter.


E. Concrete coating systems application requirements: 1. Concrete coating minimum dry film thickness excludes parge coat, block filler,

and sealer.

3.11 COATING SYSTEM SCHEDULE

A. Appendix A specifies surfaces to be coated in the field with the coating systems required.

3.12 SURFACES NOT REQUIRING COATING

A. Stainless steel piping, valves, pipe supports, instrument sunshades.

B. Sliding surfaces on expansion joints, motor and pump shafts, machined surfaces at bearings and seals, grease fittings, etc.

C. Galvanized structural steel framing, galvanized roof decking, galvanized pipe supports.

D. Copper and brass pipe, fittings, valves, etc.

E. Bronze valves, bearings, bushings, and fasteners.

F. Corrosion resistant special alloys: Inconel, Alloy 20, Hastelloy, etc.

G. Exterior Concrete.

H. Plastic surfaces except coat PVC, CPVC, and other plastic piping system exposed to sunlight.

I. Buried Piping that is encased in concrete or cement mortar.

3.13 QUALITY CONTROL

A. Owner-provided inspection or inspection by others does not limit the Contractor’s or CSA’s responsibilities for quality workmanship or quality control as specified or as required by the CSM’s instructions. Owner inspection is in addition to any inspection required of the Contractor.

B. Owner may perform, or contract with an inspection agency to perform, quality control inspection and testing of the coating work covered by this Section. These inspections may include the following: 1. Inspect materials upon receipt to ensure that the CSM supplied them. 2. Verify that specified storage conditions for the coating system materials,

solvents, and abrasives are provided. 3. Inspect and record findings for substrate cleanliness. 4. Inspect and record pH of concrete and metal substrates. 5. Inspect and record substrate profile (anchor pattern). 6. Measure and record ambient air and substrate temperature. 7. Measure and record relative humidity. 8. Check for substrate moisture in concrete. 9. Verify that mixing of coating system materials is in accordance with CSM’s

instructions.


10. Inspect, confirm, and record that coating system materials' "pot life" is not exceeded during installation. Inspect to verify that recoat limitations for coating materials are not exceeded.

11. Perform adhesion testing. 12. Measure and record the coating system's thickness. 13. Verify proper curing of the coating system in accordance with the CSM's

instructions. 14. Holiday or continuity testing in accordance with NACE SP0188 for coatings

that will be immersed or exposed to aggressively corrosive conditions.

C. Contractor shall perform holiday testing in accordance with NACE SP0188 to identify holidays or pinholes needing repair for coating over 100 percent of surfaces: 1. Coated steel that will be immersed or exposed to aggressively corrosive

conditions. 2. Coated concrete. 3. Perform holiday tests after proper application and coating system cure.

3.14 CORRECTIVE MEASURES

A. Repair pinholes or holidays identified by Holiday Testing as follows: 1. Remove the coating system with a grinder or other suitable power tool. 2. Remove coating system at all pinholes and holidays at least 2 inches diameter

around the defect back to expose substrate. 3. Concrete voids: chip back to expose entire cavity in all directions.

a. Completely fill void with approved filler/surfacer material using a putty knife or other suitable tool, and strike off. Cure per CSM’s recommendations.

4. Aggressively abrade or sand the intact coating system surface at least 3 inches beyond the removal area in all directions to produce a uniform 6- to 8-mil profile in the intact coating system.

5. Vacuum the prepared area to remove all dust, dirt, etc., leaving clean, sound surfaces.

6. Tape to mask the periphery of the prepared intact coating area to prevent coating repair application onto the prepared area.

7. Apply the coating system with enough coats to achieve the specified finish coat thickness over the defect and coating removal area. Feather the coating onto the abraded coated surfaces around the removal area to avoid a lip and to achieve a neat repair outline.

8. Follow curing time between coats as specified by CSM for the site conditions. Solvent wash and abrasive blast per CSM's instructions, if the maximum recoat time is exceeded.

9. Apply coating at specified dry film thickness.

3.15 CLEANUP

A. Remove surplus materials, protective coverings, and accumulated rubbish after completing coating. Thoroughly clean surfaces and repair overspray or other coating-related damage.


3.16 FINAL INSPECTION

A. Conduct final inspection of coating system work to determine whether it meets specifications requirements.

B. Conduct subsequent final inspection with Engineer to ensure work conforms to contract documents requirements.

C. Mark any rework required: 1. Re-clean and repair, as specified, at no additional cost to the Owner.

END OF SECTION

January 2020 - DRAFT 10880-1 11168A60 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/10880 (PDS)

SECTION 10880

INDUSTRIAL WEIGHING SCALES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Pitless type, concrete deck motor truck scale, associated electronic controls and related wiring and accessories.

B. Related sections: 1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all. 2. It is the Contractor’s responsibility for scheduling and coordinating the Work of

subcontractors, suppliers, and other individuals or entities performing or furnishing any of Contractor’s Work.

C. Reference Location: 1. Cake Loading Facility.

1.02 REFERENCES

A. Missouri Department of Agriculture and all other applicable Missouri State and County agencies.

B. National Electrical Code (NEC).

C. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

D. National Institute of Standards and Technology (NIST): 1. Handbook 44 - Specifications, Tolerances, and Other Technical Requirements

for Weighing and Measuring Devices.

1.03 DEFINITIONS

A. NEMA: 1. Type 4X enclosure in accordance with NEMA 250. 2. Type 12 enclosure in accordance with NEMA 250.

1.04 SYSTEM DESCRIPTION

A. Design requirements: 1. Pitless type, concrete deck motor truck scale. 2. Each truck scale shall be a fully electronic and shall not incorporate any

mechanical weighing elements, check rods, or check stays. 3. Scale shall meet the requirements set forth by the current edition of the NIST

Handbook 44. Scale manufacturer shall submit Certificate of Conformance (NTEP Certification) to these standards.


4. Each truck scale shall have a 50-ton minimum gross weight capacity and a 45,000-pound tandem axle capacity, with a reinforced concrete weigh bridge 60 feet long by 11 feet wide.

5. Maximum height from top of load cell mounting platform to top of weigh bridge shall be 16-inches.

6. Junction boxes, load cells, and load cell mounting hardware shall be constructed of 316 stainless steel. The cables shall be stainless steel sheathed.

7. Each scale shall be complete with weigh bridge, load cells, splice boxes, electronics with digital indicator, and all instrumentation, electrical, and other accessories required for a complete operational unit.

8. The system shall consist of multiple load cells that are environmentally sealed, rocker pin or double link style suspension system, corrosion-resistant anchor bolts, assembly fasteners, and all appurtenances necessary for complete assembly. Anchor bolts and fasteners shall be 316 stainless steel.

9. Load cells: a. Load cells shall be strain gauge type, specially sealed, in accordance with

manufacturer's recommendations for continuous operation in an environment containing trace quantities of hydrogen sulfide.

10. Load cell parameters shall not exceed the following:

Calibration Accuracy 0.1 percent Rated Output Nonlinearity .05 percent Full Scale Creep .03 percent Full Scale Temperature Effect .0008 percent Full

Scale/Degrees Fahrenheit Hysteresis .02 percent Full Scale Repeatability .02 percent Full Scale Zero Stability 1.0 percent Full Scale

11. Truck scale manufacturer is responsible for providing the truck scale, load cells and weight indicating transmitters. Quantity of load cells and weight transmitters to be determined by the truck scale manufacturer. Only one set of instrument (one load cell and one weight transmitter) is shown on the drawings for clarity. a. Contractor to coordinate with truck scale manufacturer and provide

additional power, PLC I/O modules, conduits, wires, manufacturer's cables and accessories for all load cells and weight transmitters similar to what is required for one set of instruments as shown on the drawings.

1.05 SUBMITTALS

A. Shop drawings: Indicate locations of equipment, service connections, loads, electrical wiring diagrams: 1. Complete fabrication, assembly and installation drawings, wiring, and

schematic diagrams; details, specifications, and data covering the materials used and the parts, devices, and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section.

2. Submitted catalog cuts sheets shall be clearly marked to show the applicable model number, optional features, and intended service of the device. Wiring diagrams shall show complete circuits and indicate all connections.


3. The initial submittal shall be substantially complete for all items and equipment furnished under this Section. a. Individual drawings and data sheets submitted at random intervals will not

be acceptable for review.

B. Certificate of Conformance (NTEP Certification) to NIST H-44 standards.

C. Close-out submittals: 1. Record drawings: Include schematics, wiring and connection diagrams. 2. Operation and maintenance data:

a. Include description of system and components. b. Include operating, maintenance, and repair instructions with

comprehensive, step-by-step procedural description of system for trouble shooting.

c. Include wiring and control schematics. d. Include cataloged list of spare parts with recommended quantities of

"parts on hand." e. Operations and maintenance manuals shall include complete product

instruction books for each item of equipment furnished. 1) Where instruction booklets cover more than 1 specific model or

range of instrument, product data sheets shall be included which indicate the instrument model number, calibrated range, and all other special features.


A. Manufacturer qualifications: Company specializing in products of the type specified in this Section with minimum 3 years experience. 1. All equipment provided under this Section shall be furnished by and through a

single manufacturer who shall be responsible for the design, coordination, and satisfactory performance of all components.

2. Manufacturer shall have quality system that has been registered to the standards of ISO 9001.

3. All welding shall be completed in accordance with, and performed by welding operators who have been certified to, the AWS D1.1 Structural Welding code.

B. Installer qualifications: Company approved by manufacturer.

1.07 REGULATORY REQUIREMENTS

A. The scale system shall conform to the following federal, state, local, and industrial standards: 1. NIST Handbook 44. 2. NEMA and the NEC.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following, no equal: 1. Cardinal Scale Manufacturing Company.


2. Mettler-Toledo Inc. Scale. 3. Rice Lake Weighing Systems.

2.02 TRUCK SCALES

A. Weigh bridge: 1. The weigh bridge shall consist of structural steel beams and cross members,

and a welded steel frame reinforced concrete deck complete with built-in heavy-duty side rails.

2. Main beams and cross members shall be designed by truck scale manufacturer. Steel properties of the beams shall not be less than the following: a. Main Cross Beams: Steel properties shall not be less than that of steel

member W 21 x 50. b. Cross Members: Steel properties shall not be less than that of steel

member W 8 x 24. 3. Designed to perform as a single weighing platform and shall have side rails. 4. Consist of factory-fabricated components that are bolted together. 5. Designed to allow top access to the junction boxes (if applicable), load cell

cables, base plates, and all foundation anchor bolts from the side of the scale platform.

6. Concrete deck shall be a minimum of 8-inches thick reinforced concrete, placed in the weigh bridge between the main beams and associated cross members. Concrete shall have a minimum strength of 4,000 psi at a 28-day cure with 5- to 7-percent air entrainment.

7. Weigh bridge and load cell mounting assemblies shall be designed to allow installation or replacement of a load cell with only one additional inch of clearance required between the top of the foundation and the bottom of the weigh bridge.

8. There shall be no bolted connections between the load cell and weigh bridge assemblies.

9. Provide built-in heavy-duty side rails along the entire length of the weigh bridge on both sides. a. Side rails shall be ASTM A-500 with 3-1/2-inch nominal size. b. Provide end caps and reflective tape on rails.

B. Load cell: 1. Each load cell shall have a minimum capacity of 50,000 pounds. 2. Load cells shall be certified by NTEP and meet the specifications set forth by

NIST H-44 for Class IIIL devices. 3. Load cell assembly shall be constructed so as to perform as a rocker pin and

shall have no positive fixed mechanical connectors, such as bolts or links, that are required in mounting the load cell to the weigh bridge or foundation base plates.

4. Load cell shall not require check rods of chain links for stabilization. 5. Stainless steel construction and hermetically sealed with a minimum NEMA

6P/IP68 (submersible) rating. 6. Load cell shall have a positive-lock quick connector integral to its housing for

connecting and disconnecting the load cell interface cable at the load cell. The connector shall be of glass-to-metal, pin-type construction to maintain a hermetic seal. Alternatively, load cell cables shall be wired directly into load cells.


7. Load cells shall be connected via a CAN (Controller area network) bus system to the weight indicating transmitter.

8. All load cell cables shall be provided by the load cell manufacturer. 9. Provide rough-in hardware, supports, connections, attachments, and other

accessories required for complete installation.

C. Electrical requirements: 1. Power supply:

a. Unless otherwise specified, the power supply to the equipment shall be 120 volts, single phase, 60 hertz.

b. Where control voltages lower than the power supply voltage is required, suitable control power transformers shall be furnished.

2. Lightning protection: Lightning protection for each scale system shall be provided to protect the load cells, instrumentation, and power supply.

3. Grounding: Tinned 1/0 copper grounding conductors shall be furnished and installed from the scales to the ground grid or to a ground rod furnished for the grounding electrode system as required by the equipment furnished.

2.03 ACCESSORIES

A. Instrumentation accessories for the truck scale shall consist of a digital readout indicator, terminal tie-in, and all cable, conduit, hookups, and appurtenances necessary to make the scale system operational.

B. Scale shall be calibrated to a minimum of 120,000 pounds by 20-pound increments.

C. Digital Weight Indicating Transmitter: 1. Weight indicating transmitter shall connect to the load cells specified in this

section via a CAN bus network. 2. Weight indicator shall be digital type with LED indication.

a. Display shall have 6-digit indication in maximum 20-pound increments. 3. Indicator shall have a zero lock key switch, "power on" LED indication, and

continuous weigh mode. 4. Automatic tare control shall allow both gross and net weight indication. 5. Unit shall operate on 120-volt, single-phase power and shall include a surge

voltage protection system. 6. Enclosure: The unit shall be housed in a NEMA Type 4X enclosure. 7. Remote weight indication. 8. Provide a 4-20 mA direct current output signal for remote weight indication,

and provide a low weight alarm contact for remote indication. 9. Provide sun-shield for all outdoor installations.

2.04 FABRICATION

A. Fabricate items straight, true to line, all components securely fastened.

B. Edge grinding: Sharp projections of cut or sheared edges of ferrous metals which are not to be welded shall be ground to a radius required to ensure satisfactory paint adherence.


C. Finishes: 1. General: Factory finish all ferrous metal with manufacturer's standard paint

finish. All ferrous metal surfaces, except stainless steel, shall receive shop finishing.

2. Surface preparation: All ferrous metal surfaces, except stainless steel, shall be cleaned in the shop in accordance with the paint manufacturer's recommendations and as specified on the coating system data sheet at the end of this Section. a. All mill scale, rust, and contaminants shall be completely removed before

shop primer is applied. 3. Shop painting: All steel surfaces, except stainless steel, shall be shop painted. 4. Additional field painting other than touch-up painting of damaged surfaces will

not be required. a. Touch-up painting shall be performed within the recoat time established

by the paint manufacturer. b. When touch up painting is required after expiration of the recoat time,

painting shall be preceded by blast cleaning or other surface preparation as recommended by the paint manufacturer to obtain satisfactory adhesion between coats.

D. Anchor bolts: All anchor bolts, nuts, and washers shall be 316 stainless steel and shall comply with the fasteners section.

PART 3 EXECUTION Not Used.

END OF SECTION


SECTION 11233

HOLDING TANK MIXING SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes: Mechanical mixing system consisting of floor-mounted mixing nozzles for both the East and West Sludge Holding Tanks arranged to positively and completely mix the holding tanks to meet the performance requirements specified herein.

1.02 GENERAL

A. Like items of equipment specified herein shall be the end products of one manufacturer in order to achieve standardization for maintenance, spare parts, operation, manufacturer's service and single source responsibility.

B. The design of the sludge holding tank mixing systems included in these contract documents is based on the Vaughan Rotamix mechanical mixing system manufactured by Vaughan Company, Inc.

C. The sludge holding tank mixing systems shall be of single source responsibility. 1. The mixing systems manufacturer shall be solely responsible for the design of

the mixing system per the system performance requirements mentioned herein. Mixing system design includes, but is not limited to, pumps, pump suction and discharge piping configurations within the tank to be mixed, nozzles, and nozzle mounting and configuration.

2. Additionally, the tank mixing systems manufacturer shall be solely responsible for the manufacturing of the mixing system components including, but not limited to, pumps and nozzles as part of a coordinated system design to meet the specified performance requirements.

1.03 OPERATIONAL REQUIREMENTS

A. Final acceptance of the sludge holding tanks mixing systems shall be contingent on the installed system meeting the system Performance Requirements described herein.

B. Shop Drawing Submittals for this system shall include a certification of performance letter as required below.

1.04 SUBMITTALS

A. Conform to Section OR-01300 - Submittal Procedures.

B. Shop Drawings: 1. A letter of certification shall be submitted stating that the sludge holding tanks

mixing systems shall meet all the performance requirements of this Specification.


2. The manufacturer of the mixing system shall submit a report, in color, and the output files which show the results of their computer modeled design specific for this Project. a. The report shall include the hydraulic calculations used to determine the

total dynamic head (TDH) required for the pump for the full range of possible sludge densities specified. 1) Hydraulic calculations provided shall include pump curves, operating

points, TDH, NPSH, and system curves. b. The report shall also include the results and output from the

Computational Fluid Dynamics (CFD) model used to determine the positioning and setting angles of the nozzles. 1) The number, positioning, and setting angles of the nozzles shall be

selected to give the best mixing for the full range of sludge densities specified and to meet the performance requirements specified.

2) A pseudo-tracer burst and washout analysis shall be performed with the CFD modeling software for verification of system performance. a) Initial system acceptance, for system procurement, will be

provided upon approved analysis results. b) Final system acceptance will occur when the system meets the

performance test requirements per Part 3.04 B. 3) Proof of current license key for CFD software shall be provided.

3. Detailed layout drawing for the mixing nozzles including number of nozzles, radial distances, nozzle discharge elevations, and setting angles. The layout drawing shall include the following tank geometry from the Drawings: diameter, floor slope, and liquid depth. The layout drawing shall also include structural members and other obstructions installed within the tank.

4. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. a. Detailed structural and mechanical drawings showing the equipment

dimensions, size, and installation. b. Make, model, and weight of each equipment assembly.

5. Factory protective coatings for all equipment and materials provided. 6. Anchor bolt calculations and mounting details for each equipment assembly.

a. Manufacturer to specify anchor bolts suitable for operational loads. Seismic and other load conditions to be analyzed by others and may require additional bolt engagement depth.

7. Electrical information including, but not limited to, full load current and locked rotor current.

8. Details of storage and off-loading requirements. 9. A minimum three year list of mixing installations for systems with similar

sludge characteristics where identical equipment by the manufacturer is currently in service; include contact name, telephone number, mailing address, and the names of the Engineer, Owner, and installation contractor.

10. Manufacturers submitting proposals for equipment that would require changes in the design shall also include detailed information on structural, electrical, mechanical, and other miscellaneous changes or modifications necessary to adapt their equipment. Proposals shall be subject to review and approval by the Engineer.

C. Torsional analysis.


D. All cutting and wear parts shall be heat treated suitable to achieve a Rockwell C hardness of 60, minimum.

E. Quality Control Submittals: 1. Manufacturer's Certificate of Compliance signed by an authorized

representative of the manufacturer certifying that the materials and assemblies to be provided meet or exceed these specifications.

2. Manufacturer's Certificate of Proper Installation signed by an authorized representative of the manufacturer certifying that the materials and assemblies have been installed correctly and are fully operational.

3. Operations and Maintenance Manual. 4. Performance affidavit.

F. Warranties: 1. Nozzle warranty. 2. Pump warranty.


A. Provide mixing system pumps and mixing nozzles from the same manufacturer. 1. Pump manufacturer is required to furnish and coordinate pump, driver, and

pump components as specified and scheduled. a. Drive controls and integration by others.

2. Pump manufacturer shall provide written installation and check out requirements.

B. Provide manufacturer’s warranty and performance affidavit for equipment to be furnished in accordance with this specification. 1. Nozzle warranty:

a. Shall be a 10-year, non-prorated warranty commencing on the initial start-up date or when the system has been certified by authorized personnel of the Vaughan Company as ready for operation, not to exceed 126 months from shipping.

2. Pump warranty: a. Warrant equipment free of defects in material and workmanship for

2 years from the date of acceptance or date of first beneficial use of equipment by the Owner, whichever is later. Warranty shall cover parts and labor.

b. Manufacturer’s warranty shall be issued in the Owner’s name. 3. Performance Affidavit:

a. A performance affidavit shall be supplied to the Contractor and Owner certifying that the system as provided will meet or exceed the performance requirements for the specific application: 1) The affidavit shall also include a statement that a minimum of

90 percent active mixing will occur within 60 minutes or less in the associated sludge holding tank with a guaranteed flow rate not less than the rated design point in the schedule.

2) Mixing Equipment: The affidavit shall also include a statement to the Owner and Contractor that the mixing pump shall be the complete responsibility of the mixing equipment supplier, guaranteeing its performance not to clog or bind on solids typically found in the application set forth.


b. Manufacturer shall confirm to Contractor and Owner that the Contract Documents have been examined and that all equipment will meet in every way the performance requirements set forth in the Contract Documents for the application specified.

c. Engineer will not review shop drawings prior to receipt of an acceptable performance affidavit.

d. The performance affidavit shall be signed by an officer of the company manufacturing the equipment and witness by a notary public.

e. The performance affidavit must include a statement that the equipment will not clog or bind on solids typically found in the application set forth.

4. The mixing system as outlined for this Project shall be the complete responsibility of the approved manufacturers listed. A complete system will be provided including, but not limited to, pumps, drivers, motors, drive arrangements as specified, shafts, seals, couplings, base plates, guards, nozzle assemblies, lifting eyes, and anchor bolts. All performance and warranty requirements shall also be the responsibility of the approved manufacturers.

5. Unless otherwise specified, the Contractor shall supply all pump suction and discharge piping to nozzles, piping supports, as well as controls panels, valves, gauges, and other specialties. a. Pump suction and discharge piping arrangements including, but not

limited to, nozzle mounting locations and elevations, within the tank shall be determined by the mixing system manufacturer.

1.06 DELIVERY, STORAGE, AND HANDLING

A. When practical, the equipment specified herein shall be factory assembled. The parts and assemblies that are of necessity 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. Generally, machined and unpainted parts shall be protected from damage by the elements of weather with the application of a strippable protective coating.

B. All items of equipment shall be cleaned at the point of origin and all openings plugged so that they arrive at the jobsite ready for assembly and operation. Provide all necessary lubricants.

PART 2 PRODUCTS


A. Each complete mixing system shall consist of mixing nozzle assemblies and mixing pumps, complete with all appurtenances and accessories. The number, location and orientation of the nozzles shall be determined by the manufacturer to meet the performance requirements.

2.02 MANUFACTURERS

A. One of the following or equal: 1. Vaughan Co., Inc.:

a. Mixing system: Rotamix®. b. Pumps: Severe Duty Chopper Pumps.


2.03 PUMP CONSTRUCTION AND MATERIALS

A. General: Pump Construction and Materials shall coincide with other chopper-type centrifugal pumps to be provided for this project. Refer to the Basis of Design report and its appendices for additional information.

2.04 PUMP DRIVERS

A. Horsepower: 1. As scheduled in this section. 2. Listed driver horsepower is the maximum to be supplied.

a. Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout.

b. When scheduled driver is a motor, increase motor horsepower if required to prevent operation in the service factor.

c. Make all structural, mechanical, and electrical changes required to accommodate increased horsepower.

B. Motors: Provide motors as specified in Section 16222 - Low Voltage Motors up to 500 Horsepower and as specified in this Section: 1. Revolutions per minute: As scheduled: 2. Enclosure: As scheduled. 3. Electrical characteristics: As scheduled. 4. Efficiency, service factor, insulation, and other motor characteristics: As

specified in Section 16222 - Low Voltage Motors up to 500 Horsepower. 5. Motor accessories: As specified in Section 16222 - Low Voltage Motors up to

500 Horsepower and in this Section. 6. Coordinate motors with the variable frequency drive manufacturer to ensure

compatibility between the motor and variable frequency drive.

C. Other drivers: As scheduled and as specified in sections listed in the Schedule.

2.05 SPARE PARTS AND SPECIAL TOOLS

A. Spare parts: Deliver the following: 1. Drive belts and sheaves: 1 set of matched belts and sheaves. 2. Mechanical seal: 1 complete seal assembly for each type supplied. 3. Pump bearings: 1 set of radial and 1 set of thrust bearings. 4. Impeller cutter bar: 1 set.

B. Special tools: Provide 1 set of all special tools required for complete assembly or disassembly of all the pump system components.

2.06 MIXING ASSEMBLIES

A. General: 1. All piping joint connections shall be watertight and shall be capable of

withstanding the pressures generated by the static head of the tank plus the discharge pressure of the sludge mixing pump. a. All piping associated with the mixing assembly shall be ASTM A536 glass-

lined cast ductile iron.


2. The mixing nozzle assemblies shall have a minimum life of 10 years without system performance degradation. Provide a statement of such warranty.

3. The number of nozzles and their location and orientation shall be determined by the mixing system manufacturer.

B. Nozzles: 1. Shall be ASTM A536 glass-lined cast ductile iron with a minimum hardness of

Rockwell 73C. 2. Wall thickness shall be 1.0-inch minimum or greater to protect against

abrasive conditions and a long, straight taper length of at least 12-inches. 3. Shall be completely self-cleaning. 4. Zinc anodes shall be provided to protect against galvanic corrosion.

C. Assembly Fittings: 1. Shall be ASTM A536 glass-lined cast ductile iron.

D. Base: 1. Shall be fabricated carbon steel, with 3/4-inch mounting holes for 5/8-inch

anchor bolts.

E. Anchor Bolts: 1. Shall be 5/8-inch diameter and of sufficient length to support thrust loads from

nozzles. Material shall be 316 stainless steel.

2.07 SOURCE QUALITY CONTROL

A. Witnessing: Source or factory testing shall be witnessed by the Engineer or Owner as scheduled.

B. Motor Factory Tests: Test as specified in Specification Section 16222 - Low Voltage Motors up to 500 Horsepower.

PART 3 EXECUTION


A. Each sludge holding tank mixing system shall positively and continuously mix the entire contents of the tank. The variation in total solids throughout the holding tank shall not vary more than plus or minus 10 percent from the mean total solids for the tank when the mean total solids concentration in the tank is within the range specified in the Holding Tank Design Criteria table below.

B. The mixing system shall be designed to produce a rotational mixing pattern within the tank, while also producing flow across the middle portion of the tank thereby preventing solids from migrating towards the center. Solids shall be effectively drafted by the nozzle discharge to the outer 30 percent of the tank where the peripheral rotation will create a homogeneous state throughout the entire process suspending both organic and inorganic solids sufficient to meet the performance requirements above. The mixing pattern shall effectively prevent mounding in the center of the process.


C. Chopper Centrifugal Pumps with Components: Pump, driver, motors, and drive arrangements as specified or as scheduled with shafts, seals or packing, couplings, base plates, guards, supports, anchor bolts, necessary valves, gauges, taps, lifting eyes, stands, and other items as required for a complete and operational system.

D. Chopping/maceration of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter box at the intake opening.

E. The pumps shall be capable of continuous operation while pumping sludge containing up to the percent solids specified in the Holding Tank Design Criteria Table below with heavy rags, plastics, grease, hair, grit, and other stringy fibrous material.

F. Holding Tank Design Criteria:

East Sludge Holding

Tank West Sludge Holding

Tank Service Raw

Primary/Secondary Sludge

Digested Blended Thermally Hydrolyzed

Sludge Solids Concentration 1% to 4% 4% to 7% Diameter 80 feet 80 feet Side Water Depth 27 feet (varies) 27 feet (varies) Bottom Slope 1 foot vertical for each

6 feet horizontal 1 foot vertical for each

6 feet horizontal Cone Depth 8 feet 8 feet Volume 1.26 MG 1.26 MG

G. Mixing Pump Design Criteria:

East Sludge

Holding Tank West Sludge Holding Tank

General Characteristics: Service Raw

Primary/Secondary Sludge

Digested Blended Thermally

Hydrolyzed Sludge Solids Concentration 1% to 4% 4% to 7% Manufacturer’s Model Number HER12W18CSB-

190 HER12W18CSB-

190 Quantity 1 (+1 standby)(1) 1 Max. Noise, dBA at 3 Feet 85 85 Torsional Analysis Required Required Minimum Pumped Fluid Degrees Fahrenheit 50 85 Normal Pumped Fluid Degrees Fahrenheit 70 95 Max. Pumped Fluid Degrees Fahrenheit 100 105


East Sludge

Holding Tank West Sludge Holding Tank

Pump Characteristics (2): Speed Control Variable Frequency

Drive Variable Frequency

Drive Maximum Pump Speed, rpm 705 705 Minimum Pump Speed, rpm 530 530 Rated Design Point: (at Maximum rpm, corresponds to 6 tank turnovers per day) Flow, gpm 5250 5250 Head, Feet 32 32 Minimum Hydraulic Efficiency, Percent 71 71 Other Conditions: Minimum Discharge Size, Inches 12 12

Pump Materials: Refer to Part 2.03 above Motor Characteristics (2):

Variable Frequency Drive As specified in Section 16264 –

Variable Frequency Drives 60 – 500

Horsepower

As specified in Section 16264 –

Variable Frequency Drives 60 – 500

Horsepower Maximum Driver Speed, rpm 1750 1750 Motor Horsepower, Maximum 75 75 Voltage/Phases/hertz 460/3/60 460/3/60 Service Factor 1.15 1.15 Enclosure Type TEFC TEFC

Source Testing: Test Witnessing Not Witnessed Not Witnessed Performance Test Level 2 2 Vibration Test Level None None Noise Test Level None None

Functional Testing: Performance Test Level 2 2 Vibration Test Level None None Noise Test Level None None Notes: (1) Provide one uninstalled complete spare pump. Pump shall be packaged for long-term

storage. (2) All pump and motor characteristics are subject to change and should be re-evaluated

when final operating levels within the sludge holding tanks are defined.


3.02 EQUIPMENT INSTALLATION

A. The equipment specified herein shall be located as shown and installed in conformance with the manufacturer's suggested method as approved, and as further specified hereunder.

B. Mixing nozzles shall be level within 1/8 inch as defined by the manufacturer.

3.03 FINISHES

A. Submerged Surfaces: Exterior and interior ferrous metal surfaces of the mixing and spray nozzle assemblies and assembly bases as well as all accessory items shall be factory prepared, primed, and coated. Except for field touchup, all coatings shall be applied in the shop. High performance coating shall be the Fusion Bonded Epoxy System as specified in Section 09960 - High Performance Coatings.

B. Pumps: Refer to Part 2.03 above.

3.04 FIELD TESTING

A. Functional Test: Prior to plant startup, the Contractor shall conduct field tests on all equipment, inspecting for proper alignment, noisy operation, and proper connection, and satisfactory performance. The manufacturer's authorized representative shall inspect the completed installation and provide written certification to the Engineer that the equipment has been installed in accordance with the manufacturer's approved method and is ready for permanent operation.

B. Performance Test: 1. To verify the performance of the mixing system, the Contractor shall conduct

the following test on each sludge holding tank: a. Total Solids Testing: After system startup and the system has achieved

stable operation, total solids samples shall be taken at various locations throughout the tank to confirm the system meets the performance requirements specified in Part 3.01 A.

2. Test data and calculations shall be furnished to the Owner 30 days prior to acceptance of the system installation.

3. If the equipment meets the requirements specified herein, the equipment will be classed as conforming. If the equipment test performance results do not meet the requirements specified herein, the equipment will be classed as nonconforming.

4. In the case of nonconforming equipment, the Owner shall have the right to require the Contractor to modify or replace the mixing system to enable said system to meet the performance requirements. Testing of the modified or replaced equipment shall be completed within 60 days of the initial performance test which the equipment failed. All testing of the modified or replaced equipment shall be in accordance with this Specification.

5. Any and all tests required as a result of the system failing to meet the performance requirements and required to demonstrate compliance of the modified or replaced equipment with this specification, shall be performed at the Contractor's sole expense. Contractor shall pay the Owner for work hours and other expenses incurred by the Owner as a result of the second and all subsequent tests, as required.


3.05 MANUFACTURERS' SERVICES

A. Require manufacturer to inspect system before initial start-up and certify that system has been correctly installed and prepared for start-up as specified in this Section.

B. The new mixing system will be constructed and tested so as not to impact existing plant operations. A performance test (tracer) shall be undertaken for each tank. A manufacturer's representative for the equipment specified herein shall be present at the jobsite and/or classroom designated by the Owner for the minimum person-days listed for the services herein under, travel time excluded: 1. 5 person-days for installation assistance, inspection, and certification of the

installation. 2. 5 person-days for functional and performance testing. The manufacturer is

responsible for supervising testing and sampling and coordinating with the Contractor.

3. 2 person-days for jobsite training and digester startup.

C. Services shall be at such times as requested by the Owner.

END OF SECTION

January 2020 - DRAFT 11312I-1 11168A60 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/11312I (PDS)

SECTION 11312I

PROGRESSING CAVITY PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Rotary, positive displacement, Moineau principal, single screw, progressing cavity type pumps with drivers, and specified components.

B. Reference: 1. Pre-THP Centrifuge Feed Pump No. 1. 2. Pre-THP Centrifuge Feed Pump No. 2. 3. Pre-THP Centrifuge Feed Pump No. 3. 4. Post-THP Centrifuge Feed Pump No. 1. 5. Post-THP Centrifuge Feed Pump No. 2.

1.02 REFERENCES

A. American Bearing Manufacturers’ Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. American Gear Manufacturers Association (AGMA).

C. American Society of Mechanical Engineers (ASME): 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings, Class 25, 125, and 250. 2. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

D. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A276 - Standard Specification for Stainless Steel Bars and Shapes. 3. A283 - Specification for Low and Intermediate Tensile Strength Carbon Steel

Plates. 4. A681 - Standard Specification for Tool Steels Alloy. 5. D2240 - Standard Test Method for Rubber Property—Durometer Hardness.

E. Hydraulic Institute (HI): 1. 3.1-3.5 - Rotary Pumps for Nomenclature, Definitions, Application and

Operation. 2. 3.6 - Rotary Pump Tests. 3. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application,

Sound Measurement and Decontamination.

F. National Electrical Manufacturers Association (NEMA).


1.03 DEFINITIONS

A. Pump head (total dynamic head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 3.1-3.5, 3.6, and 9.1-9.5 and as modified in the Specifications.

B. Suction head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.


A. Pump type and components: 1. Rotary, positive displacement, Moineau principle, single screw, progressing

cavity type pumps with components. 2. System includes pump, motor with adjustable frequency drive, drive

arrangements, seals or packing, couplings, base plates, guards, supports, anchor bolts, necessary valves, gauges, taps, lifting eyes, stands, and other items as required for a complete and operational system.

B. Design requirements: 1. Pump performance characteristics:

a. As specified in the Pump Schedule. 2. Motor characteristics: As specified in the Pump Schedule.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Pumps: One of the following, no equal: 1. Seepex, BN-SCT Series. 2. Moyno Industrial Products Division of Robbins & Meyers, Inc., Model Series

EZ Strip.

2.02 MATERIALS

A. General: Materials in the Pump Schedule shall be the type and grade as specified in this Section.

B. Cast iron: ASTM A48, Class 30 minimum.

C. Buna-N: Synthetic rubber with a minimum Durometer hardness of 70 in accordance with ASTM D2240 test methods.

D. Tool steel: ASTM A681, with 0.020 inch minimum chrome plating thickness oversized and finish to Rockwell hardness of not less than C60.

E. Stainless steel: ASTM A276, Type as scheduled.

F. Structural steel: ASTM A283, Grade D.


2.03 PUMP CASINGS

A. Construction: Material as scheduled of sufficient strength, weight, and thickness to provide accurate alignment, and prevent excessive deflection.

B. Housing cover one of the following: 1. 2-piece split housing for 360-degree access to split coupling rod and pump de-

ragging. 2. Include 2 rectangular inspection/clean-out ports, 180 degrees apart, to provide

access to universal joints and enable de-ragging/unblocking of suction chamber.

C. Design Working Pressure: Not less than the maximum of 1.25 the Rated Design Point head or 1.1 times the maximum discharge pressure at the maximum revolutions per minute in vendor published information for the specified model.

D. Hydrostatic test: 5-minute hydrostatic test minimum 1.5 times Design Working Pressure.

E. Suction and discharge piping connections: Flanged in accordance with ASME B16.1, Class 125, or ASME B16.5, Class 150; provide higher pressure class as required to meet Design Working Pressure.

F. Vent and taps: Provide casings with both 3/4 inch National Pipe Thread high point vent and low point drain taps.

2.04 STATOR AND ROTOR

A. Stages: As scheduled.

B. Materials: As scheduled.

C. Rotation: Clockwise looking from driver, unless otherwise indicated on the Drawings.

2.05 DRIVE SHAFTS

A. Type: 1. Solid shaft (plug-in type).

B. Moyno EZstrip™ Pump: 1. Shaft-rotor connections:

a. Solid shaft shall be connected to rotor via connecting rod and oil sealed universal pin-joint.

b. Shaft turned and polished. 2. Material: Stainless steel. 3. Joint shall be rated for a minimum of 10,000 hours of operation. 4. Strength: Able to withstand minimum 1.5 times maximum operating torque and

other loads, and of ample strength and stiffness to operate without distortion or vibration which may reduce pump life at normal speeds as shown in the manufacturer's literature. a. Resonant frequency: As specified.


5. Shaft connecting rod: Design to limit operating angle to within 1-degree angular deflection.

C. Seepex: 1. Shaft-rotor connection:

a. Plug-in shaft. b. Standard Seepex universal pin joint with universal joint sleeve protection

made from stainless steel. 2. Material: Stainless steel. 3. Joint guaranteed for minimum of 10,000 hours of operation. 4. Strength: Able to withstand minimum 1.5 times maximum operating torque and

other loads, and of ample strength and stiffness to operate without distortion or vibration which may reduce pump life at normal speeds as shown in the manufacturer’s literature.

5. Resonant frequency: As required.

D. Shaft connecting rod: Design to limit operating angle to within 1-degree angular deflection.

2.06 GEAR BOX BEARINGS

A. The pumps shall be of the compact, close-coupled design. The gear reducer shall be sized for a minimum service factor of 1.5 and designed with a thrust load capability of 150 percent of the actual thrust load.

B. Bearing life: Minimum L10 life of 100,000 hours at rated design point but not less than 24,000 hours in accordance with ABMA 9 or 11 at bearing design load imposed by pump shutoff with maximum sized impeller at rated speed.

2.07 SHAFT STUFFING BOX

A. Materials: Same as pump casing.

B. Shaft seal type: As scheduled.

C. Drain size: Minimum 3/4 inch, with drain line routed to nearest equipment floor drain.

2.08 COUPLINGS

A. Types: When driver or gear coupled to pump, provide flexible coupling.

B. Flexible coupling life: Infinite at up to 0.30-degree misalignment angle total or per disk for disk type at maximum operating loads.

C. Design coupling to withstand a minimum of 1.5 times the maximum operating torque and other imposed loads.


2.09 SUPPORTS, PEDESTALS, AND BASEPLATES

A. Type: Single piece base plate with drive arrangement.

B. Materials: Type 316 SS or structural steel, hot-dip galvanized after fabrication and coated.

C. Pump and driver support strength: Able to withstand minimum 1.5 times maximum imposed operating loads or imposed seismic loads, whichever is greater.

D. Configuration: Allow easy access to stuffing boxes, bearing frames, suction housing and couplings; suction flange at least 2 inches above pump foundation; factory mount pump and driver to baseplate.

E. Motor arrangement: 1. For overhead, piggyback or side motor arrangements: Provide motor base with

slide rails to allow for adequate belt and alignment adjustment of pump and motor.

2. When in-line motor arrangement scheduled: a. Motor centerline to coincide with pump centerline. b. Provide gearbox as needed to provide specified pump speed.

3. When piggyback or overhead motor arrangement scheduled: a. Support motor directly above pump centerline. b. Mount motor minimum of 6 inches above top of pump on structural frame.

4. When side-mounted motor arrangement scheduled: a. Mount side-mounted motors adjacent to pump, secured directly to

baseplates. b. Provide side-mounted motors “left-handed” or right-handed” as indicated

on the Drawings.

F. Anchor bolts: As specified.

2.10 SPEED REDUCERS

A. Gear reducers (when scheduled or required for a pump in this Section): 1. Provide with NEMA C face connection between motor and gearbox. 2. Provide helical reduction gears, rated for AGMA Class II service with a

1.5 service factor. 3. Provide oil bath lubricated.

B. V-belt drives (when scheduled or required for a pump in this Section): 1. Design to transfer torque of installed driver. 2. Limit speed reduction ratio to 5 to 1.

2.11 EQUIPMENT GUARDS

A. Provide equipment safety guards.

2.12 DRIVERS

A. Horsepower: 1. As scheduled.


2. Listed driver horsepower is the minimum to be supplied. a. Increase driver horsepower if required to prevent driver overload while

operating at any point of the supplied pump operating head-flow curve including runout.



B. Motors: Provide motors as specified in this Section: 1. Revolutions per minute: As scheduled: 2. Enclosure: As scheduled. 3. Electrical characteristics: As scheduled. 4. Efficiency, service factor, insulation, and other motor characteristics: As

specified. 5. Motor accessories: As specified in this Section. 6. Coordinate motors with the adjustable frequency drive manufacturer to ensure

compatibility between the motor and adjustable frequency drive. a. Coordinate pump starting torque requirements to ensure supplied

adjustable frequency drive provides sufficient starting torque capacity for all operational conditions, including after extended shutdown periods while in service pumping process fluids and sludge.

7. Provide motor winding heater rated for 120 VAC.

C. Other drivers: As scheduled and as specified in sections listed in the Schedule.

2.13 PUMP ACCESSORIES

A. Provide stator run dry protection for all supplied pumps: 1. Run dry protection shall be provided for the pump stator through the

measurement of temperature at the stator/rotor interface. The temperature run dry protection shall shut down the pump upon high temperature before stator damage occurs.

2. As part of the run dry protection package, provide thermistor, thermowell drilled and tapped into pump stator, explosion proof connection head, and in relay controller type that can be housed in pump controller. a. Connection head shall be aluminum. b. Controller shall display indicating stator temperature and alarm setpoint. c. Controller shall include fault output for remote monitoring. d. Controller shall be mounted within NEMA 4X LCP located near pump.

1) LCP shall be provided by Contractor. 3. Provide relay to allow annunciation of a high stator temperature (fail) alarm if

the temperature reaches an adjustable preset temperature. Setpoint for alarm condition shall be set in the field per Manufacturer’s recommendations.

4. Electrical characteristic: 120 volts, single phase, 60 Hertz.


PART 3 EXECUTION

3.01 PUMP SCHEDULE

General Characteristics Service Post-THP sludge Pre-THP Sludge Quantity 2 3 Percent Solids 4-6% 1-3% Approved Manufacturers Seepex

Moyno Industrial Products, Model Series EZ Strip

Seepex Moyno Industrial Products, Model Series EZ Strip

Model BN 130-12 / A1-C1-L8-F0-GA (Seepex)

BN 130-12 / A1-C1-L8-F0-GA (Seepex)

Pump Characteristics Number of Rotor Sealing Stages

1 1

Bearing Lubrication Greased Greased Shaft Seal Type Double Mechanical Cartridge Double Mechanical Cartridge Coupling Type Spacer Spacer Speed Control Constant Torque Variable

Frequency Drive Constant Torque Variable

Frequency Drive Minimum Pump revolutions per minute

50 50

Maximum Pump revolutions per minute

1800 1800

Rated Design Point (At Maximum Revolutions per Minute) Flow, gallons per minute 250 500 Head, feet 21 45

Second Design Point Flow, gallons per minute 250 200

Head, feet 4 15

Other Conditions Minimum NPSHa at Every Specified Flow, feet

38 19.75

Pump Materials Pump Casing Cast Iron Cast Iron Stator Buna-N Buna-N Rotor 316 SST 316 SST Shaft 420 SS 420 SS Pump Bearing Frame None None


Driver Characteristics Driver Type Motor Motor Drive Arrangement Close Coupled Close Coupled Non-reverse Ratchets Required Required Minimum Driver Horsepower 15 40

Motor Characteristics (when motor is driver type) Inverter Duty Rated Yes Yes Motor Voltage/Phases/Hertz 460/3/60 460/3/60 Enclosure Type TEFC TEFC

END OF SECTION

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SECTION 11312Z

SEVERE DUTY PROGRESSIVE CAVITY PUMPS

PART 1 GENERAL

1.01 SECTION INCLUDES

A. This Section specifies the design, manufacture, supply, factory testing, delivery, installation, and supervision of installation, testing and commissioning of horizontally mounted, top suction, heavy-duty progressive cavity pumps for pumping high temperature sludge.

1.02 SCOPE OF SUPPLY

A. This Specification includes the following pumps: 1. Reactor Feed/Pulper Circulation Pumps – transfer dewatered sludge (DWS)

from pulper tank to the THP reactors and/or circulation back to pulper tank. 2. Digester Feed Pumps – transfer thermally hydrolyzed sludge (THS) from THP

flash tank to blending point with recirculated digested sludge (DS) to form blended digester feed (BDF).

1.03 REFERENCE STANDARDS

A. American Gear Manufacturers’ Association: 1. ANSI/AGMA Std.

B. American Bearing Manufacturers’ Association: 1. ANSI/ABMA Std. 9, Load Ratings and Fatigue Life for Ball Bearings. 2. ANSI/ABMA Std. 11, Load Ratings and Fatigue Life for Roller Bearings.

C. ANSI B16.1, Cast Iron Pipe Flanges and Flanged Fittings.

D. American Society for Testing and Materials (ASTM): 1. ASTM A48, Gray Iron Castings. 2. ASTM A276, Stainless Steel and Heat-Resisting Steel Bars and Shapes.

E. Hydraulic Institute (HI) Standards.

F. National Electrical Manufacturer’s Association (NEMA): MG 1, Motors and Generators.

1.04 DESIGN AND REGULATORY REQUIREMENTS

A. Provide NEMA approved electrical equipment.

B. Design equipment for the following classification and zone: 1. THP skid: Class 1, Group D, Unclassified.


1.05 SHOP DRAWINGS

A. Provide Shop Drawings in accordance with the requirements of the Design Build Contract. In addition, provide the following information: 1. Manufacturer's data including name, type, model, year, capacity, equipment

weight and serial number. 2. Letter of confirmation that the pump, combined with the electric motor as

specified in the Project Technical Requirements and variable frequency drive as specified in Division 16, are compatible.

3. Performance curves developed for specified operating conditions indicating relationship between speed, capacity, head, horsepower, efficiency, and required NPSH; indicate the rated operating points on the curves.

4. Complete motor nameplate data, as defined by NEMA, and motor manufacturer, including any motor specifications.

5. A copy of this Section with addenda and all referenced Specification sections with addenda, with each paragraph check-marked to indicate Specification compliance or marked and indexed to indicate requested deviations and clarifications from the specified requirements. If deviations and clarifications from the Specifications are indicated provide a detailed written justification for each deviation and clarification. Failure to include a copy of the marked-up Specification sections and or the detailed justifications for any requested deviation or clarification will result in submittal return without review until marked-up Specifications and justifications are submitted in a complete package.

1.06 OTHER SUBMITTALS

A. In addition to the submittals specified in the Design Build Contract, provide the following: 1. Warrant that the pumps stators will last for greater than 8,000 hours at the

operating conditions as noted in this Specification. 2. Complete catalogue information, descriptive literature, specifications, and

identification of materials of construction. 3. Provide list and description of standard factory tests, and other tests available. 4. Description of Manufacturer’s standard finish. 5. List of special tools, materials, spare parts and supplies furnished with

equipment. 6. Approximate shipping weight of the equipment. 7. Mill certificates confirming hardness of casings, suction housing, rotor, drive

shaft and shaft sleeves, as applicable.

1.07 CLOSEOUT SUBMITTALS

A. In addition to the operating and maintenance data specified in the Design Build Contract, provide the following: 1. Complete description of operation, together with general arrangements and

detailed drawings, wiring diagrams for power and control schematics, parts catalogues with complete list of repair and replacement parts with section drawings, illustrating the connections and the part manufacturer’s identifying numbers.


1.08 QUALITY CONTROL

A. Select a stator material that has been successfully used in the pumping of heated dewatered secondary and primary sludge and thermally hydrolyzed sludge, through the concentration range noted in the documents and at the speed selected for this application. The stator material selection is expected to provide a minimum of 8760 hours of service without the need for replacement, based on a starting and stopping frequency of one start/stop cycle per day.

B. In the event that the selected stator material proves unable to meet the basic performance requirements stated above, be responsible for the replacement of the stators in all pumps with a material that proves more resilient to the operating conditions. Replacement stators, including those required to replenish spare parts, will be made available to The City at no cost and will be installed by City forces.

C. In the event that the second selected stator material proves unable to meet the basic performance requirements stated above, be responsible for the replacement of the stators in all pumps with a material that proves more resilient to the operating conditions. Replacement stators, including those required to replenish spare parts, will be made available to The City at no cost and will be installed by City forces.

1.09 EXTENDED WARRANTY

A. Refer to the Contract Documents for the standard warranty requirements.

B. In addition to these requirements, obtain an extended warranty for the work commencing upon issuance of the Construction Completion Certificate and continuing for a minimum of 5 years.

C. The extended warrantee will cover the following: 1. Rotor joint.

D. Through the entire extended warrantee period, the Construction Manager will be responsible for the full cost of repair or replacement of failed or malfunctioning components or systems, at the discretion of the Engineer, as required to return the system to operational status.

E. Warrantee claims will not be made for components or systems that have failed or malfunctioned as a result of incorrect operation, a lack of maintenance, or incorrect maintenance that does not comply with the requirements included in the Manufacturer’s recommended operating and maintenance instructions.

F. Warrantee claims will not be made for components or systems that have failed or malfunctioned as a result of expected normal wear and tear, as determined by the Engineer.

1.10 COORDINATION

A. Coordinate pump requirements with drive manufacturer and be responsible for pump and drive requirements, compatible with variable frequency drive for speed control.


1.11 SHIPMENT, PROTECTION, AND STORAGE

A. Ship, unload, protect, and store equipment in accordance with the Project Technical Requirements.

B. Ship pre-assembled to the degree possible. Inform Construction Manager of any site assembly requirements.

C. Identify special storage requirements.

PART 2 PRODUCTS

2.01 FUNCTION

A. These severe duty progressive cavity pumps will convey sludge (THS or DWSL) as described above.

B. Provide pumps with dry-run protection, incorporating a flush mount pressure sensor with gauge and separate pressure switch on the pump discharge.

C. Provide a thermocouple into the stator that shuts down the pump on high temperature.

D. The DWL is a polymerized sludge from a mixture of primary and waste activated sludge, screened to 6 mm, dewatered to 16.5 percent and diluted and heated to about 190 degrees Fahrenheit in the pulper tank.

E. THS is DWS that has been thermally hydrolyzed and discharged from the flash tank at a temperature not exceeding 190 degrees Fahrenheit, after post-dilution to about 10 percent dry solids sludge. Blended digester feed (BDF) sludge consists of a blend of THS and digested sludge streams.

2.02 EQUIPMENT TAG NUMBERS

A. Refer to equipment data sheets in the Project Technical Requirements for respective pump design criteria: 1. Reactor Feed/Pulper Circulation Pumps. 2. Digester Feed Pumps.

2.03 DESIGN STANDARD AND ACCEPTABLE MANUFACTURERS

A. Supply products modified as necessary by the Manufacturer to provide the specified features and to meet the specified operating conditions.

B. Acceptable Manufacturers and rotor joint types: 1. Moyno – gear joint version only. 2. Netzsch – gear or pin joint versions. 3. Seepex – pin joint version.


2.04 PERFORMANCE

A. THP supplier is responsible for selecting pumps that meet the design and performance requirements for the THP system specified in Section 11355 - Thermal Hydrolysis Process System. Each pump shall have capacity, head and sufficient horsepower to satisfy the pumping requirements under all operating conditions expected for the THP system.

B. Provide pump of standard and industry proven design, designed and sized for the full range of operating duties and conditions specified.

C. Size progressive cavity pumps that are used for sludge with a maximum speed of 250 rpm.

D. Provide pump and electric motor designed for variable speed operation.

E. Design pumps to operate without excessive noise or vibration during reduction in flow from the specified operating capacity range to the specified minimum sustained operating conditions.

F. Design and select pumps specifically for high efficiency, continuous duty pumping without clogging or fouling at any operating condition within the range of service specified.

G. Provide severe duty progressing cavity pumps that operate at given conditions without any damage to the rotor, stator, bearings, seal, drive shaft and any other stationary or rotating parts.

H. Provide non-overloading motor sufficient to start and operate the pump at the flow range and total dynamic head (TDH) specified by the THP Supplier.

2.05 MATERIALS

A. Pump casing: Ductile iron, ASTM A536, or cast iron, ASTM A48.

B. Suction housing and bearing housing: Thick walled cast iron, ASTM A48.

C. Solid Drive Shaft: Stainless steel, ASTM A276, Type 316.

D. Rotor: Hardened tool steel, to Rockwell hardness of C58-62, with nominal chrome plate thickness of 0.254 mm, or high strength stainless steel without chrome plating.

E. Stator: Synthetic rubber or elastomer, formulated to withstand operating conditions in services anticipated while maintaining optimum pumping efficiency. It is the responsibility of the manufacturer to select a stator material that is able to operate continuously or intermittently for more than one calendar year in the described service.

F. Mounting base plate: Steel.

G. Equipment Identification Plate: 16 gauge stainless steel.


H. Select materials suitable to the conditions of the fluid being pumped. Ensure materials selection is suitable for the higher temperature of the sludge (up to 190 degrees Fahrenheit).

2.06 CASING/STATOR

A. Pump housing shall have tapped/plugged or boss connections for vents, drains and gauges.

B. Provide suction housing with hand hole and cover.

C. Provide Class 125 or Class 250 suction and discharge nozzles flanged, faced and drilled to conform to ANSI standards B16.1.

D. Provide discharge flanges rated for the casing test pressure.

E. Provide and test casing, capable of withstanding 1.5 times the maximum pressure developed by the pump.

F. Fit the rotor and stator so that at the point of contact the stator material is sufficiently compressed to form a good seal and to prevent leakage from the discharge back to the inlet end of the pumping chamber.

G. Design the casing to accommodate the selected stator material and at least three other stator materials.

2.07 ROTOR

A. Provide precision machined rotor.

B. Provide multi-stage pumps for sludge service and for the pressure required for the THP reactor (reactor feed/pulper circulation pumps). Each stage, as a maximum, will be allowed to handle a differential pressure of 50 psi.

2.08 ROTOR JOINT

A. Depending on the Manufacturer, gear or pin joint may be acceptable. Refer to clause 2.3.

2.09 SHAFT

A. Provide solid drive shaft, rigid and capable of supporting the eccentric loads from rotor and of transmitting loads without slip, vibration or undue deflection at any operating loads.

B. Provide shaft suitable for use in variable speed pumping applications.

2.10 BEARINGS

A. Provide permanently grease lubricated thrust and radial bearings designed for all loads imposed by the specified service.

B. Minimum B-10 life of 100,000 hours at maximum operating conditions.


2.11 CLEANOUT PORT

A. Provide hand sized inspection/hand hole cleanout ports integral with the suction housing, to permit access to the joint.

2.12 BASE

A. Provide motor mounting blocks such that one size greater motor frame may be accommodated by replacing mounting blocks.

B. Mount pumps, along with associated drive appurtenances, on a common fabricated baseplate.

C. Provide baseplate with lifting lugs. Ensure the baseplate, with all equipment mounted, will not permanently distort, or otherwise damage the baseplate or machinery mounted on it.

D. Anchor bolts to conform with requirements of the Project Technical Requirements.

2.13 SEAL

A. Provide cartridge type, double mechanical seals, externally mounted.

B. Provide non-destructive, self-aligning seals of the stationary design, which require no wearing sleeve for the shaft.

C. Construct metal parts of seals of type 316 or 317L stainless steel, springs of 316 or Hastelloy C, Viton O-rings and Tungsten Carbide on Sintered Silicon Carbide faces.

D. Provide seal water connection.

2.14 SEAL WATER CONNECTION

A. For seal water piping and fittings, unless otherwise specified, use 12 mm diameter tubing.

B. Seal water connections consist of the following: 1. Isolating valve – Ball valve: Stainless steel valve and ball, two piece

construction, blow out proof stem. 2. Filter strainer, spin-off cartridge type, complete with 150 micron strainer

elements, sized for 8 L/min. 3. Seal water control element, complete with pressure sensing/indication and

control and flow sensing/indication and control. Suitable for 2,000 kPa at 65°C and 800 kPa at 150°C. a. Design standard: John Crane Safeunit Model SFD.

2.15 DRIVE UNITS

A. Provide horizontally mounted, electric motors.

B. Provide totally enclosed fan cooled (TEFC) motors suitable for the electrical area classification shown in the drawings.


C. Where required for variable speed operation, provide motors compatible with variable speed drives, with turndown capability of 10:1.

D. Provide gear drives rated in accordance with AGMA Class III with a service factor of 2.0.

2.16 INSTRUMENTS

A. To monitor high pressure conditions on discharge, provide flush mount type pressure sensors with gauge and a separate pressure switch hard wired to the pump MCC for mounting on pump discharge: 1. Ensure that the gauge can be removed without breaking the vacuum seal. 2. Provide high pressure switches with manual reset (automatic reset is not

acceptable).

B. Provide a temperature sensor in the stator sleeve of each pump for dry-run protection, and associated electronic control relay.

2.17 FACTORY TESTS

A. Factory performance test each pump as a complete unit for flow and pressure in compliance with Hydraulic Institute standards for progressive cavity pumps.

B. Certify test results and summarize findings in a short report. Submit report within three weeks of completing factory tests.

2.18 PROTECTIVE COATINGS

A. Shop prime all equipment.

B. Preparation and primer: in accordance with Section 09960 - High-Performance Coatings.

C. Protect internal machine surfaces with a corrosion-protective compound.

2.19 SPARE PARTS

A. Provide spare parts in accordance with the Design Build Contract.

B. As a minimum, provide the following spare parts for each pump size and type: 1. One (1) rotor. 2. Three (3) stators. 3. One (1) complete set of connection assembly (connecting rod or other). 4. Complete set of keys, dowels, pins, washers, retention screws, and other

special spare parts subject to wear.

C. Tag and store spare parts in accordance with the Project Technical Requirements.

2.20 SPECIAL TOOLS

A. Provide any special tools required for the maintenance of the equipment supplied. Special tools are defined as tools which are not normally available in mechanic’s or millwright’s tool kit and which are peculiar to the equipment supplied.


PART 3 EXECUTION

3.01 MANUFACTURER’S REPRESENTATIVE

A. Provide the services of a qualified Manufacturer’s representative for installation, testing and commissioning as defined in the Design Build Contract.

B. Provide the services of a qualified Manufacturer’s representative for personnel training.

3.02 INSTALLATION

A. Ensure the equipment is installed as required to provide satisfactory service.

B. Have the Manufacturer’s representative instruct the Design Builder in the methods and precautions to be followed in the installation of the equipment. Certify the Design Builder’s knowledge understanding by completing documentation.

C. Have the Manufacturer’s representative supervise and cooperate with the Design Builder as necessary.

D. Have the Manufacturer’s Representative verify successful installation.

3.03 TESTING

A. Conduct and document testing on each pump to prove equipment operation, performance, and function.

B. Provide lubrication to ensure that the stator does not get damaged during testing.

3.04 TRAINING

A. Provide the services of a qualified technical representative for personnel training in accordance with the Design Build Contract.

3.05 COMMISSIONING

A. Manufacturer’s representative will attend commissioning of the process system, which includes the equipment specified in this Section, and ensure the equipment functions as intended in the process system.

B. Complete any documentation required by the Design Build Contract.

END OF SECTION

January 2020 - DRAFT 11313J-1 11168A60 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/11313J (PDS)

SECTION 11313J

PROGRESSING CAVITY CAKE PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Rotary, positive displacement, Moineau principal, single screw, progressing cavity cake type pumps with bridge breaker/auger and drivers, and other specified components.

B. Reference Location: 1. Pre-THP Cake Pump No. 1. 2. Pre-THP Cake Pump No. 2.

1.02 REFERENCES

A. American Bearing Manufacturers’ Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. American Gear Manufacturers Association (AGMA).

C. American Society of Mechanical Engineers (ASME): 1. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

D. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A276 - Standard Specification for Stainless Steel Bars and Shapes. 3. A283 - Specification for Low and Intermediate Tensile Strength Carbon Steel

Plates. 4. A681 - Standard Specification for Tool Steels Alloy. 5. D2240 - Standard Test Method for Rubber Property-Durometer Hardness.

E. Hydraulic Institute (HI): 1. 3.1-3.5 - Rotary Pumps for Nomenclature, Definitions, Application and

Operation. 2. 3.6 - Rotary Pump Tests. 3. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application,

Sound Measurement and Decontamination.

F. National Electrical Manufacturers Association (NEMA).

1.03 DEFINITIONS

A. Pump head (total dynamic head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 3.1-3.5, 3.6, and 9.1-9.5 and as modified in the Specifications.


B. Suction head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Pumps: The following: 1. Moyno Ind. Products Division of Robbins & Meyers, Inc., Model Series 2000

Cake Pump.


A. Pump type and components: 1. Rotary, positive displacement, Moineau principle, single screw, progressing

cavity cake type pumps and other components. 2. System includes pump, bridge breaker/auger section, motors, seals or

packing, couplings, base plates, guards, supports, anchor bolts, necessary valves, gauges, taps, lifting eyes, stands, and other items as required for a complete and operational system.

B. Design requirements: 1. Pump performance characteristics:

a. As specified in the Pump Schedule. 2. Motor characteristics: As specified in the Pump Schedule.

2.03 MATERIALS

A. General: Materials in the Pump Schedule shall be the type and grade as specified in this Section.

B. Cast iron: ASTM A48, Class 30 minimum.

C. Buna-N: Synthetic rubber with a minimum Durometer hardness of 70 in accordance with ASTM D2240 test methods.

D. Tool steel: ASTM A681, with 0.020-inch minimum chrome plating thickness oversized and finish to Rockwell hardness of not less than C60.

E. Stainless steel: ASTM A276, Type as scheduled.

F. Structural steel: ASTM A283, Grade D.

2.04 PUMP CASINGS

A. Construction: Cast iron of sufficient strength, weight, and thickness to provide accurate alignment, and prevent excessive deflection.

B. Housing cover plates: 2 on suction housing, 1 each side for access to rotor and shaft ends without otherwise dismantling the pump.


C. Design Working Pressure: Not less than the maximum of 1.25 the Rated Design Point head or 1.1 times the maximum discharge pressure at the maximum revolutions per minute in vendor published information for the specified model.

D. Hydrostatic test: 5-minute hydrostatic test minimum 1.5 times Design Working Pressure.

E. Discharge piping connections: 1. Flanged in accordance with ASME B16.5. 2. Provide pressure class as required to meet 1.5 times the Design Working

Pressure.

F. Vent and taps: Provide casings with both 3/4-inch National Pipe Thread high point vent and low point drain taps.

2.05 STATOR AND ROTOR

A. Stages: As scheduled.

B. Materials: Buna-N.

C. Stator removal: Removable for maintenance replacement.

D. Rotation: Clockwise looking from driver.

2.06 DRIVE SHAFTS

A. Type: Hollow shaft, rigidly connected to the rotor through a connecting rod and grease lubricated, gear type U-joint. 1. Pin shaft joints or flexible shafts are not acceptable. 2. Shaft turned and polished.

B. Material: Tool steel.

C. Strength: Able to withstand minimum 1.5 times maximum operating torque and other loads, and of ample strength and stiffness to operate without distortion or vibration which may reduce pump life at normal speeds as shown in the manufacturer’s literature.

D. Shaft connecting rod: Design to limit operating angle to within 1.5-degree angular deflection.

2.07 BEARINGS AND BEARING FRAME

A. Materials: 1. Pump bearing frame: As scheduled.

B. Bearing type: Mount shaft in 2 sets of antifriction tapered roller bearings or radial ball bearings meeting ABMA standards and adequate to withstand radial or axial thrust forces and complying with following: 1. Inboard set: Single. 2. Outboard set: Single or Dual.


3. Shaft expansion: Make provisions in shaft and bearing mounting to prevent distortion of shaft due to temperature expansion.

C. Bearing lubrication: Grease with external grease fittings: 1. Size sufficiently to safely absorb heat energy normally generated in bearing

under maximum ambient temperature of 60 degrees Celsius. 2. Equip with grease relief pipe.

D. Bearing life: Minimum L10 life of 100,000 hours at rated design point but not less than 24,000 hours in accordance with ABMA 9 or 11 at bearing design load imposed by pump shutoff with maximum sized impeller at rated speed.

2.08 SHAFT STUFFING BOX


B. Shaft seal type: As scheduled.

C. Drain size: Minimum 3/4-inch, with drain line routed to nearest equipment floor drain.

2.09 COUPLINGS

A. Types: Provide flexible coupling as specified.

B. Flexible coupling life: Infinite at up to 0.30-degree misalignment angle total or per disk for disk type at maximum operating loads.

C. Design coupling to withstand a minimum of 1.5 times the maximum operating torque and other imposed loads.

2.10 AUGER SYSTEM AND BRIDGE BREAKER


B. Bridge breaker: 1. Counter rotation shafts with paddles above the auger feed: 2. 2. Driven by separate motor with speed reducer.

C. Auger: 1. Single ribbon auger feed mechanism to move the sludge cake into the rotor

driven by the pump motor. 2. Designed to maximize the chamber filling.

D. Provide clean out flange on the hopper/auger area.

2.11 SUPPORTS, PEDESTALS, AND BASEPLATES

A. Type: Single piece base plate with drive arrangement as scheduled.

B. Materials: Structural steel and coated as specified.


C. Pump and driver support strength: Able to withstand minimum 1.5 times maximum imposed operating loads or imposed seismic loads, whichever is greater.

D. Configuration: Allow easy access to stuffing boxes, bearing frames, suction housing and couplings; suction flange at least 2 inches above pump foundation; factory mount pump and driver to baseplate.

E. Motor arrangement: 1. When in-line motor arrangement scheduled:

a. Motor centerline to coincide with pump centerline. b. Provide gearbox as needed to provide specified pump speed.

2. When overhead motor arrangement scheduled: a. Right angle gear motor directly above pump centerline. b. Mount motor minimum of 6 inches above top of pump on structural frame.

3. When side-mounted motor arrangement scheduled: a. Mount side-mounted right angle gear motors adjacent to pump, secured

directly to baseplates. b. Provide side-mounted motors “left-handed” or right-handed” per

OWNER’s preference.

F. Anchor bolts: As specified in the Project Technical Requirements.

2.12 SPEED REDUCERS

A. Gear reducers: 1. Provide with NEMA C face connection between motor and gearbox. 2. Provide helical reduction gears, rated for AGMA Class II service with a

1.5 service factor. 3. Provide oil bath lubricated. 4. As specified in the Project Technical Requirements.

2.13 EQUIPMENT GUARDS

A. Provide equipment safety guards as specified in the Project Technical Requirements.

2.14 DRIVERS

A. Horsepower: 1. As scheduled. 2. Listed driver horsepower is the minimum to be supplied:

a. Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout.



B. Motors: Provide motors as specified: 1. Revolutions per minute: As scheduled. 2. Enclosure: As scheduled. 3. Electrical characteristics: As scheduled.


4. Efficiency, service factor, insulation, and other motor characteristics. 5. Coordinate motors with the variable frequency drive manufacturer to ensure

compatibility between the motor and variable frequency drive. a. Coordinate pump starting torque requirements to ensure supplied variable

frequency drive provides sufficient starting torque capacity for all operational conditions, including after extended shutdown periods while in service pumping process fluids and sludge.

PART 3 EXECUTION

3.01 PUMP SCHEDULE

General Characteristics

Manufacturer Moyno

Model Number SK92-400TSC

Service Dewatered Cake Transfer

Quantity 2

Maximum Sludge Density, pounds/cubic foot 65

Minimum Sludge Density, pounds/cubic foot 60

Maximum Sludge Moisture, percent 75

Minimum Sludge Moisture, percent 65

Pump Characteristics

Number of Rotor Sealing Stages 6

Bearing Lubrication Grease

Shaft Seal Type Double Mechanical Cartridge

Speed Control Constant Torque Variable Frequency Drive

Rated Design Point (At Maximum Revolutions per Minute):

Flow, gallons per minute 75

Head, feet 150

Required Condition 2:

Flow, gallons per minute 125

Head Range, feet 275

Pump Driver Characteristics

Drive Arrangement Side-mount

Inverter Duty Rated Yes

Minimum Driver Horsepower 50

Maximum Driver Speed, revolutions per minute 400


Motor Voltage/Phases/Hertz 460/3/60

Enclosure Type TEFC

Bridge Breaker Driver Characteristics Inverter Duty Rated Yes

Minimum Driver Horsepower 5

Maximum Driver Speed, revolutions per minute 30

Motor Voltage/Phases/Hertz 460/3/60

Enclosure Type TEFC

END OF SECTION


SECTION 11334

IN-LINE GRINDER

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes: In-line grinder including main housing, cutter-drive assembly, and vendor control panel (VCP).

B. Reference Location: 1. Pre-THP Centrifuge Feed Pump No. 1. 2. Pre-THP Centrifuge Feed Pump No. 2. 3. Pre-THP Centrifuge Feed Pump No. 3. 4. Post-THP Centrifuge Feed Pump No. 1. 5. Post-THP Centrifuge Feed Pump No. 2.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. ANSI 4130 - Heat Treated Alloy Steel. 2. ANSI 4140 - Heat Treated Hexagon Steel.

B. American Society of Mechanical Engineers (ASME). 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and

250.

C. American Society for Testing Materials (ASTM): 1. A 395 - Standard Specification for Ferritic Ductile Iron Pressure Retaining

Castings.

D. National Electrical Manufacturers Association (NEMA).


A. Five (5) in-line grinders shall be provided.

B. Design Requirements:

Flow Rates

Pre-THP Post-THP

Maximum: 500 gpm 500 pgm

Design 350 gpm 350 gpm

Minimum: 200 gpm 200 gpm

Percent Solids: 1-4% 10-15 %


Pressure Drop (Head Loss)

Maximum: 6 inches 6 inches

Pipe Sizes

Inlet: 6 inches 6 inches

Outlet: 6 inches 6 inches

Motor

Minimum Horsepower 3 hp 3 hp


A. Manufacturer Qualifications: Manufacturer shall have at least 5 years experience in the design, application, and supply of inline grinders for wastewater sludge, and provide a list of not less than ten operating installations in the United States as evidence of meeting the experience requirement.

B. Modifications: Modify standard equipment to meet, as a minimum, the values specified for dimension, design, and intent of this specification section.

1.05 MAINTENANCE

A. Provide the following Spare Parts: 1. Three fuses. 2. Three 6V, long life lamps. 3. One complete rotating assembly. 4. One complete mechanical seal.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Grinder: Manufacturers: The following, no equal: 1. JWC Environmental, Model No. 30004T-1208 In-line Muffin Monster. 2. Moyno , EZSTRIP TR Muncher. 3. Vogelsang Xripper XRS 186-130Q.

B. The Drawings are based on grinders manufactured by JWC Environmental.

2.02 MATERIALS

A. General: 1. Sewage grinders shall consist of the following three main components:

a. Main housing. b. Cutter and drive assembly. c. Vendor control panel.

B. Main Housing: 1. Main housing shall be a solid cast structure made of ASTM A 395 ductile iron.


2. Inside profile of the main housing shall be concave to follow the radial arc of the cutters. To direct larger particles toward the cutters and assure fineness of grind, the main housing must maintain a clearance not to exceed 5/16 inch between the major diameter of the cutter and the concave arc of the housing.

3. Main housing to be provided with a covered access port for equipment inspection. Access port covers to be ASTM A 395 ductile iron.

4. Maintenance and Service Components: a. Provide easy access opening in the base of the grinder for tightening the

cutter stacks. Stack compression to be accomplished by torquing the stack nuts on the bottom of the grinder. The stack nuts shall be externally accessible.

C. Cutter Cartridge and Drive Assembly: 1. Cutter cartridge and drive assembly shall be two-shaft design and be capable

of continuous operation, processing wet or dry. Single shaft devices utilizing a single rotating cutter bar with stationary cutters will not be acceptable.

2. Two-shaft design shall consist of parallel shafts alternately stacked with intermeshing cutters and spacers positioned on the shaft to form a helical pattern. The shafts shall counter-rotate with the driven shaft operating at approximately 2/3 the speed of the drive shaft.

3. Cutters and Spacers: a. Inside configuration of both cutters and spacers shall be hexagonal so as

to fit the shafts with a total clearance not to exceed 0.025 inch across the flats to assure positive drive and increase the compressive strength of the spacers.

b. Cutters and spacers to be AISI 4130 Heat Treated Alloy Steel, surface ground for uniformity and through-hardened to a minimum 43-48 Rockwell C.

c. Cutter configuration shall consist of two shafts with 11-tooth cam cutters. To maintain particle size, the height of the tooth must not exceed 1/2 inch above the root diameter. Cutter root diameter overlap to be not less than 1/16 inch or greater than 1/4 inch to maintain the best possible cutting efficiency while incurring the least amount of frictional losses.

4. Grinder drive and driven shafts to be made of AISI 4140 Heat Treated Hexagon Steel with a tensile-strength rating of not less than 149,000 pounds per square inch. Each shaft hex to be a minimum of 2 inches.

5. Reducer: a. The gear speed reducer to be a grease filled planetary type of reducer

with "Heavy Shock" load classification. The reduction ratio to be 29:1. High-speed shaft of the grinder to be directly coupled with the reducer using a two-piece coupling.

6. Motor: a. Motor to be TEFC design, minimum 3 hp, 1,800 rpm, 460 volt, 60 hertz,

three-phase. Motor service factor to be 1.15, the efficiency factor not less than 81 percent at full load and the power factor not less than 75 percent at full load.

b. Provide high temperature switch rated for 120 VAC operation. 7. Required Running Torque and peak force requirements:

a. Minimum peak shaft torque: 4,752 lb-in/hp. b. Minimum peak force at cutter tip: 2,051 lb/hp.


8. Cutter cartridge seal housing and cover to be cast of ASTM A395-80 ductile iron and designed to protect the seal labyrinth while guiding particles directly into the cutting chamber.

9. Bearings and Seals: a. Radial and axial loads of the shafts to be borne by 4 sealed oversize

deep-groove ball bearings. b. Bearings to be protected by a combination of a replaceable and

independent tortuous path device and end face mechanical seals. c. Face materials must be a minimum of tungsten carbide to tungsten

carbide, not requiring an external flush or any type of lubrication. d. The mechanical seal to be rated at 90 pounds per square inch continuous

duty by the seal manufacturer. e. Bearings and seals to be housed in a replaceable cartridge that supports

and aligns the bearings and seals, as well as protects the shafts and end housings. O-rings to be made of Buna-N elastomers.

f. Products requiring continuous or occasional lubrication or flushing will not be accepted.

2.03 VENDOR CONTROL PANEL

A. General: 1. Provide a motor controller in a NEMA 4X 316SS Vendor Control Panel one for

each Grinder. 2. Upon the grinder encountering a jam condition, the VCP will stop the grinder

and reverse its rotation to clear the obstruction. If the jam is cleared, the VCP will return to normal operation. If the jam condition still exists, the VCP will go through two additional reversing cycles within 30 seconds (three times total) before signaling a grinder overload condition. Upon a grinder overload condition, the VCP will shut the grinder off and activate a FAIL contact.

3. If a power failure occurs while the grinder is running, the grinder will resume running when power is restored. If the grinder is stopped due to an overload condition and a power failure occurs, the overload indicator will reactivate when power is restored.

4. Controller to provide overcurrent protection. The overload relay to be adjustable so that the range selected includes the full load amps rating and service factor.

5. VCP shall have the following indicator lights: a. Red for RUNNING. b. Green for STOPPED. c. Amber for FAILED. d. White for POWER ON.

6. The VCP shall be rated 460 volts three-phase, 60 hertz and a short circuit interrupting current of 65k AIC.

7. Each Grinder shall be provided with one VCP to house all the starter and the controls associated with it. The VCP shall be provided with the indicator of all the associated grinder mounted on it, located locally at the field.

B. Components: 1. Control devices:

a. Mount control devices in the front panel of the enclosure. Indicating lights shall be integral transformer type with low voltage long life six volt lamps.


Lamps, selector switches, and pushbuttons to be heavy duty NEMA 4X type.

b. Provide a normally open dry relay contact for FAIL and RUN signals. c. Provide selector switch for Local/Remote START STOP operation. d. The Grinder VCP shall also be provided with Emergency Stop

Pushbuttons, which immediately shuts down the corresponding Grinder and sends a status/alarm back to the VCP.

e. Terminal strips: 1) Provide terminal strips for landing all external wiring.

f. Relays, timers, and other components as required to provide the specified functionality and remote monitoring connections.

2. Enclosure: a. Enclosure to be NEMA 4X, fabricated of Type 316 Stainless Steel and

shall be suitable for mounting on uni-strut outdoors, as indicated on drawings.

b. Doors shall have Type 316 SS hinges and latches. 3. Reversing motor starter:

a. Starters shall be full voltage reversing type with a 120 volt operating coil, interlock, and captive terminal screws. Overload relay shall be mounted directly to the contactor and shall be sized to the motor full load amperage.

b. Motor circuit protector circuit breaker. 4. Control power transformer:

a. Control power transformers shall be provided and sized to power all loads requiring voltages other than 480V, plus 10 percent spare capacity.

b. Provide primary and secondary fusing. 5. Electrical components:

a. Main circuit breaker: 1) Flange-mounted operator:

a) Pad-lockable in the off position. 2) Disconnect all power to the panel. 3) Provide an interlock with the panel door.

a) Provide a defeat mechanism for interlock. 6. I/O Interface:

a. The VCP shall provide the following dry contacts rated for 120 VAC/24 VDC operation: 1) Grinder running. 2) Grinder Failed. 3) Grinder Remote. 4) Emergency Stop feedback.

b. The VCP shall accept the following dry contacts rated for 120 VAC/24 VDC operation: 1) Grinder Run Command in Remote Mode.


A. Performance Test: 1. If alternative manufacturers are proposed, the OWNER or OWNER's

Representative will require alternative manufacturers and specified equipment manufacturer to perform a comparative list to qualify performance of the alternative grinding equipment by demonstration. The test will be conducted in the presence of the OWNER or OWNER's Representative. All costs such as


providing test grinders, test materials, and electric power hook-up, will be borne by the CONTRACTOR. A proof of performance demonstration test certificate shall be submitted by the CONTRACTOR.

2. Test equipment to be of the same model number, size, horsepower, and configuration as the unit to be provided under this Section. The performance test to be a dry test.

3. The test shall be conducted such that test materials are fed into the grinder by item. The full quantity of each item shall be fed at 1 time and each set of items shall be fed at separate times. The grinder shall be allowed to clear after the full quantity of each item is fed through.

4. The following occurrences shall be recorded: a. Alarms (based on three reversals). b. Motor overheat. c. Motor overload.

5. The test items are as specified below: a. 5 soda cans. b. 5 each 12 inch square rags (mechanical shop rags). c. 8 pair pantyhose [four (4) pair tied into three (3) knots each]. d. 4 medium size rubber gloves. e. 3 inch plastic rope, 20 feet long. f. 2 pair long athletic socks. g. 1/2 inch wide steel strapping band, 5 feet long. h. 1 woman's wig (synthetic or human hair). i. 1 box of 12 plastic tampons with applicators. j. 1 wooden broom handle cut into 1 foot lengths. k. 5 medium size disposable diapers. l. 1 pair size eight canvas tennis shoes.

6. The individually ground material to be kept segregated for evaluation of particle size.

7. Categories of Evaluation of Test Results Shall Include: a. Numbers of alarm status occurrences with number of motor overheat, and

motor overload situations counted. The alarm status shall be limited to 2 alarms during the entire test. The alarm activation to be based upon 3 reversals.

b. Before and after test, inspect and record grinder motor amperage to verify motor nameplate data, revolutions per minute of cutters, and motor reversal amperage. Motor reversal amperage shall not be more than 80 percent of locked rotor amperage.

PART 3 EXECUTION

Not Used.

END OF SECTION


SECTION 11339

PRESSURIZED, IN-LINE, SLUDGE SCREEN

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Pressurized, in-line sludge screen including main housing, perforated screen,

screw assembly and drive, and motor controller.

1.02 REFERENCES

A. American Society for Testing and Materials (ASTM) Publications: 1. Section A322: Carbon and Alloy Steel Bar Specifications. 2. Section A507-10: Standard Specification for Drawing Alloy Steel, Sheet and

Strip, Hot-Rolled and Cold Rolled.

B. Anti-Friction Bearing Manufacturers Association (AFBMA) Publications: 1. Standard 9-90 Load Ratings and Fatigue Life for Ball Bearings. 2. Standard 11-90 Load Ratings and Fatigue Life for Roller Bearings.

C. American Institute of Steel Construction (AISC) Publications.

D. American Welding Society (AWS) Publications.

E. American Structures Painting Council (ASPC) Publications.

F. National Fire Prevention Association (NFPA) Publications.

G. NFPA 820-28, Chapter 6 Solids Treatment Processes.


A. General: 1. The pressurized, in-line sludge screen shall consist of a cylindrical screen with

an integral screw conveyor and screenings press. 2. The screen shall use a single drive for screening, conveying, dewatering and

compressing the screening material. The screen shall have be mounted horizontally.

3. The screen shall rest on a frame assembly provided by Manufacturer.

B. Design requirements: 1. Number of screens: 2 (941-SCR-80, 941-SCR-90). 2. Capacity, per screen, GPM: 640. 3. Maximum solids concentration at peak flow: 2.5 percent D.S. 4. Inlet size, in: 6. 5. Outlet size, in: 6. 6. Discharge height from bottom of supports, in: 17. 7. Screen opening size, mm: 3.


8. Compaction zone opening size, mm: 3. 9. Location rating: Unclassified. 10. Feed stream: Raw sludge.

1.04 SUBMITTALS

A. The manufacturer shall submit product data and shop drawings including operation and maintenance manuals to the Engineer for review in accordance with Section OR-01770 – Closeout Procedures and the Project Technical Requirements.

B. The Contractor shall coordinate and provide simultaneous submittal of the shop drawings for the sludge screens, sludge screen support system, and piping system associated with the sludge screens.

C. Shop drawings: The following shall be submitted as specified in the Project Technical Requirements: 1. Make, model, and weight of each equipment assembly. 2. Complete catalog information, descriptive literature, specifications, and

materials of construction. 3. Detailed structural and mechanical drawings showing the equipment

dimensions, size, and installation. 4. Detailed structural and mechanical drawings showing motors, thickener drives,

schematic wiring diagrams and interconnections wiring diagrams, interconnecting piping, pipe supports, control panel layouts, and size and length of each support frame member.

5. Factory protective coatings. 6. Electrical information including, but not limited to, full load current and locked

rotor current. 7. All submittal information as required per the Project Technical Requirements. 8. Weight and dimensions for vendor-supplied control panels. 9. Details of storage and offloading requirements. 10. Sample warranty.

D. Calculations: Include calculations of the following to support structural adequacy as specified in the Project Technical Requirements. 1. Anchor bolt calculations and mounting details for each equipment assembly as

required by the Project Technical Requirements. 2. Structural anchor points to concrete foundation. 3. Distribution of stresses through the sludge screen frame. 4. Seismic loads on frame and anchor bolts. 5. Bearing compliance bearing life requirement at maximum loading, based on

ABMA/ISO capacity formula.

E. Manufacturer's qualifications references.

F. Technician qualifications resume: Submit resume of technician to perform sludge screen adjustments, inspections, observations of test operations, and training.

G. Training course outline.

H. Quality control submittals: 1. Factory functional test report. 2. Field performance test report.


3. Certificate of Installation. 4. Manufacturer’s installation manuals.

I. Maintenance manual: 1. The following shall be included in the maintenance manual:

a. Lubrication Instructions. b. Maintenance Instructions. c. Operation Instructions. d. Start-up Instructions. e. Unloading and Handling Methods.

2. Additional data as required.

J. Warranties.

K. Certificates.


A. Manufacturer qualifications: 1. Manufacturer shall have a minimum of 20 years' experience producing

equipment substantially similar to that required and shall be able to submit documentation of at least 15 independent installations, with at least 5 of these installations in the United States using the same equipment as detailed in the below. Five installations must have been in satisfactory operation for at least 5 years.

B. Modifications: 1. Modify standard equipment to meet, as a minimum, the values specified for

dimension, design, and intent of this Section.


A. As specified in the Project Technical Requirements.

B. All equipment shall be shipped and delivered fully assembled, except where partial disassembly is required in order to conform to transportation regulations or for the protection of components.

C. The Contractor shall be responsible for unloading of the machinery and shall have equipment on-site available at the time of delivery permitting proper hoisting of the equipment.

1.07 PROJECT CONDITIONS

A. Environmental requirements: As specified in the Project Technical Requirements.

1.08 SEQUENCING AND SCHEDULING

A. Coordinate work with restrictions as specified in Section OR-01140 - Work Restrictions.

B. Coordinate work with Commissioning and Startup as specified in Section OR-01757 - Commissioning.


1.09 WARRANTY

A. As specified in Section OR-01770 - Closeout Procedures.

1.10 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following: 1. Huber Technology, Inc., Strainpress® 430. 2. Hydro-International, Hydro-Sludge Screen.

B. The equipment layout, support stands, electrical system, and control system are based on the Huber Strainpress 430.

C. If the Contractor chooses to submit any other manufacturer or model than the Huber Strainpress 430, Contractor shall submit layout plans showing the equipment layout with all necessary building, structural, piping, ducting, electrical, control and other modifications. Contractor shall be responsible for all modifications required to provide a fully functioning sludge screening system that meets required performance criteria. All required modifications shall be at no additional cost to the Owner.

2.02 IDENTIFICATION

A. Each unit of equipment shall be identified with a corrosion-resistant nameplate, securely affixed in a conspicuous place. 1. Nameplate information shall include equipment model number, serial number,

manufacturer's name, and location.

B. Provide as specified in the Project Technical Requirements.

2.03 COMPONENTS

A. General: 1. Manufacturer shall provide screen, motor, gear reducer, controls, control

panels, lifting attachments, and support stands as a complete integrated package to ensure proper coordination, compatibility, and operation of the system. The manufacturer shall test-run the fully assembled machine in his factory before shipment.

2. Unless otherwise specified in these specifications, the entire equipment shall be manufactured from AISI 304L austenitic stainless steel shapes (rods, angles, and channels), pipes, and sheets. All mechanical parts shall be designed to handle the forces that may be exerted on the unit during fabrication, shipping, erection, and proper operation according to the O&M manual.


3. The entire unit shall be manufactured from AISI 304L stainless steel shapes. All components made of stainless steel shall be passivated by full submergence in a pickling bath for perfect surface finishing.

4. The equipment, after its fabrication, shall undergo a passivation (pickling) process to ensure maximum resistance to corrosion. All stainless steel components and structures shall be submersed in a chemical bath of nitric acid and hydrofluoric acid to remove any residues that may be present on the material as a result of forming, manufacture, or handling. After removal from the pickling bath, the equipment must be washed with a high-pressure wash of cold water to remove any remaining surface debris and promote the formation of an oxidized passive layer which is critical to the long life of the stainless steel. Spray on chemical treatments and glass bead blasting are an acceptable alternative.

5. Bolts, nuts, and washers shall be selected from AISI 304L or 316L stainless steel such that they are anti-seizing.

B. Screen: 1. Influent flow is pumped to the unit. Waste activated sludge enters the inlet to

the inside of the straining section. The inlet housing shall be constructed of stainless steel. Epoxy coated cast iron is not acceptable due to corrosion concerns. The waste activated sludge will pass through the screen and exit through the outlet while coarse material is retained inside the screening area. All structural and functional parts shall be sized for the loads encountered during screening, conveying and pressing operations.

2. The screen shall be divided into two sections; a screening section and a pressing section. The screening zone shall be equipped with flanged inlet and outlet connections. The flanges are to be slip flange type with a welded face ring. The flanges shall have an ANSI type bolt pattern and be manufactured equivalent to Class 150 ANSI/ASME B16.5 rated flanges.

3. The screening and compaction zones are in two sections with a flanged connection for easy opening. This allows easy access to the internal components of the sludge cleaner. The screen section shall be mounted on fixed stainless steel supports with feet permanently attaching to the finished floor. The compaction section shall be supported on 4 adjustable castors for easy movement during maintenance and inspection. A restriction plate will separate the two sections restricting screened sludge flow into the pressing zone area, but will allow filtrate from the compaction zone to drain into the screen area to the screen outlet.

4. The screen basket shall be of a conical shape. The perforated openings shall be around the entire basket circumference and length of the screen. Bars or wedge wire will not be acceptable screen media.

5. The sludge screen shall be designed and built to withstand static and hydraulic forces exerted by the liquid to the screen. All structural and functional parts shall be sized for the loads encountered during the screening, conveying and pressing operations. All submerged components and all components of the rotary screen in contact with the screened solids shall be of stainless steel construction. Cast iron ends and auger will be acceptable.

C. Conveyor and press screw: 1. A shafted auger screw that is entirely made of stainless steel shall be provided

to transport and dewater the screened material. An auger screw constructed of carbon steel with stellite tip is also acceptable. A shaft-less screw shall not be


acceptable. Screw flights shall be of decreasing width approaching the compaction zone matching the decreasing width of the screening section basket. In the compaction section of the screen, the shafted auger shall have flights with a continuous width to match the conical compaction zone basket. All flights shall be fully welded to the screw shaft.

2. A compaction zone shall be an integral part of the screenings screw conveyor and transport tube design. The compaction zone shall be designed to form a screenings plug of material and to return waste activated sludge that is released from the screened material into the screened stream discharge through circular holes that are perforated into the screenings compaction basket. The screening compaction basket shall include re-enforcement bars on the outlet end to withstand deformation under high loads.

3. The auger shaft shall be fitted with screen end and discharge end solid stub shafts. The stubs and screw shaft shall be accurately machined and shrink-fitted. Stub shaft of mild steel is an acceptable alternative.

4. The screen end of the screenings conveyor shall be supported by the screen gearbox. Where the shaft protrudes through the screen section enclosure, the shaft shall be sealed with the housing with lip seals. The lip seals shall be lubricated with a battery operated automatic lubricator. The gear box bearing shall not take any thrust load from the screw conveyor.

5. The discharge end of the conveyor screw shall be supported via a self-aligning roller bearing and shall incorporate two screw adjustment/locking nuts which are used to maintain positive contact between the screw and conical screening basket.

6. To minimize odors and nuisance, the conveyance, dewatering and compaction zones shall be completely enclosed.

D. Compaction and discharge zone: 1. A compaction zone shall be provided as an integral part of the screw conveyor

and tube. The discharge housing is to be made of stainless steel or cast iron. The compaction zone shall be designed to form a plug of screenings material and to return water released from the screened material to the outlet through perforations.

2. The discharge section shall be provided with an adjustable pneumatic solids retention cone and pneumatic cylinders to maintain a positive pressure against the screenings plug. The cone shall be manufactured of high strength plastic (Polyamide PA 6 G or Nylon 6/6).

3. The retention cone shall maintain a positive pressure against the screenings plug via 2 automatically adjusting pneumatic cylinders.

4. To minimize odors and nuisance, the conveyance, dewatering and compaction zones shall be completely enclosed.

E. Drive: 1. A gear box support flange with a minimum thickness of 0.7 inches shall be

welded to the screen section end of the screenings transport tube for attachment of the drive assembly.

2. The basket mechanism and transport screw shall be driven by a shaft mounted geared motor. The geared motor shall have a minimum service factor of 1.0.


3. The gear reducer shall be driven by a 3-phase, 60 Hertz, 230/460 volt, NEMA 4X, Group D continuous-duty, totally-enclosed, fan-cooled motor which leads to a conduit box for outdoor operation. The motor rating shall be a minimum of 5 HP.

F. Anchor bolts: 1. Equipment manufacturer shall furnish all anchor bolts of ample size and

strength required to securely anchor each item of equipment. Anchor bolts, hex nuts, and washers shall be stainless steel. Anchor bolts shall be wedge or epoxy type.

2. Anchor bolts shall be set by the contractor. Equipment shall be placed on the foundations, leveled, shimmed, bolted down, and grouted with a non-shrinking grout.

G. Support stands: 1. Provide full structural steel ground supports.

a. The design of the support structure shall be integrated with other conveyors and the sludge hopper.

2. Provide sludge screen support stands fabricated of welded Type 316/316L stainless steel structural members. a. The sludge screen manufacturer shall be responsible for sizing the

support structural members and anchors and shall include all required bracing to meet the application and Specification requirements.

3. For support design, assume the sludge screen 100 percent full with material weighing 60 pound per cubic feet.

4. The support stands shall be designed to accommodate all operating and static loads without deflection, deformation, or vibration which will in any manner degrade performance of the equipment.

5. All structural supporting members shall be designed such that the ratio of the unbraced length to least radius of gyration (slenderness ratio) shall not exceed 120 for any compression member and shall not exceed 240 for any tension member (of angles about Z-Z axis).

6. All structural members and connections shall be designed so that the unit stresses will not exceed the AISC allowable stresses by more than 1/3 when subject to loading of twice the maximum design operating torque of the drive motors.

7. Design the supports of avoid interference with other equipment or equipment supports.

8. The sludge screen manufacturer shall allow for 1-inch of grout beneath each support footpad for the contractor to compensate for uneven floor elevation.

9. All shop welding shall conform to the latest standards of the AWS. 10. Design shall include designing all bolts and connections. Bolt to concrete

anchorage shall meet ACI 318 appendix D. 11. Submit calculations, design and drawings sealed by a PE in the state of TX for

engineers review.

H. Control system: 1. All controls necessary for the fully automatic operation of the screen shall be

provided, including a main control panel, a local control station, and a pneumatic panel. a. NEMA 4X SST enclosure type as specified in the Project Technical

Requirements.


2. The electrical control system shall provide for automatic control of the screen via preset pressure levels using pressure transducers mounted in the screen inlet and outlet sections. A differential pressure level shall be monitored across the screen section via the 2 inlet and outlet section mounted pressure transducers.

3. The control system shall be designed such that the operating characteristics of the screen can be changed via the programmable controller. Systems which do not offer this feature will not be acceptable for this project.

4. The control system shall be capable of communicating with the plant control system (SCADA) via Ethernet/IP over a CAT6 cable connection. All statuses and alarms are to be transmitted to SCADA over the Ethernet/IP connection and SCADA shall be able to send START and STOP operational commands to the control system over the Ethernet/IP connection.

5. Main control panel shall be suitable for outdoor, wall-mounting. Enclosure with lockable door latch, and shall include the following: a. Door-interlocked and fused flange-mounted disconnect. b. 600 VAC terminal block. c. NEMA non-reversing motor starter and MCP type circuit breaker for

screen motor. d. Control power transformer with 120 VAC transient voltage surge

compressor (TVSC) and fused primary and secondary. e. Programmable logic controller (PLC), in accordance with the Project

Technical Requirements. f. Operator Interface (OIU), Allen Bradley Panelview Plus Graphic Terminal. g. Pilot lights for:

1) Control power on (white). 2) Screen running (green). 3) Screen high pressure (amber). 4) Screen fault (red). 5) E-stop push button (red). 6) Screen reset push button (black).

h. Analog inputs for the following: 1) Inlet pressure (4-20mA). 2) Outlet pressure (4-20mA).

i. Discrete inputs for the following: 1) High moisture detection. 2) Inspection hatch opened. 3) In Auto.

j. Remote dry contact outputs for the following: 1) Screen running. 2) Screen fault. 3) Screen E-stop. 4) Screen high pressure level. 5) One spare output.

k. Flashing alarm light and alarm horn with silencer-reset button. l. Plastic Nameplates.

6. A local operator station shall be provided, and shall be suitable for wall-mounting, and shall include the following: a. Hand-Off-Auto selector switch. b. E-stop pushbutton (red).


7. A pneumatic panel shall be provided, and shall be suitable for wall-mounting, and shall include the following: a. Air compressor. b. Fittings and hoses. c. Air reservoir. d. Two (2) Pressure reducing valves. e. Pressure Switch. f. Microfilter. g. Pressure gauge. h. Manual valve. i. Electro-pneumatic transducer.

2.04 FINISHES

A. As specified in Section 09960 - High-Performance Coatings.

B. Electric motors, gear reducers, and other self-contained or enclosed components shall have an acrylic enamel finish.


A. The screening equipment shall produce dewatered screenings capable of passing the EPA Paint Filter Test as described in method 9095 of EPA Publication SW-486.

B. All stainless steel parts of the unit shall be fully submerged into a pickling bath for at least 8 hours to remove welding spots and to protect the stainless steel against corrosion. Glass bead blast or chemically treated stainless steel shall also be acceptable.

C. Fabrication shall be done in compliance with all applicable ASTM standards or equivalent international standards.

D. All welding in the factory shall use shielded arc, inert gas, MIG or TIG method. Filler wire shall be added to all welds to provide for a cross section equal to or greater than the parent metal. Butt welds shall fully penetrate to the interior surface and gas shielding to interior and exterior of the joint shall be provided.

E. Manufacturer shall have established an ISO 9001 certified quality management system. Equipment suppliers not utilizing ISO 9001 facilities shall not be considered or approved for this project. Equipment supplier shall provide evidence of certification before being named as an acceptable manufacturer.

F. Manufacturer shall have established an ISO 14001 certified environmental protection management system designed to monitor and help minimize the harmful effects on the environment caused by its manufacturing processes. Equipment suppliers not utilizing ISO 14001 facilities shall not be considered or approved for this project. Equipment supplier shall provide evidence of certification before being named as an acceptable manufacturer.

G. All welding is performed in accordance with American Welding Society (AWS) D1.1 Structural Welding Code, or equivalent.



A. The screen shall be designed to handle the maximum flow with the maximum solids loading as specified above.

B. The nominal screen opening size specified above shall be the diameter of the circular perforated openings. Screen designs which define the bar spacing as the distance between rectangular openings using a wedge wire screen or a fixed bar element and a moving adjacent bar element are not acceptable. Screens using rotating rakes, screw flight mounted brushes, or traveling filter media are also not acceptable.

C. Operation of the screen shall be automatically initiated at a preset minimum pressure level and will remain operating until pressure falls below this level or if a high pressure is reached and maintained for a period of time and then the machine will fault and shut off. The screenings shall be transported through a compaction and dewatering zone and then shall be discharged.

D. All open spaces of the screen shall be cleaned via the rotating screw.

PART 3 EXECUTION

3.01 EXAMINATION


3.02 FIELD PREPARATION AND PAINTING

A. Contractor shall touch-up all shipping damage to the paint and stainless steel as soon as the equipment arrives on the job site.

B. Contractor shall supply paint for field touch-up and field painting.

C. Contractor shall coat all stainless steel bolts and nut threads with a non-seizing compound prior to final assembly.

3.03 INSTALLATION

A. Contractor shall verify all dimensions in the field to ensure compliance of equipment dimensions with the drawings. Contractor shall notify Engineer of significant deviations.

B. Installation of the equipment shall be in strict accordance with the contract documents and the manufacturer’s instructions and shop drawings. Manufacturer shall supply anchor bolts for the equipment. Contractors shall install the anchor bolts in accordance with the manufacturer’s recommendations.

3.04 FIELD QUALITY CONTROL

A. Manufacturer shall furnish the services of a factory-trained Service Engineer for 2 trips including 4 days to inspect the installation, carry-out the equipment start-up


procedures, and provide training to the operators in how to effectively operate and maintain the equipment. 1. Equipment shall not be energized, or “bumped” to check the electrical

connection for motor rotation without the Service Engineer present. 2. The Service Engineer shall make all necessary adjustments and settings to

the controls.

B. Manufacturer shall provide services by a factory-trained Service Engineer, specifically trained on the type of equipment specified. The Service Engineer requirements include, but are not limited to the following: 1. The Service Engineer shall be present during initial energizing of equipment to

determine directional testing. 2. The Service Engineer shall inspect and verify location of anchor bolts,

placement, leveling, alignment, and field erection of equipment, as well as control panel operation and electrical connections.

3. The Service Engineer shall provide classroom and/or field training on the operation and maintenance of the equipment to operator personnel. These instructions may include the use of slides, videos, literature, and/or oral presentations.

C. Manufacturer shall state field service rates for a service engineer to owner and contractor. In the event that the field service time required by this section should not be sufficient to properly place the equipment into operation, and the requirement for additional time is beyond the manufacturer’s responsibility, additional time shall be purchased by contractor to correct deficiencies in installation, equipment, or material without additional cost to Owner.

3.05 DEMONSTRATION

A. Demonstrate operation of equipment as specified in Section OR-01770 - Closeout Procedures.

3.06 TRAINING

A. As specified in Section OR-01757 - Commissioning.

END OF SECTION

January 2020 - DRAFT 11355-1 11168A60 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/Specs-Jacobs/11355 (PDS)

SECTION 11355

THERMAL HYDROLYSIS PROCESS SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. This Section covers the work necessary for the design, manufacture, supply, delivery, installation, training, testing and commissioning of a Thermal Hydrolysis Process (THP) system. All equipment will be installed outdoors on a concrete slab, adjacent to the Solids Handling Building.

B. The systems upstream, providing the feedstock to the THP, and the ancillary systems are critical parts to the operation of the THP and must, therefore be fully integrated into the design of the THP. The pre-THP dewatering system (including the centrifuges, centrifuge feed tanks, polymer system, centrate tanks, associated pumps, silos and THP feed pumps), will be provided by the Design Builder. For the systems provided by others, coordination will be required between Suppliers and the Design Builder. The systems included in the THP Supplier package are mentioned in this section as well as described in further detail in other specification sections that make up part of this Contract. Also, component parts of the THP are specified in more detail in other sections.

C. Unit Responsibility and Scope of Supply: 1. Provide a complete THP System, including all accessories and

appurtenances, from a single Supplier having complete system responsibility. 2. Provide motors suitable for operation by variable speed drives (VFDs), where

specified, to obtain the performance specified. 3. The system must include but not be limited to:

a. THP reactors and vessels, as described in this Section. b. Interconnecting sludge, water (if required for dilution, flushing, gas

condensing), gas and steam piping, including all necessary fittings and valves within the THP skid or module. Piping will extend to boundary of the skid, terminating in flanges for the interconnection of piping installed by the Design Builder.

c. THP reactor feed/recirculation pumps and fittings. Refer to Section 11312Z - Severe Duty Progressive Cavity Pumps for the requirements associated with severe duty progressive cavity pumps.

d. Digester feed pumps and fittings. Refer to Section 11312Z - Severe Duty Progressive Cavity Pumps for the requirements associated with severe duty progressive cavity pumps.

e. Dilution/cooling system, including all fittings, control valves and instrumentation, connected upstream of digester feed pumps and connections to piping provided by Design Builder.

f. Process gas system skids including condensing/cooling systems, all safety and regulating valves, instruments and controls, and flanged connections to piping provided by the Design Builder.


g. Control systems complete with all accessories and appurtenances, including main control panels, instruments and devices directly connected to equipment within the scope of supply or on equipment skids, pneumatic tubing, airsets, instrument air piping within the boundary of the skids, and connections at the skid boundary for interconnection by the Design Builder.

h. Electrical wiring within the boundary of the skids, with terminations at junction boxes, for connection to the Plant’s electrical power supply by the Design Builder.

i. Safety systems including pressure/vacuum relief valves, pressure safety valves, emergency stops/pullcords for each piece of equipment, etc.

j. Steam feed lances and control valves. k. Insulation and cladding. l. Testing (as required) and registration as per ASME. m. Structural components including supporting framework, anchoring

systems, service platforms, handrails, staircases etc. that fit within the boundaries of the equipment skids.

4. The products must be the end product of one responsible overall system Supplier. The overall system Supplier must ensure that all individual equipment suppliers (for pumps, valves, etc.) and Sub-System suppliers provide equipment and Sub-Systems in conformance with the Project Technical Requirements and that the overall system meets the system functionality and performance requirements.

5. Provide all components and accessories of the system to enhance ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features and functions.

6. The Supplier is responsible for the THP vessel design including all layouts, 3D models, structural calculations for support platforms and structures, and vessel material and sizing.

7. The Supplier is responsible for the design of interconnecting piping and valves supplied and pre-assembled as part of the THP package (on skid piping or piping that is part of a module), including supporting structure and pipe supports, and stress analysis for all steam and sludge piping.

D. To ensure compatibility and integration, the THP Supplier will also review the design and installation of the pre-THP dewatering system, storage and feed system, polymer system, steam generation system, and ancillary systems to ensure that they are acceptable to the THP Supplier.

E. Instrumentation and Controls must meet the requirements of the Project Technical Requirements.

F. Electrical equipment and wiring must meet the requirements of the Project Technical Requirements.

1.02 REFERENCES

A. Reference Codes and Standards: The design, manufacture, and installation of this system must meet or exceed the applicable provisions and recommendations of the following codes and standards authorities: 1. AGMA: American Gear Manufacturers Association.


2. AISC: American Institute of Steel Construction: a. Manual of Steel Construction. b. Specification for the Design, Fabrication, and Erection of Structural Steel

for Buildings. 3. ANSI: American National Standards Institute. 4. API: American Petroleum Institute (Standard 620). 5. ASME: American Society of Mechanical Engineers. 6. ASME Section V, Boiler and Pressure Vessel Code; Non-destructive Testing. 7. ASME Section VII, Boiler and Pressure Vessel Code; Pressure Vessels. 8. ASME Section IX, Boiler and Pressure Vessel Code; Welding and Brazing

Requirements. 9. ASME B31.1, Power Piping. 10. ASME B31.3, Process Piping. 11. ASME B40.100, Pressure Gauges and Gauge Attachments. 12. ASME B40.200, Thermometers, Direct Reading and Remote Reading. 13. ASTM: American Society of Testing and Materials. 14. AWS: American Welding Society. 15. AWS D1.1: Structural Steel Welding Code. 16. AWS D1.6: Structural Welding Code – Stainless Steel. 17. AWS QC1: Standard for AWS Certification of Welding Inspectors. 18. City of Kansas City Building and Rehabilitation Code:

a. International Building Code (2012 IBC) and Kansas City Amendments. b. International Existing Building Code (2012 IEBC) and Kansas City

Amendments. c. International Energy Conservation Code (2012 IECC) and Kansas City

Amendments. 19. EPA 40 CFR Part 503 503 Standards for the Use or Disposal of Sewage

Sludge related to Class A pathogen production and vector attraction reduction. 20. FM: Factory Mutual Research. 21. IEC: International Electrotechnical Commission, IEC60079 Series: Electrical

Apparatus for Explosive Gas Atmospheres. 22. IEEE: Institute of Electrical and Electronics Engineers. 23. ISA: Instrument Society of America. 24. ANSI/ISA Tr 12.24.01 and 12.01.01. 25. ISO: International Standardization Organization. 26. NACE (National Association of Corrosion Engineers). 27. NEMA: National Electrical Manufacturers Association. 28. NFPA: National Fire Protection Association. 29. NFPA 70 – National Electrical Code. 30. NLGI: National Lubricating Grease Institute. 31. Occupational Safety and Health Act (OSHA). 32. Underwriters Laboratories Inc. (UL). 33. SAE: Society of Automotive Engineers. 34. SMACNA: Sheet Metal and Air Conditioning Contractors' National Association. 35. All local laws and ordinances.

1.03 DEFINITIONS

A. The following is a list of abbreviations which may be used in this Section: 1. BDF Blended Digester Feed. 2. DS: Dry Solids. 3. DSL Digested Sludge.


4. DWS: Dewatered Sludge. 5. H2S: Hydrogen Sulphide. 6. P&ID: Piping and Instrumentation Diagram. 7. PCN: Process Control Narratives. 8. PLC: Programmable Logic Controller. 9. TEW: Treated Effluent Water. 10. THP: Thermal Hydrolysis Process. 11. THS: Thermally Hydrolyzed Sludge. 12. TPS: Thickened Primary Sludge. 13. TSS: Total Suspended Solids. 14. TWAS: Thickened Waste Activated Sludge. 15. WAS: Waste Activated Sludge.

1.04 MATERIALS, WORKMANSHIP AND QUALITY ASSURANCE

A. Supplier will fabricate, pre-assemble, and test the equipment provided under this Section in their fabrication shop to the extent possible and as required for shop testing. The Supplier will then disassemble and make the equipment ready for shipment for installation and reassembly by the Design Builder on site. The Design Builder will install the equipment in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the Supplier, unless exceptions are approved, in advance, by the Engineer and The City.

B. This Section directs attention to certain features, but does not purport to cover all details entering into the design of the equipment. Design and proportion all parts to have adequate strength and durability to ensure that the equipment performs in accordance with the requirements of the Contract.

C. Confirm material and equipment complies with the latest edition of the applicable standards in force at the time of tendering. In the case of a conflict between this Section and any standards, the more stringent of the two will apply.

D. Provide materials and equipment as follows: 1. New and of the highest quality in every respect. Reconditioned equipment is

not acceptable. 2. Suitable for the service intended. 3. Selected and fabricated according to best engineering practice. 4. With an equipment design life exceeding 20 years.

E. Design machinery such that all working parts are readily accessible for inspection and repair, and each part is suitable for the service required.

F. Design equipment to have adequate strength, power and capacity for both continuous and intermittent service.

G. Equipment Tag Numbers: All items of equipment, piping, and piping accessories will be identified by a tag number. These tag numbers will be assigned by the Design Builder prior to Submittals and should be used throughout the project as a unique identifier for the equipment and information associated with that equipment.


1.05 SUBMITTALS

A. Submittals must be made in accordance with the Design Build Contract. Shop Drawings, Submittals for Information Only, Other Documents for Review, catalogue cuts, samples, and other material required to completely describe and specify the system and equipment must be submitted to the Design Builder for review based on the requirements of Design Build Contract, and based on design progress and delineation of work type (i.e. design schematic and P&IDs, equipment information, electrical information, etc.).

B. Provide the Submittals in two stages - an initial Submittal including all process data, shop drawings for mechanical, and structural elements and a second submittal including the remainder of the Shop Drawings, Other Submittals for Review, Submittals for Information Only, draft O&M Manuals, Training Plans and Training Materials for the complete scope of supply within the time specified in Design Build Contract.

C. With the Submittals, provide a copy of the Technical Specifications marked up to reflect any revisions, additions, or deletions. Summarize any revisions, additions, or deletions in an attached document, clearly identifying the revision, addition, or deletion, and including an explanation. Include all deviations or exceptions to the Contract with detailed explanation of the deviation, and impacts on the function of the process, performance of the process, interfacing equipment or systems, and utility requirements.

D. For the Initial Submittal, provide the following Shop Drawings: 1. General arrangement drawings showing the layout of the THP and associated

systems, including dimensions. Include a plan view of the THP system and elevation/section views from the side and from the front of the THP system. As a minimum, also provide drawings for the following: a. All primary units of mechanical and electrical equipment showing outside

dimensions. b. All maintenance and access platforms. c. Process piping and ductwork with diameter or maximum cross-section

dimension of greater than or equal to 4 inches in double line format and piping and tubing less than 4 inches in single line format.

d. Locations for all interfaces with process, structural, mechanical, and electrical and controls equipment supplied under other packages, including clearly identified tie-in points.

e. Routing of piping, ductwork. f. Isometrics and 3D models, AutoDesk Revit 3D BIM of the THP system

including spool sheets for the piping. 2. A detailed schematic process flow diagram (PFD) of the system to fully

illustrate interconnection of equipment, location of critical monitoring and control instrumentation and to describe the functionality of the process. The process flow streams in the diagram must be cross referenced to the heat and mass balance summary (noted below), to completely describe the process.

3. A complete list of equipment, including primary equipment design criteria, proposed manufacturer's name and model number, and shipping and operating weights (when full). Append and cross reference equipment catalogue descriptions to the equipment list, where applicable.


4. A summary of utility requirements for total system operation, including steam requirements, dilution/cooling water, wash water/flushing water, and instrument air. This summary must be based on the same conditions as the heat and mass balances described in this Section. Itemize utility requirements for each equipment component and list peak volumetric flow rate (gpm), maximum month, maximum week and annual average demands (gpm), design and operating pressures (psi), and design and operating temperatures (degrees Fahrenheit).

5. Materials of construction for major components. 6. Outline drawings and specifications of all major items of equipment to be

supplied showing all dimensions, parts, weight, and construction details and materials.

7. Detailed drawings showing safety systems to be employed. 8. Complete piping and instrumentation diagrams (P&IDs). The P&IDs must

graphically describe the process, the flow streams, the major equipment, and the control method. Show and label each pump, instrument, valve, line, and other similar item. a. The P&ID must accurately represent the relative position of equipment

and control sensors within the process network so that the purpose and the operating ranges can be determined. Optionally, identify flow quantities and temperatures at appropriate points on the P&ID to clarify the process.

b. Electrical interlocks and control functions must be represented by standard symbols on the P&ID.

c. All equipment, valves, lines, and instruments must be tagged per The City of Kansas City Missouri’s standards. The PLC programming must use The City’s tagging system.

9. Process control narratives to complement the P&IDs. a. Overview: Describe the goals and intent of each unit process within the

THP system. 1) The overview must provide a functional description of the process,

including key operating parameters, control schemes, and interfaces to the plant monitoring and control system (SCADA). The description must include the purpose of, and process reactions expected from each control device for all modes of operation, including reactions to fault conditions.

2) The description must also include all manual actions required of the plant operator. Automatic operations must be clarified as to discrete (ON/OFF or step) type actions and analog (proportional or gradual) type actions.

b. Detailed Description: Describe in detail the monitoring and control functions of each unit process within the THP system. 1) The detailed descriptions must provide definition of all interlocks,

alarms and permissives. 2) Define all dependent steps required for start-up, shutdown, and the

consequences of out-of-sequence operator action. Describe start-up and shutdown steps for both the entire system and for select components of the system (e.g. one reactor vessel).

3) Describe adverse operating conditions and define operator action for each adverse operating condition.

4) Address all possible fault conditions to the process.


5) Indicate the extent of automatic and manual control action required for fail-safe reactions to fault conditions.

6) Define all the requirements for process interlocks with the rest of the process.

7) Provide cause and effect diagrams. c. PCNs to be updated and provided after Commissioning with all

commissioning settings and modifications, as part of the final submittals.

E. As part of the Second Submittal provide the following additional Shop Drawings: 1. Locations and details of sampling stations if any are provided directly mounted

to equipment in this Supply Contract. 2. Locations and details of all drain and vent connections. 3. Piping less than 1/2 inch diameter may be shown in a schematic form for initial

submission purposes. Actual routing drawings for piping less than 1/2 inch diameter are required for final shop drawings.

4. A finish schedule for equipment, piping, and structural steel members, including a color schedule.

5. A schedule, or graphic, that delineates all piping and ductwork materials to be used in the system, by service. This submittal must include, as a minimum, size, material with grade designations, operating pressure and temperature, test pressure and test type (pneumatic or hydrostatic), insulation thickness and type, and recovering/jacketing to be used.

6. A valve schedule that indicates for each valve: the valve number (as assigned on the P&IDs, subject to final approval by the Design Builder), service, the valve type, size, manufacturer and model/series number, and temperature/pressure ratings. In addition, catalogue information fully describing the materials of construction and manufacturer's service requirements must be submitted. a. For all actuated valves, include torque requirements, actuator type (where

appropriate), fail position, and stroke time, as well as proximity switches (where appropriate).

b. For all actuated valves, include actuator catalogue information, tubing diagrams and wiring diagrams.

c. For self-contained automatic valves (pressure relief, pressure reducing, backpressure sustaining, etc.), include catalogue information describing materials of construction and manufacturer's service requirements. Include information describing pilot devices, tubing, and other attachments as necessary.

d. For self-contained automatic valves, include in the valve schedule the initial factory set point of the valve.

7. Submit a detailed test protocol and draft Operations and Maintenance Manual to the Design Builder for review. Include: a. A list of pressure test conditions for piping systems for review before the

tests will proceed. This list must include the following: pipe service, piping material, operating pressure, test pressure, test type (pneumatic or hydrostatic), and operating temperature.

8. For the welding of pressure vessels and steel and stainless steel piping and ductwork, the following welding submittal information must be provided: a. Submit all documentation necessary to validate that piping and pressure

vessels, including the completed systems, comply with ASME requirements for fabrication shop inspection, shop testing, quality control, and certification; for the services required for the piping, pressure vessels


and complete systems. Where the Supplier has obtained certification from ASME and has the National Board of Boiler and Pressure Vessel Inspectors Registration provide proof of ASME and National Board of Boiler and Pressure Vessel Inspectors documentation.

F. Provide the following Submittals for Information Only: 1. Detailed heat and mass balance summary and basis of design for the

complete THP system based on the requirements of this Section. Provide drawings stamped by an Engineer. Base the heat and mass balance on conditions specified below in this Section under Design Conditions. Include, at a minimum, the following: a. Dry solids mass rates, total wet mass (dry solids and moisture) rates,

percent dry solids concentrations, temperatures, and pressures for each process, recycle, discharge and exhaust stream.

b. Heating and fuel requirements (natural gas and steam flows), including maximum design and operating temperatures and pressures.

c. Cooling water requirements (if required), itemized for each point of usage within the system, including flow rates, temperature and pressure of cooling water supply and cooling water discharge streams.

d. All system exhaust gas flow rates, temperatures, pressures, density and quality, including H2S, methane and oxygen concentrations.

2. The heat and mass balances to be submitted and displayed graphically, using a flow schematic of the THP to display the figures. In addition, utility system requirements must be displayed. The following units must be used: a. For solid material flows:

Mass flow rate pounds per hour or US tons per day of dry material (lbDS/h or tDS/d)

Solids concentration percent dry solids (%DS) Volumetric flow rate gallons per minute or day (gpm or gpd) Temperature degrees Fahrenheit (°F) Pressure (gauge) pounds per square inch (gauge) (psi(g)) Enthalpy British thermal units per pound (Btu/lb) Heat flow/power million Btu per day (mmBtu/d) and kilowatts

(kW)

b. For liquid flows:

Mass flow rate pounds per hour or day (lb/h or lb/d) Volumetric flow rate gallons per minute (gpm) or gallons per day

(gpd) Temperature degrees Fahrenheit (°F) Pressure (gauge) pounds per square inch (gauge) (psi(g)) Enthalpy British thermal units per pound (Btu/lb) Heat flow/power million Btu per day (mmBtu/d) and kilowatts

(kW)


c. For gaseous flows (natural gas, biogas, process gas):

Mass flow rate pounds per hour (lb/h) Volumetric flow rate standard and actual cubic ft per minute (scfm,

cfm). standard conditions are defined as 1 atmosphere pressure and 60 degrees Fahrenheit. Relative humidity is 0 percent.

Temperature degrees Fahrenheit (°F) Pressure (gauge) pounds per square inch (gauge) (psi(g)) Enthalpy British thermal units per pound (Btu/lb) Heat flow/power million Btu per day (mmBtu/d) and kilowatts

(kW)

d. For air flows:

Mass flow rate pounds per hour (lb/h) Volumetric flow rate standard and actual cubic ft per minute (scfm,

cfm). standard conditions are defined as 1 atmosphere pressure and 60 degrees Fahrenheit. Relative humidity is 0 percent.

Temperature degrees Fahrenheit (°F) Pressure (gauge) pounds per square inch (gauge) (psi(g)) Enthalpy British thermal units per pound (Btu/lb) Heat flow/power million Btu per day (mmBtu/d) and kilowatts

(kW)

e. For steam flows:

Mass flow rate pounds per hour (lb/h) Volumetric flow rate Gallons per minute gpm expressed as cold

water equivalent (CWE) Temperature degrees Fahrenheit (°F) Pressure (gauge) pounds per square inch (gauge) (psi(g)) Enthalpy British thermal units per pound (Btu/lb) Heat flow/power Million Btu per day (mmBtu/d) and kilowatts

(kW)

3. Pressure Vessels: In addition to Product Data and Shop Drawings, submit vessel calculations stamped and sealed by an engineer licensed in the State of Missouri and provide certifications and test reports as required by the applicable ASME codes and requirements.

4. Stress analysis results for skid mounted piping greater than 100 mm in diameter.

5. A preliminary safety assessment of the system (for use in the HAZOP), summarizing hazard potential and mitigation measures included in the design.


6. Safety Plan, prepared by the Supplier, addressing equipment and features incorporated into the design, control attributes, and procedures to be followed for start-up, shutdown, normal operation, and emergency shutdown conditions including power failure, to assure a safe working environment for the THP system.

7. Structural calculations for support structures for all equipment and appurtenances, and for all access platforms, elevated walkways, stairs, and landings stamped by an Engineer licensed in the State of Missouri.

8. Anchor bolt design calculations. Refer to the Project Technical Requirements for anchor bolt requirements for rotating equipment and structural anchor bolt requirements.

9. A description, including narrative and drawings (where necessary), of equipment hoisting and maintenance access required. This description must include a summary plan for the maintenance of, and removal/replacement of all major equipment items. Hoisting and maintenance access to be provided by the Design Builder. Coordinate with the Design Builder.

G. Electrical Shop: 1. Motor starters and VFDs will be provided by the Design Builder and housed in

the motor control centers (MCCs) also provided and installed by the Design Builder in the electrical room.

2. Provide sufficient electrical loading information to allow for sizing electrical distribution equipment, motor starting equipment and power cabling to power the proposed systems and equipment.

3. Electrical load list. 4. Plan drawings showing locations of all equipment, devices and control panels. 5. Interior layout drawings for electrical and instrumentation panels and major

electrical cabling and instrumentation and controls cabling and wiring. 6. Recommended list of equipment that requires emergency or standby power for

process safety, controls or any special requirements. 7. Additional submittals and details as required.

H. Instrumentation and Control Shop Drawings: 1. Control system architecture drawings depicting layout and location of

hardware and communication interfaces. 2. Technical information and descriptive data for all instruments and control

devices provided under this Supply Contract. 3. For the digital based control system provide I/O and memory mapping and

detailed operating description consisting of flow charts that describe the functionality of the programmed logic.

4. Provide digital control system hardware information depicting component layout drawings including terminal wiring schematics, I/O addressing, I/O rack/card assignments, and complete Bill of Materials.

5. Provide digital control systems software information in the form of program files and Human Machine Interface (HMI) development files. In addition, provide a spreadsheet with a data base listing tag names, data type, units, ranges or states, text description and memory location of all system data elements.


1.06 OPERATIONS AND MAINTENANCE MANUALS

A. Provide Operations and Maintenance Manuals for the systems specified herein, including: 1. Manual specifically written for the THP system provided in accordance with

these documents and including detailed process operating instructions, start-up and shutdown procedures, process control and troubleshooting procedures, all emergency procedures, and safety procedures.

2. The approved safety plan in a separate tabbed section of the manual. 3. Recommended settings for all automatic control functions. 4. A set of complete as-approved information, and as-built electrical,

instrumentation, and control wiring diagrams. 5. Descriptive data and operating characteristics of all electrical and control

equipment including; equipment ratings, testing and adjustment information, troubleshooting procedures, final devices settings or programmed features, programming manuals, Shop Drawing information updated to site record information and any other information required for operating and maintaining the devices or systems.

6. A copy of final programs and program listings in native device format on hard media that can be used to reload the programs on the device(s).

7. An index of all equipment Suppliers, listing current names, addresses, and telephone numbers of those who should be contacted for service, information, and assistance.

8. Test certificates and warranty certificates from all manufacturers. 9. Local authorities' inspection, approval and acceptance certificates. 10. As-fabricated drawings.

1.07 SPARES

A. Provide spare parts, materials, and special tools in compliance with the Design Build Contract.


A. Compatibility and Integration: 1. To ensure compatibility and integration, the design and installation of feed

systems and ancillary systems supplied by others must be reviewed by the THP system supplier. These systems include as a minimum: a. Pre-THP Dewatering System (including centrifuge feed tanks and

associated pumps, centrifuges, silos, THP feed pumps, centrate tanks and pumps, polymer system, tempered water system etc.).

b. Steam Supply System (including steam boilers, and boiler feed water treatment system).

B. Supply equipment free from defect in design, manufacture, workmanship and materials.

1.09 SAFETY

A. The THP System must comply with all Federal, State and local Legislation, Standards and Codes of Practice.


B. A safety plan must be produced and submitted, as detailed in this Section, demonstrating compliance and demonstrating that the principles of designing for safety have been followed.

C. An overall HAZOP Study must be completed during the design phase of the THP system. As a minimum the process, electrical and I&C engineers from the THP system Supplier must attend, along with representatives from the Design Builder, the Engineer, and The City. The HAZOP Study will be held at Kansas City, Missouri.

D. A HAZOP facilitator will be selected by the Design Builder in consultation with the City.

E. The THP system supplier will provide the P&IDs and models for the equipment under their scope of supply. The Design Builder will provide the rest of the P&IDs and models for the complete system.

1.10 WARRANTY

A. Submit warranties for each specific piece of equipment or component in accordance with the Design Build Contract.

B. In addition to standard equipment warranties, provide specific warranties as required for other equipment items.

C. Provide Process Guarantee as per the Design Build Contract and also as defined in this Section.

PART 2 PRODUCTS

2.01 DESCRIPTION

A. The Thermal Hydrolysis Process (THP) will hydrolyse primary and waste activated sludge) that has been dewatered and transfer the hydrolyzed sludge (THS) to the anaerobic digesters via cooling heat exchangers. THS will be mixed with recirculated digested sludge (DS) prior to entering the cooling heat exchangers.

B. The various components of the THP system will include the following. Unless noted otherwise, the various components will all be provided by the Supplier. 1. A dewatering system (by others) will be installed upstream of the THP, which

will include centrifuge feed tanks (receiving primary and waste activates sludge), centrifuge feed pumps, centrifuges, and ancillary systems including centrate system, centrifuge slop system, polymer system, etc.

2. A dewatered collection, storage and distribution system (by others) will be provided that includes classifying conveyors, silo distribution conveyors, storage silos, extraction conveyors and the THP feed pumps. This system will accept the dewatered sludge (DWS) from the centrifuges, direct it to the storage silos for storage, and from the storage silos, distribute the feed sludge to the THP feed pumps (by others).


3. The THP system will thermally hydrolyze the delivered DWS, converting it to THS. The function of the THP system is described in this Section. The THP system will include: a. Pulper tanks (duty/standby). b. Reactor feed/pulper circulation pumps (duty/standby for each pulper tank). c. Reactor vessels (minimum 4 batch tanks). d. Flash tanks (duty/standby). e. Dilution/cooling system for THS. f. Digester feed pumps (duty/standby). g. Process gas system that provides cooling/condensation of process gases

and separation and discharge of non-condensable gases to blended digester feed system.

h. Instrument air system as required to operate all pneumatically actuated valves, appurtenances and instrumentation.

4. The digester feed pumps will pump the thermally hydrolyzed sludge to the blend point with recirculated DSL (by others).

5. Prior to the digester feed pumps, dilution/cooling water will be added at a controlled rate to dilute the THS to approximately 10 percent dry solids and cool below 190 degrees Fahrenheit.

2.02 FUNCTION OF THE THP SYSTEM

A. The THP must be a complete system designed for the sole function of hydrolysing dewatered primary and waste activated sludge. The hydrolyzed sludge (THS) will achieve the following benefits: 1. Reduce viscosity, allowing the downstream mesophilic anaerobic digestion to

be operated at higher solids contents. 2. Enhance anaerobic digestion performance in terms of solids destruction and

biogas yield. 3. Enhance eventual dewaterability of the digested sludge.

B. Thermal hydrolysis must be achieved using a step-wise heating of the sludge as a batch process. Centrifuge feed tanks (by others) and storage silos (by others) will be provided upstream and anaerobic digesters (by others) will be provided downstream to ensure the feed to, and discharge from, the THP system is continuous at all but the lowest flows.

C. The associated upstream and ancillary services are to be integral parts of the THP and function together to achieve the required performance in a safe, efficient and stable manner. Certain components that are part of the THP Supplier supplied system, are mentioned in this Section but are described by separate specifications.

D. To heat the contents of the THP reactors, directly inject live steam. Incorporate steam recycling within the THP system to minimize live steam requirements. Design and build the THP system to operate efficiently in terms of electrical power and steam consumption.

E. The THP system will accept DWS from the THP feed pumps located beneath each of the centrifuge storage silos, operated more or less continuously.


F. The flow of hydrolyzed sludge will be blended with pumped recirculated DS, cooled in sludge cooling heat exchangers and distributed to two anaerobic digesters. Once mixed with DSL, the flow is designated blended digester feed (BDF). This piping and the cooling heat exchangers will be provided and installed by the Design Builder.

2.03 MATERIALS OF CONSTRUCTION

A. Reactors and Pressure Vessels: Stainless Steel Type 316L or Duplex 2205 Stainless Steel.

B. Refer to the Project Technical Requirements included in this Supply Contract for materials of construction for the other equipment, valves, piping and appurtenances included in THP Supplier’s scope of supply.

C. Miscellaneous Metals including structural support frames and access platforms as per the Project Technical Requirements.

D. Anchor Bolts: 316 Stainless Steel as per the Project Technical Requirements.

E. Bolts, nuts, threaded components and hardware: Stainless steel, meeting the requirements of ASTM A193, A194, A962, A563 and F593.

F. Control panels: 1. Provide control panels in accordance with the Project Technical Requirements.

All field control panel enclosures are to be NEMA 4X, stainless steel with air pressurization and cooling.

2.04 REDUNDANCY

A. Provide N+1 redundancy at annual average flow conditions as defined in this Section for THP reactors.

B. Provide redundancy for all vessels (flash tanks and pulper tanks) such that if one tank is out of service, the THP system can remain in operation at maximum month flow conditions with the remaining tanks in service.

C. Provide all recirculation/feed and other process pumping within the THP system with at least 100 percent capacity redundancy. Provide at least two identical pumps configured as duty and standby for each service.

2.05 DESIGN CONDITIONS

A. Ambient Conditions: 1. BRWWTP Average Grade Elevation: 760 ft. 2. Atmospheric Pressure: 90 kPa(a). 3. Ambient Temperatures:

a. Winter, dry bulb – ASHRAE 99.9 percent. b. Summer dry bulb/wet bulb – ASHRAE 99.9 percent. c. Mean annual extremes – ASHRAE 99.9 percent. d. Extreme wind speed – ASHRAE 0.1 percent.


B. THP System: 1. Design the THP system for the DWS feed predicted to occur in the design year

(estimated to be 2035), but ensure it has the flexibility to efficiently operate at initial conditions.

2. Design the THP system to be expandable to allow for future hydrolysis of sludge. It is expected that additional reactors, vessels, pumping and mechanical equipment will be required for this expansion. The area has been designed to be expandable to the north to accommodate additional equipment.

3. Table of design parameters:

Parameter 2025 2035 Loading Condition Annual

Average Max Month Annual

Average Max Month

Primary Sludge, Tons DS/day

45.5 59.0 45.2 58.6

Secondary Sludge, Tons DS/day

22.8 28.7 28.3 37.1

Total Sludge, Tons DS/day

68.3 87.7 73.5 95.7

Pre-dewatered Sludge Concentration, % TS [Sludge will be diluted using water or screened sludge to the vendor required feed concentration, not to exceed 18% TS]

20% - 24% 20% - 24% 20% - 24% 20% - 24%

Total Sludge to THP, Tons DS/day

66.9 85.9 72.0 93.7

Volatile Solids, % VS/TS 72% - 76% 72% - 76% 72% - 76% 72% - 76%

4. Based on the above design conditions, provide heat and mass balances for the following cases: a. Minimum Flow Condition: Minimum flow at Start-Up, with a feed DWS

concentration of 18 percent total solids. b. Maximum Flow Condition: Maximum month flow at Design Year with a

feed DWS concentration of 16.5 percent total solids. c. Average Flow Condition: Average annual flow at Design Year with a feed

DWS concentration of 16.5 percent total solids.

C. The chlorides concentration of the sludge will be between 90 to 125 mg/L.

D. Utilities Service Conditions: 1. Steam - as the primary source of steam to the THP system will be provided by

the steam boiler system designed by the Design Builder, to the specifications provided by the THP Supplier for steam quantity, quality, temperature and pressure: a. Steam Quantity: b. Maximum: defined by the THP Supplier, lb/hr. c. Minimum: defined by the THP Supplier, lb/hr.


d. Minimum Pressure at THP System Interface: defined by the THP Supplier, psig.

e. Steam Quality: maximum 0.25 percent liquid water at the THP System interface.

f. Total Hardness (as CaCO3): less than 0.5 mg/L.

E. Area Classifications: mechanical, electrical, instrumentation and control equipment in the process areas of the THP skid must be rated for Class 1, Group D, Unclassified general purpose. Instruments in direct contact with the sludge or the headspace above the sludge must be rated for Class 1, Group D, Division 2.

2.06 REACTOR FEED AND DIGESTER FEED PUMPS

A. Provide pumps to feed reactors and recirculate sludge to pulper tank and to transfer the hydrolyzed sludge to the blend point with recirculated digested sludge (DS) prior to BDF cooling and feed to digesters.

B. Pump selection, design and materials selection must account for the high temperatures of the DWS and THS (post THP dilution) as well as abrasion caused by debris that may be found in the sludge, based on typical requirements for systems hydrolysing primary/waste activated sludge.

C. Progressive cavity pumps are acceptable. Refer to the Project Technical Requirements and Section 11312Z - Severe Duty Progressive Cavity Pumps for the requirements associated with severe duty progressive cavity pumps.

2.07 PRESSURE VESSELS

A. Pressure vessels to be designed, fabricated, tested and Code stamped in accordance with the latest edition of Section VIII, Division 1, Pressure Vessels of ASME Boiler and Pressure Vessel Code and addenda.

B. Design pressure vessels rated for maximum hydrostatic test pressure as per the ASME Boiler and Pressure Vessel Code Section VIII and full vacuum.

C. Flanges to comply with ANSI B16.5.

D. Where required, provide properly installed blind flanges, Type 316 stainless steel, securely tightened using Type 316 stainless steel spiral wound gaskets and ASTM A193 B8M grade bolts.

E. Provide top and bottom skirts as required for stiffening and support with access openings and pipe penetrations, as required, including drain holes and drain piping at low points.

F. Include manways, with davit and handle bars for easy removal, minimum 900 mm diameter, one at a low point in each vessel and a second hatch 900 mm in diameter on the roof or side of each vessel near the top.

G. Insulate vessels as required to minimize heat loss and for thermal protection as described in this Section.


H. Nozzles to penetrate a minimum of 6 inches into the vessel unless otherwise indicated.

2.08 STEAM

A. The primary source of steam will come from the steam boiler system which uses digester biogas or natural gas for fuel.

B. Provide steam quantity, quality and operating conditions at all throughputs, including peak instantaneous steam demand (defined as the load required to heat all the reactors required to treat maximum week throughput), durations (including short term surges), steam use patterns, reliability requirements (i.e how long can the THP system sit in “hold” mode without steam during a changeover between duty and standby boiler), and any other operating constraints.

C. All steam piping (by Supplier on equipment skids and by Design Builder for interconnecting piping) to meet the requirements of ASME and ANSI and generally with the Project Technical Requirements.

D. Provide the necessary monitoring elements and transmitters to measure and report to the THP control system and the SCADA the mass flow, temperature and pressure of the steam to the THP and calculate and record cumulative mass flow and daily average temperature and pressure in the THP control system, in accordance with the Project Technical Requirements.

2.09 PROCESS GAS SYSTEM

A. Any process gases arising from the THP must be treated and injected into the anaerobic digestion system. Venting process gas directly to atmosphere is not acceptable as part of normal operations.

B. Locate process gas handling units on or adjacent to the THP skid. The enclosure will be rated Class 1, Zone 1, Group D area.

C. Process gases to be collected, condensed and injected into the BDF piping downstream of the sludge cooling heat exchangers. Condensate from the process gas units to be returned to the THP system.

D. Design the process gas system units and all associated piping and valve connections to prevent leakage. All process gas piping to be seamless welded stainless steel. Minimize the number of flanges. Threaded fittings are not permitted.

E. All materials in contact with the process gas must be stainless steel of a type that is resistant to organic gases at a pH between 2.0 and 7.0. Provide Type 316L stainless steel for all wetted parts.

F. Provide sufficient freeboard between the liquid surface and the process gas outlet to prevent sludge carry over in the process gas.

2.10 PRESSURE/VACUUM RELIEF VALVES (PRVS)

A. Provide relief valves capable of relieving pressure and vacuum on the pressure vessels.


B. Equip the inlet side of all safety valves, which otherwise would be in constant or intermittent contact with sludge and particulate, with rupture discs. Provide pressure indication between rupture disks and PRVs, including transmission to the local control system.

C. Design Builder to pipe discharges from PRVs on all pressure vessels to the caisson supplied as part of the THP system. The caisson allows safe discharge from any pressure relief valve to the atmosphere.

D. PRVs on pressure vessels to meet ASME steam safety valve requirements as well as API 520 and API 521 code requirements.

E. Provide full-bore valves designed to meet maximum venting requirements, clearly marked with correct pressure settings, readily accessible for testing and recertification.

F. Select materials resistant to organic gases at a pH between 2.0 and 7.0.

2.11 UTILITIES

A. Provide tie-in connections for all utility systems, clearly identified, including, steam, service water, process gas, instrument air, electrical and communication services, drains, etc. that serve the THP. Clearly identify these tie-in conditions on the drawings.

2.12 METAL WORK

A. Provide all platforms, stairways, handrails, anchor bolts, and ladders as required, in accordance with the Project Technical Requirements to provide convenient and safe access to all areas of equipment requiring maintenance or access to instrumentation.

B. Maintenance platforms must allow maintenance personnel access to equipment drive systems, lubrication points, sample points, valves, relief valves, instrumentation, and other equipment items commonly requiring attention, within reasonable and safe reach for a person on the platform, and must not require additional stools or ladders for work to be performed.

C. Platforms located in areas where wet material is handled, around sample points, and around material transfer points must incorporate tray sections to prevent material from falling through to the floor level below.

2.13 SYSTEM EQUIPMENT AND APPURTENANCES

A. General: 1. Provide all other equipment and appurtenances required for a complete

package that meets the criteria of this Section. 2. Select all equipment for type and function and size the equipment to

accomplish the performance requirements specified herein.

B. Equipment Identification Nameplate.


C. Bearings: All rotating equipment antifriction bearings must be rated for a minimum ABMA L 10 life of 100,000 hours.

D. Lifting Lugs: Provide lifting lugs or other provisions for easy handling on all equipment and removable parts weighing over 85 lb. Lifting beams will be provided over pumps for removal by the City, unless the pumps are located on the THP skid, in which case, provide lifting beams incorporated into the THP skid framework.

E. Anchor Bolts: Stainless steel or steel alloy, sized by the equipment manufacturer. Provide anchor bolts for installation by the Design Builder. Design anchor bolts for static, dynamic, operating, thermal and seismic loads.

F. Coupling guards must meet OSHA requirements.

G. Thermal Expansion Provisions: Design the THP with all necessary provisions to accommodate the effects of thermally induced movement and stress on all parts of the THP system. The provisions must allow operation of the THP under all normal and abnormal upset thermal conditions and must prevent overstressing the THP materials of construction and excessive movement of THP system components.

H. Sampling Points: 1. Permanent sampling provisions must be provided for the sampling of the

following materials in the general locations indicated: a. DWS feed to the THP at the THP feed pump discharge. b. DWS feed to the THP at the inlet to the pulper tank or reactors. c. THS output from the THP. d. Additional sampling points as recommended by the Supplier to monitor

performance. e. Provide flushing connections and proper drains for sampling points.

2. Sample points in interconnecting piping (not on the Supplier’s skids) will be provided by the Design Builder as per the standard details provided in the Construction Contract. Sampling points directly mounted to any equipment within this THP Supply must be provided by the Supplier. Provide sampling locations with easy access, arranged in a manner that is safe for the operator and minimizes or eliminates material leakage and/or spillage while sampling is conducted.

3. Design sample connections, if any, directly connected to Supplied equipment, as per the standard details provided in the drawings included in the Design Build Contract.

I. Grounding: All equipment, piping, and ductwork must be electrically continuous and attached to a grounding conductor. Internal components of equipment must be static conducting and connected to the equipment grounding conductor.

J. Fail-Safe Provisions: 1. Make provisions for safe operating and shutdown conditions in the event of

power failures and equipment failures. 2. Include automatic controls to shut off valves and gates to prevent uncontrolled

sludge, steam, gas, or liquid flow. On loss of power, ensure valves fail to a safe position that prevents unsafe conditions or equipment damage.


K. Cooling Equipment and Temperature Control: 1. Cooling of hydrolyzed sludge to the operating temperature range required by

the digesters is incorporated into the Design Build Contract.

2.14 PIPING, DUCTWORK AND VALVES

A. General: 1. Provide all piping, piping supports, miscellaneous piping appurtenances, and

valves for the THP skids or modules which shall meet ASME requirements and generally comply with the Project Technical Requirements. Route and install piping so as to provide headroom and easy access to all process components and instruments. Deliver skids or modules pre-piped. Extend piping to the boundary of the skid terminating in flanges for the connection of interconnecting piping installed by the Design Builder.

2. Design Builder to provide all necessary interconnecting piping, piping support systems, miscellaneous piping appurtenances, and valves required to connect skids/modules to other skids/modules or equipment to provide a complete and operable system.

3. Design piping with minimum use of bellows type expansion joints. Use standard long radius elbows for all sludge piping except DWS piping. Use 3D radius elbows for all DWS piping.

4. Design piping to accommodate thermal displacement. Conduct stress analysis on all piping.

5. Provide each piece of equipment having a baseplate or other drainage connection with a piping connection extending from the baseplate or other drainage connection to allow for tie-in by the Design Builder to the nearest drainage gutter, drain sump, or floor drain.

6. Welding procedures for stainless steel piping must comply with ASME requirements and generally with the Project Technical Requirements.

B. Valves: 1. Provide manual valves and pneumatic operated valves. Select valves in

conformance ASME requirements and in general compliance with the Project Technical Requirements.

2. Provide self-contained automatic valves, solenoid valves, and valves for modulating service, sized to meet the process requirements and installed where necessary and/or where shown on the Design Builder and Supplier’s P&IDs to provide a complete and functional system.

3. Provide isolation valves at all process equipment connections to allow for maintenance. Include spectacle blinds in addition to the isolation valves as a means of double blocking on tank connections where personnel access is required in accordance with OSHA requirements.

4. Provide drain and air release valves as required to facilitate easy start-up, shutdown, operation and cleaning of the system. Provide valves for each process stream. Include flushing connections to allow for pipe cleaning during maintenance.

5. Include open and closed limit switches on manual isolation valves that are operated more than once per month or that need to be open for another piece of equipment to operate.

6. Select materials suitable for the process fluid and conditions. For sludge valves, select abrasion resistant materials.


C. Actuators: 1. Provide pneumatic actuators. 2. Provide visual position indicators, manual override and limit switches for

OPEN and CLOSE indication for both pneumatic and mechanically actuated valves.

3. For modulating valves include position indicators with indication at the local control and plant SCADA control systems.

4. On a local control station in close proximity to each actuated valve, include selector switches to select hand/off/auto control modes and open/close switches or toggles as appropriate. In the “Hand” position provide hold-to-start spring return switch. Provide the contacts necessary to transmit the position of hand/off/auto switch positions in the control system and provide this information to the plant SCADA.

D. Insulation: 1. Provide insulation on all hot surfaces of suitable thickness for outdoor

temperatures in Kansas City, Missouri during winter. Where necessary, provide heat tracing systems, where insulation thickness required is not practical.

2. Provide insulation/barriers to limit the surface temperature of stacks, ductwork, piping, and other hot surfaces.

3. Insulate equipment, ductwork, piping and other cold surfaces to minimize condensation build-up.

4. Provide protective, heat dissipating barriers to prevent surface temperatures of all equipment, vessels, ductwork, and piping that is reachable from the ground, stairs, walkways and platforms from exceeding 120 degrees Fahrenheit.

5. Provide aluminum recovery jackets on all insulated piping and tanks.

2.15 ELECTRICAL SYSTEMS

A. Provide a complete electrical power distribution system including local control panels, operator stations and accessories in accordance with the Project Technical Requirements.

B. Motor control centers and variable frequency drives (VFDs) with power feeders to loads are by the Design Builder. Coordinate with the Design Builder to ensure that the motors are compatible with the selected VFDs. Provide induction motor suitable for VFD service.

C. Pre-wire each skid or module. Provide electrical wiring within the boundary of the skids, with terminations at junction boxes, for connection to the Plant's electrical power supply by the Design Builder.

D. Make all power and signal wiring between sub-systems suitable for wet and corrosive locations in accordance with NEC requirements.

E. Power Supply: 1. Power will be supplied at either 480 V/208 V, 3 phase, 60 Hz, or 120 V, single

phase. 2. Control system voltages are to meet plant standards.


2.16 INSTRUMENTATION AND CONTROLS

A. General: 1. Provide instrumentation and control components in accordance with the

Project Technical Requirements. 2. Provide control systems complete with all accessories and appurtenances,

including control panels, instruments and devices, pneumatic tubing, airsets, and instrument air piping within the boundary of the skids/modules, and connections at the boundary of the skid/module for interconnection by the Design Builder.

3. Provide a reliable, effective method of cooling for control panels containing electronic components or control elements. Plant standard uses compressed air for panel pressurization and cooling. Ensure that the maximum temperature in the control panel does not exceed 75 percent of the design maximum temperature that any component within that control panel is capable of withstanding.

4. Configure the THP control systems such that no single failure will render the THP system inoperable.

5. Provide a THP standalone PLC based control system for overall control and monitoring of the complete THP system including all the associated subsystems specified herein. Configure the THP controls to shut down the THP to a safe and stable condition in the event of emergency shutdown conditions. Provide hardware, software, and software configuration for a fully operational system as further described herein.

6. Interface the THP control system with the plant SCADA. 7. The plant SCADA will send a permissive to the THP to start or modulate the

THP feed pumps, based on available digester capacity, as set with the digester feed pumps.

8. The SCADA will give a permissive to start or modulate the digester feed pumps based on the availability of digester capacity.

9. Include security settings to prevent operators from accidentally altering the controls that could damage the equipment or cause safety issues.

10. Instruments used for safety must not be used for process control, must be of a higher reliability rating than standard control instrumentation and must be hardwired to the plant control system for signaling alarms. Develop an SIS based safety system for process critical parameters and parameters that can induce life safety failure (gas release).

B. Inputs and Outputs: 1. Provide a complete I/O list, including all support equipment. 2. Provide adequate I/O space and connectivity with 25 percent spare capacity

for each type of input required. 3. Provide a list of critical I/O for the THP system, including all common support

equipment. Critical I/O is defined as any field signal which results in a complete shutdown of the THP train on loss of signal, or any field signal which results in a safety hazard on loss of signal.

4. For all critical I/O provide duplicate sensors wired to separate I/O modules, such that no single point of failure will cause a loss of signal.

5. Provide diagnostic programming to automatically select the sensor to be used as the control signal. When an I/O fault occurs in the selected signal, provide for automatic and bump-less switchover to the duplicate sensor.


6. As a minimum, an I/O fault is to be detected and alarmed if any one of the following conditions occurs: a. Instrument failure. b. Loss of signal.

C. Plant Communications: 1. Where hardwired control is necessary, provide volt free contacts for hardwired

status information between the controls systems as detailed below. 2. Communication with plant SCADA can be accomplished by means of an

industry standard communication protocol on an Ethernet Communication Link, as specified by the Design Builder.

3. Provide alarms to indicate to plant operators that maintenance attention is required or to indicate an extreme alarm condition in which the THP performance or safety may be jeopardized.

4. In addition to the SCADA interface requirements, provide the following signals, as a minimum, for each piece of equipment or instrument:

Signal Description Type From: To: Run Permissives

Digester Feed Pumps Run Permissive DI SCADA LCP THP Feed Pumps Run Permissive DI SCADA LCP

Statuses THP System Run Status DO LCP SCADA THP Feed Pump Run Status DO LCP SCADA Digester Feed Pump Run Status Comm LCP SCADA Reactor Feed pump Run Status Comm LCP SCADA Pulper Online Status Comm LCP SCADA Status of each Reactor (Fill, React, Draw) Comm LCP SCADA Flash Tank Online Status Comm LCP SCADA Valve Status Comm LCP SCADA Pump Status Comm LCP SCADA Process Gas Unit Status Comm LCP SCADA

Monitoring Parameters Instantaneous Sludge Feed Flow into each Reactor

Comm LCP SCADA

Cumulative Sludge Feed Volume for each Reactor

Comm LCP SCADA

Instantaneous Dry Mass of Sludge Feed Comm LCP SCADA Cumulative Dry Mass of Sludge Feed Comm LCP SCADA Sludge Feed Temperature Comm LCP SCADA Reactor and Vessel Temperatures Comm LCP SCADA Reactor and Vessel Pressures Comm LCP SCADA Sludge Levels in Reactors and Vessels Comm LCP SCADA Reaction Time Comm LCP SCADA Rate of Temperature Increase Comm LCP SCADA Instantaneous Live Steam Mass Flow Rate Comm LCP SCADA


Signal Description Type From: To: Cumulative Live Steam Mass Flow Rate Comm LCP SCADA Live Steam Temperature Comm LCP SCADA Live Steam Pressure Comm LCP SCADA Flowrate for each THP Feed Pump Comm LCP SCADA Flowrate for each Digester Feed Pump Comm LCP SCADA

Alarms THP System Fault: Priority 1 Alarm DO LCP SCADA THP Feed Pump Fault: Priority 1 Alarm Comm LCP SCADA Digester Feed Pump Fault: Priority 1 Alarm Comm LCP SCADA Reactor Feed pump Fault: Priority 1 Alarm Comm LCP SCADA PRV Alarm (Rupture Disc) Comm LCP SCADA PRV Alarm (Lifting Detection) Comm LCP SCADA High Level Alarms: Priority 1 Alarm DO LCP SCADA High Pressure Alarms: Priority 1 Alarm Comm LCP SCADA Low Pressure Alarms: Priority 1 Alarm Comm LCP SCADA High Temperature Alarms Comm LCP SCADA Process Gas System Fault: Priority 1 Alarm Comm LCP SCADA Setpoint Temperature not Reached within Reaction Time: Priority 2 Alarm

Comm LCP SCADA

5. List any additional functions available at the local control panel (LCP) that can be transferred to the SCADA via Communications Link. Ensure that all information transmitted to the LCP is transmitted to the DCS.

6. Allow for an Operator to manually adjust the reaction time/cycle time through the HMI connected to the SCADA.

7. Allow the Operator to change the following setpoints through the HMI on the SCADA: a. THP feed pumping rate by adjusting the flow setpoint and using the

controls to change the VFD speed so that the flow matches the setpoint. b. Digester feed pumping rate by adjusting the flow setpoint and using the

controls to change the VFD speed so that the flow matches the setpoint. c. THP throughput. d. Reactor total cycle time. e. Reaction time. f. Reaction Temperature. g. Alarm set-points (excluding safety alarms). h. Time of day, date, year.

8. Control Signals: Provide the following control signals for process interlocks between the THP Control System and the SCADA: a. DWS storage silo low level initiates a warning. The DWS storage silo low-

low level shuts down the THP feed pumps. 9. Provide status information, alarms, and analog values for remote monitoring

by the SCADA HMI. a. Status information, alarms, and analog values must be in contiguous

blocks of data registers in the THP Control System. b. Provide for 25 percent spares within the contiguous block of data

registers.


10. Application Software: The Supplier must provide all application software and system configuration necessary to make the THP control system functional. Provide communication processors, LANs, Ethernet switches, and communication interfaces to communicate with the SCADA.

D. Control Panels: 1. Furnish a self-contained process control system in the MCP for automatic and

manual control (to the extent possible for testing and maintenance without sacrificing the safety and process functionality) of the THP system fully assembled, wired, pre-programmed, and factory tested.

E. Operator Interface: 1. Provide a menu-driven operator interface with automatic fault message

windows appearing upon alarm conditions. 2. The SCADA will archive all alarms, including time and date, and will leave the

most recent in RAM for ready access, as per Plant standards. On the HMI, display the current alarms.

3. The process graphic displays provided by the Supplier on the HMI must have the following display and operator interface capabilities: a. Display process flow streams with labels and color coding. b. Illustrate all major equipment items. c. Illustrate all control devices such as gates, valves, dampers, etc. d. Display equipment operational status and alarm conditions. e. Display process signal values for all measuring devices.

4. Provide for selection of control functions and access to associated graphic displays.

5. Real-Time Trending Displays: Real-time trend displays must be configured to display the last four hours of trend data for all field analogue values monitored.

PART 3 EXECUTION

3.01 SHOP PAINTING AND CORROSION PROTECTION

A. Provide factory applied prime coat protective and maintenance coatings, as applicable. Such equipment will be finish painted by the Design Builder to meet color coding requirements for the Plant.

B. All factory-primed equipment must have removable tags attached by the manufacturer or the Contractor, identifying the applied coating system, paint manufacturer, and product name and number, where applicable.

C. For all surfaces, use corrosion-resistant materials or protect with corrosion protection systems. Materials or protection systems must adequately protect the equipment and appurtenances from corrosion caused by the service environment including chemicals and pH extremes.

D. Edge Grinding: Grind sharp corners of cut or sheared edges to a radius by multiple passes of a high-speed grinder as required to ensure satisfactory paint adherence.


E. Surface Preparation: Shop clean by sandblasting, or an equivalent process, all ferrous metal surfaces except motors, speed reducers, and stainless steel, in conformance with the paint manufacturer's recommendations. Remove all mill scale, rust, and contaminants before shop primer is applied.

F. Coating Repairs: Repair all damage to coating systems prior to acceptance by the Design Builder at delivery. Design Builder will be responsible for any coating repairs after delivery and acceptance on Site and due to installation of the THP equipment. Design Builder’s repairs will be performed according to the paint manufacturer's recommendations. Provide required touch up paint to the Design Builder at no additional cost.

3.02 SOURCE QUALITY CONTROL (FACTORY TESTING)

A. Complete factory testing in conformance with the Project Technical Requirements and as required to meet ASME code requirements.

B. All factory fabricated system components must be factory tested and inspected for compliance with the quality and functional requirements specified herein, and a certification of the results of these tests must be submitted to the City. Notify the City a minimum of 14 days prior to factory testing of equipment to allow the City time to schedule witnessing of shop tests at the City's discretion.

C. Perform non-destructive testing on factory welds on tanks and piping assemblies as per the requirements in this Section.

D. Conduct hydrostatic testing of all vessels and piping assemblies as per the requirements of ASME BPVC Section VIII.

E. Factory test all pressure relief valves in accordance with ASME BPVC Section VIII.

F. Motor Tests: Motor tests must be conducted in accordance with NEC.

G. The complete THP Control System, including network communications, must be tested in the factory for all required functions. Perform a System Integration and Functionality (SIFT) test. Provide sufficient software and hardware simulations to allow demonstration testing of the required functions. Factory Acceptance Test (FAT) will test 100 percent of the control loops by simulation and 20 percent of all DI/DO and AI/AO and fieldbus interfaces.

H. Operating noise levels must be such that the average noise level measured at three (3) feet around the periphery of the complete assembly does not exceed 85 dBA (in simulated free field) when tested at the manufacturing facility. If operating noise levels exceed 85 dBA at 3 ft, take appropriate measures to attenuate the sound.

3.03 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Comply with the requirements of the Project Technical Requirements.

B. Coordinate the delivery, storage and handling with the Design Builder.

C. Ship equipment in fabricated assemblies, when applicable, match marked, painted and knocked down for shipment.


3.04 WELDING AND NONDESTRUCTIVE TESTING

A. Weld in conformance to AWS D1.1, AWS D1.6, ASME BPVC-IX and ANSI B31.3. Use AWS D1.6 qualified welders. Use inert gas backing (GMAW or GTAW) for field and shop welds. For stainless steel, solar flux welding is not acceptable. Adhere to latest edition of NACE SP0178. Use an all stainless steel shop and equipment to prevent mild steel particles from contaminating stainless steel surfaces and joints.

B. The Supplier is to engage an independent welding inspection firm to conduct a series of factory weld tests. Any site welds performed will also be subject to these requirements.

C. The Supplier must retain the services of a AWS D1.6 certified weld testing agency that provides the services of an AWS QC1 certified welding inspector experienced with the referenced governing welding codes indicated above. The testing agency must be certified in accordance with the current AWS standards for Non-destructive Testing (NDT). The welding inspector must be present for the welding of the systems outlined above, whether in the shop or in the field. The welding inspector's responsibilities include: 1. Monitoring conformance with the approved welding procedure specifications. 2. Checking weld quality. 3. Ensuring that welding finishes conform to the specifications listed below. 4. Checking welding and welding operator qualifications. 5. Supervising of non-destructive testing personnel and evaluation of test results.

D. Provide 100 percent visual inspection in accordance with AWS D1.6. AWS QC1 Certified Welding Inspectors (CWI).

E. Provide Ultrasonic Testing (UT) of 10 percent of all butt/groove welds using acceptance criteria per ASME BPVC Section VIII, Div. 1, Appendix 12. Provide ANST Level 2 UT Inspectors Certified in accordance with SNT-TC-1A.

F. Provide Die Penetrant Testing (PT) of 10 percent of all fillet welds (minimum 10 percent of total weld length) using acceptance criteria per ASME BPVC, Section VIII, Div 1, Appendix 8.

G. In the event of test failure(s), the Supplier will be directed to undertake additional weld tests, of a number up to 10 times the number of failures, at his cost.

H. Further failures will result in another group of welds being tested, again of a number equal to 10 times the number of failures. This re-testing will be repeated until there are no failures.

I. All factory welds which fail the tests must be repaired and re-tested at the Supplier's expense. All site welds which fail the tests must be repaired and re-tested at the Design Builder's expense.

J. Fabrication and welding of access platforms, stairs, ladders and piping must meet the requirements of ASME standards and be in general conformance with the Project Technical Requirements.

K. Seal watertight by continuous welds all welded joints which are exposed to view or in contact with the process streams. Partial welds are not acceptable.


L. Pickle and passivate all stainless steel welds according to the applicable codes and standards.

3.05 INSTALLATION

A. THP System equipment items must be installed in accordance with the Supplier’s written installation instructions and the Design Build Contract.

B. All strain from attached piping must be eliminated from equipment and any evidence of noisy operation or other signs of improper setting must be corrected by the Design Builder under the direction of the THP Supplier.

3.06 FIELD PAINTING

A. Final field painting, by Design Builder, must be in accordance with Section 09960 - High-Performance Coatings.

B. For field fabricated equipment, prepare and coat exposed exterior ferrous metal surfaces in accordance with Section 09960 - High-Performance Coatings.

C. Prepare and coat ferrous metal surfaces of equipment with elevated skin temperatures in accordance with Section 09960 - High-Performance Coatings.


A. Comply with the requirements of the Design Build Contract.

B. The following paragraphs outline how progressive testing of the THP system installation be carried out the Design Builder and the Supplier: 1. Installation Inspection: Review installation as necessary to verify that the

equipment has been installed in accordance with the Supplier's directions and recommendations. Any remedial measures identified during the Installation Inspection will be completed prior to running the Demonstration Test.

2. Demonstration Test: Run equipment dry for one (1) hour to illustrate that motor, drive, and ancillaries function as required. Conduct measurements and checks that ensure that the equipment is functioning as expected.

3. Operational Tests: These tests consist of equipment and system operational tests. Equipment Operational Testing involves three (3) successful days of testing using “clean water” (treated plant effluent (TEW) is acceptable), demonstrating that the process mechanical, structural, electrical and instrumentation and control elements related to a process equipment have been installed as intended and operate over the range of design conditions specified. Once the individual pieces of equipment have been tested, the System Operational Testing will be conducted over a period sufficient to achieve seven (7) days of successful operation, of which, the last three (3) days must be consecutive, with clean water (TEW) being fed to the various components, systems and sub-systems that constitute the overall THP system. Each item of equipment will undergo an operational test as required to prove successful operation at the maximum or most severe, average, and minimum or least severe conditions. Conduct hydrostatic tests for each tank, vessel and piping assembly on the skid(s) using clean water. Conform to the applicable code requirements for hydrostatic testing of pressure vessels.


Vibration and noise tests will be conducted during the operational test period as required.

4. Commissioning: This test will be conducted with sludge (DWS) and steam. Systems and sub-systems will be tested in steps to ensure that each component is operating correctly before sludge is fed to the next step in the THP Facility. Once each system and sub-system has been tested to the satisfaction of the Design Builder, the entire THP Facility (from the centrifuge feed tanks to the digester feed pumps) will be operated with sludge and steam over a period sufficient to achieve fourteen (14) successful days of operation, of which, the last seven (7) days must be consecutive.

5. Guaranteed Performance Tests (GPT): Validating the performance of the THP system in terms of sludge throughput, reaction temperatures and pressures, steam consumption, and energy consumption will be undertaken after Plant commissioning during a period of relatively stable operation.

C. Installation Inspection and Demonstration Test - Specific Requirements (Start-up and Field Mechanical Check): 1. The Design Builder will install the THP Equipment as directed by the Supplier's

representative. 2. Conduct the Supplier Inspection and Demonstration Test in relatively quick

succession. 3. The Supplier's representative will be responsible for checking certain settings,

measurements, etc., as required to ensure satisfactory installation.

D. Operational Test with clean water - Specific Requirements: 1. This test can only proceed after installation of the units and after all

accessories are in an operable condition. System controls do not need to be completely functional at this time. Equipment must be able to operate in manual mode.

2. Conduct hydrostatic tests on all tanks, vessels and piping assemblies. 3. In conjunction with the initial periods of the Operational Testing, the Design

Builder is to perform a field mechanical test under the supervision of the Supplier and in the presence of the City, as described below: a. Submit each unit to complete normal start, normal stop, and emergency

stop cycles. Submit each unit to a minimum 12 hour running test when the THP system is being fed with clean water. During this running test, observe and record all thermometers, pressure gauges, and flow indicators at the beginning, at two hour intervals, and end of the test. Check all safety devices for satisfactory operation.

b. Correct any malfunctions appearing during the tests and extend the test period, as directed by the Engineer, to ensure that the defective or maladjusted equipment will perform satisfactorily after adjustment.

c. In conjunction with the start-up of the facility and after the field mechanical test, make the THP equipment available to assist with start-up activities related to auxiliary equipment, including sludge dewatering, conveyance, and storage, steam feed, and other related equipment. The start-up of this auxiliary equipment requires the THP system to be on-line. The Supplier's field representative is to operate the THP equipment throughout this period.

4. The Supplier's representative will be responsible for ensuring satisfactory operational testing.


E. Commissioning – Specific Requirements: 1. Once the Operational Testing is complete, begin the Commissioning. 2. For this test to occur, in addition to the equipment supplied under this Supply

Contract, the centrifuges, centrifuge feed tanks and pumps, polymer system, sludge cooling heat exchangers, digested sludge recirculation system and digester feed pumps, and other ancillary systems (such as the centrate system, slop system, tempered water system that provides tempered water to the polymer system, seal water system, etc.) as required to operate the entire system as a whole, must have their Operational Testing successfully completed. Coordinate with the Design Builder and other equipment Suppliers. Furthermore, the polymer system (by others) needs to be tested with polymer to ensure it can make a successful batch of polymer and the steam boiler system must have their Operational Testing completed and be capable of supplying steam.

3. Conduct the Commissioning with sludge and steam. 4. Test systems and sub-systems in steps to ensure that each component is

operating correctly before sludge is fed to the next step in the THP system. 5. The Design Builder, with support from the Supplier, will provide an initial

detailed Commissioning Plan for City review. The final Commissioning Plan will be prepared by the Commissioning Team (including the City, Supplier and Design Builder). The following steps provide an indication of the anticipated testing process. These steps are provided as an overall indication of the Commissioning process and are not meant to replace the detailed testing plan prepared by the Design Builder with the Supplier’s assistance: a. Step 1: With sludge in the East Sludge Holding Tank, test the operation of

the east holding tank supply loop pumps. b. Step 2: Test one of the pre-THP centrifuge feed pumps by slowly

introducing sludge to one of the centrifuges. c. Step 3: Operate the centrifuge and associated classifying conveyor until

the sludge consistency reaches 16 percent dry solids, sending the centrifuge waste to the slop tank.

d. Step 4: Test one of the centrifuge slop pumps by returning the slop to drain.

e. Step 5: Once the sludge reaches 16 percent consistency begin transferring sludge to one of the silos using one of the silo distribution conveyors.

f. Step 6: Several batches of sludge may be required to fill a silo. Once the silo is half full, begin pumping sludge to the selected pulper.

g. Step 7: Test one of the digester recirculation pumps. Pump digested sludge through the sludge coolers and back to the digesters, initially pumping at a low flow rate, increasing to design flow rate.

h. Step 8: test one of the cooling towers and cooling water circulation pumps and pump cooling water through the sludge coolers.

i. Step 9: Operate one of the reactor feed/pulper circulation pumps and add sludge and steam to heat the reactor/pair of reactors to the required temperature and pressure.

j. Step 10: Cycle the reactor(s) through a complete cycle and then transfer the batch of hydrolyzed sludge to one of the selected flash tank.

k. Step 11: Pump the THS using one of the digester feed pumps to an anaerobic digester via the blending point with circulated digested sludge and through the sludge coolers.


6. Collect samples at each step of the Commissioning process, as appropriate to determine the operation of the Systems, and have the samples analyzed at a certified third party lab. Record all operating data and field observations. As a minimum, sample the sludge at the THP feed pump discharge, inlet to the THP reactors/pulper tank after dilution/lubrication, and at the discharge of the digester feed pumps and determine the solids concentrations. Employ a certified, third party laboratory to test all samples. The City, at its discretion, may request duplicate samples for testing at The City lab.

7. Once each system and sub-system has been tested to the satisfaction of the Design Builder, the entire THP system (from the east sludge holding tanks to the digester feed pumps) will be operated with sludge and steam over a period sufficient to achieve fourteen (14) successful days of operation, of which, the last seven (7) must be consecutive.

F. Guaranteed Performance Test: 1. After Commissioning has been completed, the Design Builder will conduct the

Guaranteed Performance Test (GPT), with the Supplier's representative present to supervise and monitor results. The City will observe the GPT. The procedures will generally align with the following.

2. Guaranteed Performance Test (GPT): a. After the THP system has been operating stably for approximately three

(3) months, conduct the GPT. b. The City's operating personnel will assist in conducting the GPT. c. Ensure that all auxiliary equipment is operational. d. Conduct GPT under the design parameters specified below. e. Supplier's responsibilities include:

1) Control of DWS feed to the THP system. 2) THP reactors operation. 3) THS feed to the digesters.

f. The Design Builder's responsibilities include: 1) Steam supply from steam boilers. 2) Dewatering system operation (centrifuges, centrifuge feed tanks and

associated pumping, centrate system, polymer system), and other ancillary systems operation (such as the tempered water system for the polymer system and seal water system).

3) Digester feed pump, sludge cooling heat exchangers and digester operations.

4) Disposal of sludge and testing water. 5) Natural gas supply (for use in the steam boiler). 6) Potable water supply (for use in the boiler feed water treatment

system and post THP dilution). 7) Polymer supply. 8) Treated effluent water supply. 9) Power supply and other utilities.

3. Guaranteed Performance Test Procedures: a. Conduct performance tests to demonstrate the equipment's ability to

consistently perform at the design parameters specified in this Section. b. The anticipated loading conditions during the GPT will be well below the

maximum capacity specified for the Design Year. Simulate the maximum month loading condition by shutting off some equipment so that the maximum month loading can be simulated in the equipment remaining in service.


c. Test the THP system at the specific design operating conditions described in Paragraph 3.08 below.

d. Operate the THP system under each design operating condition for a minimum of seven (7) consecutive days for each test condition.

e. Maintain steady state operation throughout each test for each of the design operating conditions. The THP system will be required to maintain acceptable performance at each of the throughput conditions specified.

f. Record all operating data and field observations. Sample the sludge at the THP feed pump discharge, inlet to the THP reactors/pulper tank after dilution/lubrication, and at the discharge of the digester feed pumps and determine the solids concentrations. Employ a certified, third party laboratory to test all samples. The City, at its discretion, may request duplicate samples for testing at The City lab.

g. The test results will be used to prove compliance with the performance requirements prior to acceptance of the equipment.

h. Should the equipment not achieve consistent compliance (greater than 95 percent of the time) with any of the proposed performance characteristics during the GPT period then the Supplier is to modify the equipment and repeat the performance tests. Supplier is to bear the costs of modifying equipment, reducing or furnishing additional equipment, and subsequent retesting.

i. Should the equipment fail to meet any of the design requirements, the equipment will be rejected and must be replaced by the Design Builder with acceptable equipment at the Supplier's expense.

j. Equipment replacement will include all costs (including engineering) for removal of any failed equipment, installation of any new equipment, and all retesting required proving compliance with the performance requirements.

G. Field Evaluation Report: 1. The Supplier shall submit a written report within two weeks of completing the

GPT presenting the results of the performance tests. Include in the report all laboratory analysis reports (for TSS concentrations of the sludge, etc.), recorded data and observations. Submit three hardcopies and one electronic version of the report to the Design Builder and City. Include all data collected during field testing, including, but not limited to, the following: a. Data from GPT to demonstrate consistent achievement of the design

conditions for the THP system. b. Conclusions from extended duration performance testing utilizing the

average of the data collected, including: solids throughput and steam consumption.

3.08 GUARANTEED PERFORMANCE REQUIREMENTS

A. General: The following are THP performance requirements to be demonstrated in the GPT. In addition to these requirements, other requirements are outlined in related specifications for specific equipment that constitutes part of the overall THP Supplier package. If more than one train is provided, both trains must be tested to prove performance requirements can be met.


B. The THP system must be capable of operating in a stable and safe manner at the conditions listed in this Section under Design Conditions, and producing the required hydrolyzed sludge as defined below while operating at any combination of these conditions.

C. As a minimum, test the THP system under the following flow conditions: 1. Minimum Flow Condition: Minimum solids loading at Start-Up (34.0 tDS/d),

with a feed DWS concentration of 18 percent total solids. 2. Maximum Flow Condition: Maximum month solids loading at Design Year

(93.7 tDS/d) with a feed DWSL concentration of 16.5 percent total solids. This sludge loading will need to be simulated by shutting off parts of the system. Test each part of the system at the simulated maximum month loading condition.

3. Average Flow Condition: Average annual loading at Design Year (72.0 tDS/d) with a feed DWSL concentration of 16.5 percent total solids.

D. The THP must consist of step-wise heating of the DWS feed with a holding time of at least 20 minutes at a temperature of 330 degrees Fahrenheit and a pressure of 87 psig.

E. Table of Guaranteed Performance Parameters.

F. Configure the test to demonstrate that the THP is capable of stable and safe operation at a solids feed rate anywhere between 40 percent and 100 percent of the maximum month design solids feed rate. This can be achieved by running fewer reactors and/or adjusting the cycle times. At 40 percent flow, the system can be operated intermittently.

G. Demonstrate that the THP system operates at the optimal steam consumption (t steam/t DS) provided by the Supplier in the table below at a DWS feed concentration of 16.5 percent DS.

H. Provide arrangements to bypass individual pressure vessels to allow a vessel to be taken out of service for annual inspection, as per Code requirements, while maintaining system operation with the remaining equipment, operating at Maximum Month Flow conditions.

I. Process Guarantee: 1. The Supplier must guarantee that the THP system achieves the performance

requirements specified in this Section. 2. Thermal efficiency and processing capacity (throughput) of the THP system

are critical to the cost effectiveness of the overall solids processing scheme at BRWWTP. THP system guaranteed performance testing (GPT) will be conducted under the conditions specified herein to determine operating conditions including thermal efficiency and the processing capacity.


3. Thermal Efficiency: a. Thermal efficiency (tons of steam/on of dry solids) is defined as the total

tons of steam (t) required by the THP to process a ton of dry material (tDS) in the feed DWS.

Sludge Temperature oC kg steam/m3 pulper feed Ton steam per ton dry solids

10 182 1.103 15 174 1.067 20 164 1.00

4. Hygenization: a. The Supplier shall guarantee sterilization as follows: b. Sterilization of treated biosolids or biowaste at pressure above 6 barg with

saturated steam. c. Hydraulic retention time more than 20 minutes above 6 barg. d. The critical process parameters, Pressure and Holding time, verifying that

sterilization has been achieved, is available to be monitored in the control system, and made available for documentation.

5. Processing Capacity (Throughput): a. During the performance test, the THP will be tested with DWS at a

minimum solids concentration of 16.5 percent and operated at the operating conditions specified. Should the tested feed capacity of the THP be below the specified throughput capacity, the Supplier may, at his expense, retest the THP to establish the capability of the THP to meet the performance requirements.

3.09 SERVICES

A. Supplier Review of Engineering Drawings: 1. Allow for a minimum of 60 hours to review the Engineering Drawings prepared

by Design Builder and provide comments at the 60 percent detailed design stage and another 40 hours to review the Engineering Drawings and provide comments at the 95 percent design stage.

2. Provide a minimum of one trip of 1 person-day to attend a 60 Percent Review Meeting with the Design Builder, the Engineer and The City.

3. Provide a minimum of one trip of 2 person-days for at least two people to attend a HAZOP Review with the Design Builder, Engineer and The City.

4. Provide a minimum of one trip of 1 person-day to attend a 95 Percent Review Meeting with Design Builder, Engineer and The City.

B. Initial Services: 1. It is anticipated that the Supplier will need to provide relatively continuous

support for a six (6) month period during installation witnessing, training, demonstration testing, operational testing, and commissioning. Allow for a minimum of two people full time (or the equivalent) 8 hr per day, 5 days per week for onsite services by the Supplier’s representatives for the following activities: a. Installation assistance, supervision and inspection. b. Completion of documentation certifying proper installation. c. All pre-commissioning checks.


d. Operational testing and completion of documentation certifying satisfactory system and sub-system performance.

e. Commissioning assistance and completion of documentation. Provide on-call assistance during "off" hours (after the normal 8 hour shift and on weekends).

f. Commissioning coordination with other areas related or interconnected to THP (such as commissioning of pre-THP centrifuges and related dewatering equipment, steam generation equipment, sludge cooling equipment and digester equipment).

g. Guaranteed Performance Testing (GPT). 2. It is anticipated that two or three Supplier’s representatives will be required to

provide full coverage. During installation and testing, normal working hours will be 8 hours per day, 5 days per week. However, a Supplier’s representative must be available on an on-call basis for the remaining 16 hours of the day and on weekends, in the event that the schedule requires overtime work to meet the end date or if an incident occurs during "off" hours that requires the attention of the Supplier’s representative. During the consecutive tests (the Operational Tests and the Commissioning), the Supplier’s representatives may be required on site for longer hours, including weekends.

3. Ensure Supplier’s representative(s) are fully qualified to provide troubleshooting services on process, mechanical, electrical, instrumentation and controls issues. Provide the services of multiple Supplier’s representatives as required.

4. Included in the initial service period extending over approximately six (6) months, provide the services of a qualified technical Supplier’s representative at the job site for the minimum person days listed for the services herein, travel time excluded.

Item Description No. of Trips

No. Person-Days per

Trip 1 Equipment Delivery and installation instruction 1 3

2 Installation Supervision and Assistance 2 9

3 Equipment Installation Inspection and Certification 1 9

4 Software Uploading, Testing and Commissioning 1 20

5 Equipment Demonstration Tests and Initial Operator and Maintenance Training

3 5

6 Assistance in Operational Testing (including at least three (3) consecutive days)

2 15

7 Assistance during Commissioning (including at least seven (7) consecutive days)

2 20

8 Assistance and Coordination during Commissioning (planning for related systems and areas not within the scope of this Supply Contract)

3 2

9 Execution of Guaranteed Performance Test

10 Final Operator and Maintenance Training 1 4

11 Control System Training 1 4


Item Description No. of Trips

No. Person-Days per

Trip 12 Control System Trouble-Shooting and Outstanding

Operator and Maintenance Classroom and Job Site Training

4 2

13 Follow-up Operations and Maintenance Training 1 4

5. Training of The City staff will take place at such times and at such locations as required and approved by The City, in conformance with the Design Build Contract.

6. Guaranteed Performance Testing assistance and completion of documentation certifying satisfactory guaranteed system performance. a. Approximately 3 months after Commissioning is complete and

documentation is signed, provide services during the GPT, allowing for a minimum of three trips each with 14 person-days for Guaranteed Performance Testing. Exact timing of GPT will be at The City’s discretion and will depend on stable operation of the digesters as well as the THP Facility.

END OF SECTION


SECTION 11358

CENTRIFUGE DEWATERING EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Sludge dewatering centrifuge system complete with control panels, remote mounted variable frequency drives, and appurtenances.

B. The Centrifuge Manufacturer is responsible for the furnishing and functional operation of each complete dewatering centrifuge system as defined herein. The Centrifuge Manufacturer shall coordinate the design, assembly, and testing of the dewatering centrifuge systems as specified herein.

C. The Centrifuge Manufacturer shall provide two complete dewatering centrifuge systems and all equipment and facilities ancillary to the dewatering process and required for the dewatering centrifuge systems to be fully functional.

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. ASTM International (ASTM): 1. G 65 – Standard Test Method for Measuring Abrasion Using the Dry

Sand/Rubber Wheel Apparatus.

C. National Electrical Manufacturers Association (NEMA): 1. 250 – Enclosures for Electrical Equipment (1000 V Maximum). 2. MG 1 – Motors and Generators.

D. Underwriters Laboratories, Inc. (UL).

1.03 DEFINITIONS

A. Centrifuge: 1. Each centrifuge shall be a complete dewatering centrifuge system that

includes the centrifuge bowl, scroll conveyor, main drive motor, backdrive system, gearbox/torque reducer, lubrication system, bearings, seals, feed tube, solids and centrate discharge chutes, control panels, AFDs, control and monitoring instrumentation, and other necessary appurtenances.

B. Centrifuge Manufacturer: 1. The Centrifuge Manufacturer as referenced herein is the same entity identified

elsewhere as the offeror or centrifuge system supplier.


C. Contractor: 1. The Contractor as referenced herein is the successful bidder for the

construction of the KCMO Blue River WWTP Solids Improvements Project.

D. Percent solids capture defined and calculated as follows:

R = Ck(Cs-Tc)Cs(Ck-Tc) × 100

Where: R = Percent Solids Capture Ck = Concentration of Dewatered Cake in percent Dry Solids Cs = Concentration of Feed Sludge in percent Dry Solids Tc = Concentration of Centrate in percent Dry Solids

E. Bowl Diameter: Internal diameter of cylindrical section of centrifuge bowl.

F. G-Volume defined and calculated as follows: G-Volume = kN2DbL(Db2 - Dd2)

Where: k = 4.83 x 10-8 N = operating bowl speed of 2,600 rpm Db = bowl diameter, inches L = bowl cylindrical length, inches Dd = solids discharge diameter, inches

1. Definitions of G-Volume other than that specified and other methods of calculation will not be accepted.

2. G-Volume shall be calculated with an operating bowl speed of 2,600 rpm.

G. Guaranteed Performance Acceptance Testing (GPAT) and Substantial Completion: 1. The term "Substantially Completed" for the dewatering process means that the

Work included in the Contract Documents has been completed to a level that allows full function of the dewatering process and that results in facilities suitable for use or occupancy to serve their intended purposes.

2. The Owner will grant Substantial Completion status to the Contractor through the issuance of a certificate of Substantial Completion for each set of centrifuges upon successful completion and acceptance of the following: a. All processes and facilities ancillary to the dewatering process and

required for the dewatering centrifuge systems to be fully functional. b. GPAT as described herein under Part 3 of this Section. c. Provision of all spare parts required for each set of centrifuges. d. Formal letter to Owner requesting Substantial Completion status.

3. Only the successful completion and acceptance of all of these items shall be defined as Substantial Completion for each set of centrifuges. All warranties and service contracts shall begin for each set of centrifuges on the day following the granting of Substantial Completion status.

H. NEMA: 1. Type 4 enclosure in accordance with NEMA 250. 2. Type 4X enclosure in accordance with NEMA 250. 3. Type 12 enclosure in accordance with NEMA 250.


1.04 DESIGN AND PERFORMANCE CRITERIA

A. Centrifuge design and performance criteria shall be met as outlined in the Conceptual Design Report.

B. Centrifuges: 1. High speed, horizontal, cylindrical-conical, solid bowl, counter-current, scroll

type designed for continuous operation. 2. Capable of performing in accordance with the requirements set forth in these

specifications. 3. Designed, fabricated, and assembled in accordance with the best engineering

and shop practices such that the maximum design operating speed is not less than 3,000 multiples of acceleration due to gravity (Gs) at the bowl wall.

4. Modified from standard equipment to meet all requirements in this Section.

C. System Requirements: Provide solid bowl, horizontal, continuous feed, counter-current, scroll-type centrifuge equipment for dewatering undigested sludge from a municipal wastewater treatment facility. 1. Centrifuge Manufacturer shall provide drive motor, AFD backdrive system,

gear reducer, scroll conveyor, lubrication system, bearings, seals, feed tube, and appurtenances for each centrifuge.

2. Centrifuge Manufacturer shall provide motor starters, separate control panels with brake controllers, and a programmable logic controller for each centrifuge.

3. Centrifuge Manufacturer shall provide a control system as described herein to monitor and control the operation of each centrifuge.

D. Structural Load Requirements: 1. As stated in the Conceptual Design Report.

E. Design Conditions: 1. As stated in the Conceptual Design Report.

F. Performance Requirements: 1. The following noise and vibration performance requirements shall be met

during Factory Mechanical Performance Testing: a. Maximum Noise:

1) The average noise level measured at 3 feet around the periphery of the complete centrifuge assembly shall not exceed 89 decibels when tested at the manufacturing facility at nameplate speed, without feed, and with the inlet and discharge closed.

b. Maximum Vibration: 1) The centrifuge, when running at nameplate speed and without feed,

shall be measured for vibration in the manufacturing facility. Peak vibration displacement shall be less than 2.4 mils unfiltered overall peak-to-peak when measured at the pillow blocks under dry shop test conditions. Peak vibration velocity shall be less than 7.0 mm/s (0.256 in/s) unfiltered overall when measured at the pillow blocks under dry shop test conditions.


1.05 SUBMITTALS

A. Centrifuge Manufacturer Qualifications: 1. Submit data proving compliance with the Centrifuge Manufacturer’s

experience, installations, and references requirements specified herein. 2. To prove compliance with the installations and references requirements,

submit the following for each installation and reference: a. Treatment plant name and location, including city and state. b. General description of sludge being dewatered (e.g., undigested blend of

municipal primary sludge and TWAS). c. Models and sizes of the centrifuges installed. d. Number of centrifuges installed. e. Year of installation. f. Name, current telephone number, and current e-mail address for contact

person at treatment plant. 3. Submit resumes and training backgrounds of service technicians who will

serve the plant.

B. Product data: 1. Complete bill of material. 2. Submit data completely describing product including plan and section views,

and listings of all components and materials of construction. 3. Recommendations for short and long-term storage of each major component.

C. Shop Drawings: 1. Outline drawings showing dimensions, weights, and locations of all

components. 2. Installation drawings with dimensions and details of construction inclusive of

vibration isolators, anchor bolts, and connections. 3. Drawings shall clearly indicate:

a. Bowl diameter. b. Bowl length (cylindrical section). c. Bowl length (conical/beach section). d. Clarification or Effective Length (inside length dimension from liquid hub to

midpoint of feed zone). e. Discharge diameter. f. Pool or pond depth. g. Cone/beach angle. h. Required clearances for disassembly and maintenance of centrifuge

system. i. Indication of how centrifuge rotating assembly is removed from system. j. Static and dynamic loads, including indication of load distribution on

vibration isolators and maximum transferred load from the isolators to the structure.

k. Required connection sizes and types (i.e. threaded, flanged, etc.) for feed, liquid discharge, solids discharge, polymer, flushing water, foul air, and lubrication system.

4. Scaled drawings with dimensioned top, bottom, and front elevations with internal and external component/device layouts for motor starter panel and control panel. Include on drawings all required clearances around panels, including for ventilation.

5. Gear box system data sheets, description, torque capacity, and reduction ratio.


6. Lubrication system data sheets, layout, and requirements. 7. Bearing temperature and vibration monitoring details and instrument data

sheets. 8. Wiring, control schematics, and control logic diagrams for all electrical,

communication, and control components furnished. 9. Process and instrumentation diagrams (P&IDs). 10. Complete description of control systems, including sequence of operation and

list of functions monitored, controlled, and alarmed. 11. A network block diagram showing all the Centrifuge Starter Panels, Centrifuge

Control Panels and interface with the plant control system. a. Show field and network components such as AFDs, Managed Ethernet

Switches, PLCs, Local Operator Interface (LOIs), and other miscellaneous network components.

12. Complete I/O list: a. A table showing all the data available over EtherNet/IP communication

protocol to the plant control system. 13. PLC cabinet:

a. Panel exterior and internal elevations with detailed bill of materials. b. PLC power schematic and I/O shop drawings. c. Product data for panel and all components. d. PLC memory and spare I/O calculations. e. UPS calculations. f. Thermal management calculations.

14. Complete description of control systems, including sequence of operation and list of functions monitored, controlled, and alarmed.

D. Design calculations: 1. Strength requirements for equipment supports and anchor bolts signed and

stamped by a Professional Engineer licensed in the state where the Project is located.

2. Provide bearing L10 life calculations in accordance with ABMA 9 or 11 calculation method for gears, motors, and other drive line components signed and stamped by a Professional Engineer. Alternatively, the DIN ISO 281 requirement for L10 calculations is also acceptable.

3. G-Volume, as defined in Article 1.04. 4. Operating torque for specified loadings and performance requirements.

E. Test Results: 1. Results from all required factory tests. 2. Results from all required field tests. 3. Results from ASTM G 65 Test Procedure A for abrasion protection

components.

F. Certificates: 1. Furnish affidavit from manufacturer stating that the centrifuge system furnished

is in compliance with the Contract Documents. 2. Furnish affidavit from manufacturer stating that the centrifuges have been

installed, tested, and are ready for operation. 3. Furnish affidavit from manufacturer stating that the bowl, scroll, and gearbox

for each unit have been independently balanced. 4. Certification of test results from ASTM G 65 Test Procedure A for abrasion

protection components.


5. Certification of results from Factory Mechanical Performance Testing. 6. Certification of results from all required Field Testing.

G. Manufacturer's installation instructions: Installation and checkout instructions including lubrication and initial start-up procedures.

H. Operation Maintenance Service Contract.


A. Centrifuge Manufacturer Qualifications: 1. Centrifuge Manufacturer must have at least 10 years' experience under the

current trade name in the United States in the design, application, and supply of centrifuge systems meeting the following requirements: a. High-speed, horizontal, cylindrical-conical, solid bowl, continuous feed,

scroll type, counter-current centrifuge equipment for dewatering municipal wastewater sludge.

b. Centrifuge systems with the same or larger bowl diameter and G-volume as the centrifuges specified for this project.

c. Centrifuge systems designed for continuous operation. d. Centrifuge systems capable of performing in accordance with the

requirements specified in the Design and Performance Criteria set forth in the Conceptual Design Report.

e. Centrifuge systems designed, fabricated, and assembled in accordance with the best engineering and shop practices such that the maximum design operating speed produces not less than 3,000 multiples of acceleration due to gravity (Gs) at the bowl wall.

2. Centrifuge Manufacturer must have at least 10 years' experience in the United States in the design, application, and supply of centrifuge systems inclusive of: a. Main drive motor, backdrive system, gearbox/torque reducer, scroll

conveyor, lubrication system, bearings, seals, feed tube, auxiliary equipment, control panels, AFDs, and other necessary appurtenances for each centrifuge.

3. Installations and References: All qualifying installations and references must be for centrifuge dewatering of municipal wastewater sludge at municipal wastewater treatment plants. Installations and references for dewatering industrial or drinking water sludge will not meet the requirements. a. Centrifuge Manufacturer must have at least five separate installations and

references for dewatering municipal wastewater sludge in the United States with centrifuges that have the same bowl diameter/G-volume, capacity, gearbox design, and bearing/lubrication design as the centrifuges specified for this project. The installations must have been in operation for at least one year prior to January 2018. The references shall be for five separate municipal wastewater treatment plants.

b. Centrifuge Manufacturer must have at least two separate installations and references for dewatering municipal wastewater sludge in the United States with centrifuges that are the same model/generation and have the same bowl diameter/G-volume, capacity, gearbox design, and bearing/lubrication design as the centrifuges proposed by the Centrifuge Manufacturer for this project. The installations must have been in operation for at least one year prior to January 2018. The references shall be for two separate municipal wastewater treatment plants.


B. Modifications: Modify standard equipment to meet, as a minimum, the values specified for dimension, design, and intent of this Section.

1.07 WARRANTY

A. The Centrifuge Manufacturer shall warrant all equipment supplied to be free of defects in material and workmanship for a period of one (1) year from Substantial Completion of each set of centrifuges as defined above. Warranty shall cover all labor and material necessary for repairs for all system components and controls furnished by the Centrifuge Manufacturer.

B. The Contractor shall guarantee all Work for a period of one year from Substantial Completion of each set of centrifuges as defined above. The Contractor shall furnish at his sole expense, all labor, material, and equipment necessary to correct any defect in material, equipment, installation, and/or workmanship which becomes evident within one year of Substantial Completion for each set of centrifuges.

1.08 MAINTENANCE

A. Special Tools: Centrifuge Manufacturer shall provide one set of all special tools and accessories required for repair, adjustment, disassembly and reassembly, and proper maintenance of the centrifuge and all appurtenances. Include the following, as applicable: 1. One Set of Universal Tools (any special wrenches, pliers, screw drivers,

T-handle screws, jacking screws, dowel pin and sleeve removers, seal holder pullers, spanners, hexagon keys, snap ring removers, sockets, plastic hammers, etc., required for units supplied).

2. One Bowl Lifter, including two flexible slings attached to horizontal steel beam designed to allow bowl assembly to be lifted by a single hoist.

3. One Scroll Conveyor Removal Lifting Device, designed to allow easy removal of scroll conveyor from bowl and insertion of scroll conveyor into bowl. Lifting device shall include accessories required for removal of scroll conveyor from bowl.

4. One Tension Bar Nut Wrench. 5. One Pillow Block Bearing Nut Wrench. 6. One Torque Wrench. 7. Two Weir Plate/Dam Removal Wrenches, if applicable. 8. One T-Handle Wrench for weir plate/dam adjustment. 9. One lockable toolbox for special tools. 10. One Hydraulic Pillow Block Bearing Remover, if applicable. 11. One Thrust Bearing Puller. 12. One Socket Wrench for lubricating nipple. 13. One Bowl Dolly/Truck with chocks designed to support bowl securely and

wheels with swivel casters of size suitable for units supplied. 14. One Set of Jigs required for proper alignment of replaceable parts. 15. Two Manual Grease Pumps, if necessary for units supplied.

B. Spare Parts: 1. Centrifuge Manufacturer shall provide the following spare parts (as applicable):

a. One feed tube assembly. b. One set of main bearings. c. One set of conveyor bearings.


d. One set of thrust bearings. e. One set of all seals and O-rings. f. One set of matched drive belts. g. One set of replaceable feed, cake, and centrate port abrasion protection

inserts. h. Two sets of various sized weir plates, if applicable. i. One-year supply of filter cartridges for lubrication system, if necessary for

units supplied. j. One-year supply of all lubricants. k. One set of all limit switches, if necessary for units supplied. l. One spare CPU.

2. Spare parts required per Related Sections shall be provided by Centrifuge Manufacturer.

C. Service Centers: 1. Centrifuge Manufacturer must have at least at least one currently operating

service center located within the United States. 2. Centrifuge Manufacturer must have at least one service technician who is

based at the service center, who has been trained specifically on the centrifuge system required for this project, and who would be available for a field service call at the Owner’s facility within 48 hours of written notice.

3. Centrifuge Manufacturer’s service center must be capable of delivering spare parts manufactured by the Centrifuge Manufacturer, excluding bowls, scrolls, and gearbox to the Owner’s facility within 48 hours after written notice.

D. Maintenance Service Contract: 1. The Centrifuge Manufacturer shall provide the services of a factory-trained

technician to provide a tiered maintenance service contract that shall include: a. Comprehensive Servicing: For a period of 5 years commencing on the

day following the granting of Substantial Completion status, the Centrifuge Manufacturer’s factory-trained technician shall provide all servicing required by the centrifuge systems, including scheduled preventative maintenance services as set forth in the preventative maintenance schedule of the centrifuge O&M Manual as well as all necessary repair, replacement, or overhaul of any system component and controls supplied by the Centrifuge Manufacturer. These services shall include, but not be limited to, maintenance, repair, replacement, and overhaul of bowls, scrolls, gearboxes, motors, any system bearing, any abrasion protection component, variable frequency drives, control panels, and controls. Any parts requiring repair, replacement, or overhaul during this Comprehensive Servicing period shall be provided by the Centrifuge Manufacturer at no cost to the Owner as required under the specified Centrifuge Manufacturer’s warranty.

b. Repair, Replacement, and Overhaul Servicing: For a period of two years following completion of the Comprehensive Servicing contract, the Centrifuge Manufacturer and his factory-trained technician shall provide servicing required to repair, replace, or overhaul any system component supplied by the Centrifuge Manufacturer. These services shall include, but not be limited to, repair, replacement, and overhaul of bowls, scrolls, gearboxes, motors, any system bearing, any abrasion protection component, variable frequency drives, control panels, and controls. Any parts requiring repair, replacement, or overhaul during the required


Centrifuge Manufacturer’s warranty period shall be provided by the Centrifuge Manufacturer at no cost to the Owner. Costs for parts requiring repair, replacement, or overhaul after expiration of the required Centrifuge Manufacturer’s warranty period shall be borne by the Owner. Scheduled preventative tasks set forth in the preventative maintenance schedule of the centrifuge O&M Manual shall be conducted by the Owner during this 2-year period.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following, no equal: 1. Alfa Laval Separation, Inc., Model ALDEC G3-125 decanter centrifuge. 2. GEA Mechanical Equipment US, Inc., Westfalia Model CF-8000. 3. Andritz-Ruthner, Inc., Andritz Model D7LL.

B. Naming of the model number above does not relieve the manufacturer from meeting the details of manufacturing requirements within this specification.

2.02 MATERIALS

A. General: 1. All wetted parts of the centrifuge rotating assembly shall be duplex stainless

steel, except for the O-rings, seals, and abrasion-resistant material. O-rings shall be Nitrile rubber; lip-type seals to be Nitrile rubber.

2. The feed tube shall be constructed of Type 316/316L or duplex stainless steel. 3. Casing shall be fabricated of Type 316/316L stainless steel. 4. All bolts, nuts, and washers shall be Type 316 stainless steel. 5. No dissimilar metals shall be in direct contact unless properly electrically

insulated. 6. All system components weighing 50 lb or more shall be provided with lifting

lugs.

B. Bowl: 1. Manufacture bowl from centrifugal castings of duplex stainless steel, and

design to operate at a minimum of 3,000 G's at the bowl wall for maximum process flexibility and reliability and to withstand all centrifugal forces encountered at design operating speed with adequate safety factors. a. Inspect bowl for cracks, shrinkage, porosity, or other defects, by means of

a liquid dye penetrate test. Submit test results with factory test results. b. Bowl speed shall not be less than 2,500 rpm and shall not exceed

2,900 rpm for maximum specified hydraulic and solids throughput. 2. Centrifuge bowl shall be a minimum 85 inches inside length, with a minimum

inside diameter of 29 inches (nominally 28 inches) in the cylindrical section, plus a conical beach extension with a beach angle between 13 and 20 degrees. Nominal bowl thickness of the cylindrical and conical section to be a minimum of 0.75 inches. a. The G-Volume of the centrifuge shall be a minimum of 458,000 when

calculated at an operating speed of 2,600 rpm. The G-Volume shall be calculated as defined in Article 1.04.


3. Front and rear bowl hubs to be centrifugally cast, and the nominal thickness shall be a minimum of 2.0 inches.

4. Centrifuge bowl shall be supported by roller bearings mounted in pillow blocks and fitted for convenient external lubrication.

5. Main bearings shall have a B-10 life of at least 100,000 hours at standard operating speeds.

6. Flow through the centrifuge shall be counter current such that there are no centrate tubes to maintain. a. Pool depth shall be readily adjustable via weir plates located at the large

diameter end of the bowl, if applicable. b. Weir plates shall be easily accessible without the need to remove the

centrifuge case top. If access to the weir plates requires removing the centrifuge top case, a hinged top case will be required.

c. Solids shall be discharged at the small diameter end of the bowl. d. The bowl shall be independently balanced at full operational speed prior

to shipment. Certification of balancing shall be provided.

C. Scroll conveyor: 1. Each centrifuge shall include a Type 316 stainless steel horizontal conical-

cylindrical scroll conveyor equipped with helical flights independently mounted concentrically within the bowl.

2. The scroll shall utilize a differential speed to convey solids from the cylindrical section to the conical section and out of the bowl with a minimum disturbance to the pool, and shall take maximum advantage of the variable speed backdrive described in this Section.

3. Scroll conveyor shall be supported on grease lubricated anti-friction ball or roller bearings sealed from process contamination.

4. The edge and the face of the conveyor flights shall be protected by a series of welded on sintered tungsten carbide tiles, as described in the abrasion protection section. a. Minimum service life of 15,000 hours or 3 years of operation, whichever

occurs first. 5. Scroll conveyor shall be designed such that the feed is evenly leaving the feed

tube and is accelerated in a feed zone. The flights on the conveyor shall be designed with flow equalization windows to allow axial flow of centrate for minimum disturbance to the pool and maximum settling of fine particles.

6. The scroll shall be independently balanced at full operational speed prior to shipment. Certification of balancing shall be provided.

D. Gear box: 1. Equip centrifuge with a multi-stage planetary or cyclo gear reducer to provide

control of the differential speed between the centrifuge bowl and conveyor. 2. Gear unit shall have a torque capacity to meet expected torque conditions at

specified loadings. a. Gear unit shall have sufficient torque capacity such that expected

operating torque at specified loadings is a maximum of 65 percent of the gear unit torque capacity.

b. Gear unit shall be capable of withstanding a 200-percent momentary overload and 150 percent intermittent overload.

3. Power transmitting elements shall be constructed of bearing steel, hardened, tempered, and ground.


4. Gear unit shall be oil-lubricated, if applicable. Housing shall include fill and drain connections and level gauge/indicator.

5. Each gear unit shall be protected from damage due to high torque overload. a. Torque overload control shall be provided to initiate centrifuge shutdown

in the event of overload condition. b. A thermal overload protection device in the drive motor shall not be

considered as providing for sufficient protection for the gear unit. 6. Gears shall meet AGMA Class 10 and 11 requirements. 7. Gearbox shall be independently balanced from the centrifuge and

interchangeable without displacement of the main bearing or re-balancing of the rotating assembly.

E. Bearings: 1. Centrifuges shall be designed so that the entire rotating assembly is supported

by two anti-friction main bearings. a. Each main bearing shall be one of the following types:

1) A spherical roller or cylindrical roller type with forced oil lubrication. The forced oil lubrication system shall include an external oil circulation system with heat exchanger.

2) Grease lubricated spherical roller or cylindrical roller type. 3) Oil-air lubricated spherical roller or cylindrical roller type.

b. Main bearings shall be housed in one piece pillow blocks. c. Equip main bearings with RTD type 100 ohm platinum temperature

sensors to monitor bearing race temperature directly. The sensors shall be interlocked with the controls to shut down the centrifuge if excessive bearing temperatures are sensed. The bearing temperatures shall be displayed and monitored at the Centrifuge Control Panel.

2. Scroll conveyor shall be supported on one of the following types of bearings: a. Grease-lubricated anti-friction cylindrical roller, spherical roller, or ball

bearings sealed from process contamination. Provide external grease fittings for scroll bearings.

b. Oil sump-lubricated anti-friction cylindrical roller, or spherical roller bearings sealed from process contamination.

3. Bearings shall be conservatively designed to withstand all stresses of the service specified. a. Main bearings shall have a minimum L-10 or DIN ISO 281 life rating of

100,000 hours at standard operating speeds at 24-hours per day service. b. Scroll bearings shall have a minimum L-10 or DIN ISO 281 life rating of

100,000 hours at standard operating speeds at 24-hours per day service. c. Calculations shall be based on the following operating criteria:

1) Standard operating speed is defined as equal to produce 3,000 G Force.

2) For an average solids concentration of up to 2 percent: Operation at 500 GPM.

3) For an average solids concentration of more than 2 percent: Operation at 5,000 pounds per hour.

F. Frame and casing: 1. Rotating assembly and bearings for the centrifuge shall rest on a frame and

casing assembly provided by Centrifuge Manufacturer and specifically designed by Centrifuge Manufacturer for rigidity and noise reduction. Upper casing shall be Type 316 stainless steel. The casing top shall be gasketed.


2. Frame and casing shall be supplied on a modular sub-frame. Modular sub-frame shall support both the drive motor and backdrive. Vibration isolators for the drive motor and backdrive shall be supplied as required.

3. Design case to act as a protective guard and to provide a complete enclosure for odor containment and noise reduction. The case shall be manufactured of 316 stainless steel.

4. Bottom of the casing shall contain a sludge cake discharge connection for the flexible splashguard and accommodate a flanged connection for the centrate.

5. Case shall be equipped with handhole openings at each end to facilitate inspection, adjustment, and minor maintenance of the centrifuge without the necessity of removing the casing top. If access handhole openings are not provided, a hinged top case will be required.

6. A conduit box for all centrifuge-mounted switches, except those specifically related to the main drive motor, shall be mounted on the base.

7. Case top shall be bolted in place, if applicable. If the top case is not bolted in-place, the top case shall be hinged with one hand spring-assisted operation. Quick release mechanisms are not acceptable due to strength and safety requirements.

8. Provide cover position switch. The switch shall be interlocked with the controls to prevent centrifuge start-up unless the cover is in closed position.

G. Feed Compartment: 1. Centrifuge Manufacturer shall provide feed tube designed to introduce sludge

into centrifuge through feed ports with minimal turbulence to pond. 2. Feed tube shall be independently removable from the rest of the centrifuge

without any major disturbance to the unit. 3. Sludge feed connection to centrifuge shall be flanged. Feed tube shall also

include threaded connections for polymer, non-potable flushing water, and a sample port as indicated on the Drawings. Connections for polymer, flushing water, and sample port shall be provided with isolation valves.

4. Manufacturer shall provide electric ball valves for centrifuge flush system. Flushing valves shall be powered with 120 VAC.

5. Required sludge feed pressure at maximum specified hydraulic loading rate shall not exceed 10 psi as measured at the inlet flange.

6. Required polymer feed pressure at maximum specified hydraulic loading rate shall not exceed 5 psi above the sludge feed pressure as measured at the inlet flange.

H. Drive System: 1. General:

a. Centrifuge Manufacturer shall provide each centrifuge with separate main drive motor, backdrive control system motor for differential adjustment, variable frequency drives, lubrication oil pump motors (if provided and applicable), and all other smaller motors required for a complete system.

b. Bowl drive system shall consist of an electric motor and a belt drive system.

c. Belt drive system shall consist of multiple belts as required to provide full load capacity and also to withstand the full starting torque of the system.

2. Main drive motor: a. Design, construction, testing, and performance of the drive motor shall

conform to NEMA Publication MG 1.


b. Motor nameplate horsepower rating shall be equal to, or greater than, the maximum brake horsepower of the drive system at its maximum hydraulic flow rate.

c. Motor shall be maximum 200 horsepower, suitable for 460 Volt, 3-phase, 60 hertz power. Motor windings shall be of high thermal capacity design.

d. Motor shall be inverter duty rated for use with a AFD and shall be provided with standard long shaft for V-belt drive and terminal box rotatable in 90 degree increments.

e. Fluid couplings or other hydraulic starting systems using water or oil shall not be allowed.

f. Motor shall be provided with thermal protection using a bi-metal thermal switch. Equip motor bearings and windings with RTD type 100 ohm platinum temperature sensors to monitor bearing race temperature and windings temperature directly.

g. Motor at ambient temperature shall be capable of making two complete starts in succession with coasting to reset between starts. Motor shall be capable of at least one restart within one hour after any shutdown. Motor shall not take longer than five minutes (each start) to accelerate to full rated revolutions per minute at 90 percent nameplate voltage.

h. Motor shall be rated by the motor manufacturer as having a noise level not exceeding 85 decibels (sound pressure) when measured at 3 feet from the motor in any direction.

i. Motor bearings shall be grease lubricated anti-friction ball or roller type of standard manufacture. Bearings shall be conservatively designed to withstand all stresses of the service specified. Motor bearings to have a minimum L-10 life rating of 60,000 hours of operation.

j. The AFD shall communicate to the CCP PLC using EtherNetI/P as communication protocol. Vendor shall be responsible for providing the required CAT6 Cable.

3. Back drive system: a. Each centrifuge shall be furnished with a complete backdrive system to

control differential speed between the scroll conveyor and bowl. Backdrive shall provide an infinite speed variation between the scroll conveyor and bowl of 1 to 20 revolutions per minute.

b. Design backdrive system to automatically vary differential speed based on torque at conveyor shaft. Each backdrive system shall be furnished with all the required instrumentation and electrical controls to meet the operating requirements of this Section.

c. Backdrive motor shall be a maximum 50 horsepower alternating current, inverter duty, and suitable for 460 Volt, 3-phase, 60 hertz power.

d. The AFD shall communicate to the CCP PLC using EtherNetI/P as communication protocol. Vendor shall be responsible for providing the required CAT6 Cable.

I. Abrasion Protection: 1. In order to minimize wear due to abrasive materials in the feed, replaceable

hard surfacing shall be provided at all points where the abrasive action of the sludge will cause wear on the metal parts of the centrifuge. The following shall be considered a minimum degree of hard surfacing required: a. Bowl Wall: Bowl wall and conical extensions shall be protected with

welded ribs or longitudinal wear strips designed to trap a protective layer of solids between the bowl wall and the conveyor.


b. Conveyor Feed Ports: Conveyor feed ports shall be protected by field replaceable solid sintered tungsten carbide inserts that shall be guaranteed for 15,000 hours of operation.

c. Solids Discharge Ports: Solids discharge ports shall be protected from abrasion by field replaceable tungsten carbide inserts.

d. Solids Discharge Casing: Solids discharge casing shall be protected by replaceable urethane or stainless steel wear liner.

e. Scroll Conveyor Flights: The edge and face of the conveyor flights shall be protected against abrasion from the solids by a series of welded-on sintered tungsten carbide tile assemblies. Each tile assembly shall be weight correct, and consist of a sintered tungsten carbide wear part attached to a stainless steel or Stellite steel back-up plate. Each assembly shall be individually replaceable, and include the ability to monitor wear by means of visual inspection. The tile assemblies must extend 0.50 inches beyond the radial edge of the conveyor flight.

f. All sintered tungsten carbide tiles and inserts shall be able to meet ASTM G 65 Test Procedure A with a volume loss as specified under Source Quality Control.

J. Noise and Vibration: 1. General:

a. Equip centrifuge with noise suppression devices of an energy efficient design, such that the average noise level measured at 3 feet around the periphery of the complete centrifuge assembly does not exceed 89 decibels when tested at the manufacturing facility without feed and with the inlet and discharge closed.

b. The centrifuge, when running without feed, shall be measured for vibration in the manufacturing facility.

c. Peak vibration displacement to be less than 2.4 mils and peak vibration velocity to be less than 7.0 mm/s RMS when measured at the pillow blocks under dry shop test conditions.

d. Centrifuge Manufacturer shall equip each centrifuge with accelerometer type vibration monitors located on each pillow block to measure vibration in the horizontal direction and to protect against excessive vibration. The monitor shall be interlocked with the controls to shut down the centrifuge if excessive vibration is sensed. Vibration shall be displayed and monitored at the Centrifuge Control Panel.

2. Vibration isolators: a. Mount centrifuge on spring-type or rubber-type vibration isolators capable

of dampening vibration in all directions. Vibration isolators shall be provided by the Centrifuge Manufacturer. The isolator shall provide a minimum 97 percent dampening effect and should not show signs of corrosion or be required to be replaced for the life of the unit.

b. The number, capacity, and vibration constant of the isolator shall be as recommended by the manufacturer for the load and impact resulting from the operation of the centrifuge provided.

c. Vibration of a predetermined displacement to automatically shut down the machine.

d. Rigid connections shall feed the tube, solids discharge or liquid discharge from the machine will not be allowed.

e. Isolators shall be designed to limit dynamic load imparted to the foundation to 10 percent of the static load (empty machine) in vertical


direction and 5 percent of the static load (empty machine) in horizontal direction.

f. Housings shall be welded steel and springs shall be oil tempered high carbon chrome vanadium steel.

3. Flexible connectors: a. To ensure a quiet installation, provide flexible connectors to isolate the

centrifuge from the building structure. Flexible connectors include the solids discharge connection, flexible feed connection, flexible centrate connection, flexible polymer connection for the feed tube, flexible flushing water connection for the feed tube, flexible lubricating oil connection (if applicable), and flexible cooling water connection. 1) Flexible connections for solids discharge, centrate discharge, and

feed tube shall be flanged for simple connection to associated piping. 2) Flexible connection for polymer and flushing water shall be threaded. 3) Flexible connections associated with lubrication system shall be of

type required for units supplied. b. Because of local conditions, flexible connectors for the drive motor,

backdrive, and centrifuge junction boxes shall be furnished by the installing contractor, such that all local electrical codes are met.

c. All flexible connectors, other than those required for these electrical components, shall be supplied by the Centrifuge Manufacturer.

K. Anchor Bolts: 1. Anchor bolts shall be Type 316 stainless steel sized by the Centrifuge

Manufacturer, and supplied by the installing contractor.

L. Solids Discharge and Centrate Chutes: 1. The Centrifuge Manufacturer shall provide the solids discharge and centrate

chutes from the centrifuge to the connections with the cake collection conveyor and centrate discharge piping system below the centrifuge. The cake conveyance system and centrate discharge pipes shall be furnished by the Contractor.

2. Solids Discharge: a. All flexible connectors required for connecting the solids chute to the

centrifuge solids outlet and cake collection conveyor shall be supplied by the Centrifuge Manufacturer.

b. Centrifuge Manufacturer shall coordinate with Contractor for proper mating of conveyance system at connection points.

c. The solids chute shall be provided with a flanged 8-inch air vent. The vent shall be connected by Contractor to the Contractor-supplied odor control system.

d. The solids chute shall be provided with an accessible and easy to open/close sample port and 316 stainless steel cake collection scoop to allow collection of discharged product as indicated on the Drawings.

3. Centrate Discharge: a. All flexible connectors required for connecting the centrate chute to the

centrifuge liquid outlet shall be supplied by the Centrifuge Manufacturer. b. Centrifuge Manufacturer shall coordinate with Contractor for proper

mating between centrate chute and centrate piping. c. The centrate chute shall be provided with a flanged 8-inch air vent. The

vent shall be connected by Contractor to the Contractor-supplied odor control system.


d. The centrate chute shall be provided with an accessible sample port to allow collection of discharged centrate as indicated on the Drawings.

e. The centrate chute shall be provided with a connection point for non-potable water for centrate foam spray at location on centrate chute as indicated on the Drawings.

4. The solids and centrate chutes shall be constructed of 316 stainless steel and supported independently. Chute weight shall not be supported from flexible connectors. Shop drawings shall be provided for review and approval prior to fabrication.

2.03 ELECTRICAL

A. Centrifuge conductors: 1. Provide AWG or kcmil sizes as required:

a. Size wire as follows: 1) In accordance with the National Electrical Code (NEC):

a) Use 75 degree Celsius ampacity ratings. b) Ampacity rating after all derating factors, equal to or greater than

rating of the overcurrent device. 2) Provide Number 12 AWG minimum for power conductors. 3) Provide Number 14 AWG minimum for control conductors.

2. Provide Class B stranding per ASTM B 8: a. Provide Class C stranding where extra flexibility is required.

3. Insulation: a. XHHW-2.

4. 90 degrees Celsius rating.

B. Control panel conductors and cables: 1. Power and Control Wiring:

a. Materials: Tinned copper. b. Insulation: 600 V type MTW. c. Minimum Sizes:

1) Primary power distribution: 12 AWG. 2) Secondary power distribution: 14 AWG. 3) Control: 16 AWG.

2. Signal Cables: a. Materials: Tinned copper. b. Insulation: 600 V, PVC outer jacket. c. Minimum Size: 16 AWG paired triad. d. Overall aluminum shield (tape). e. Copper drain wire. f. Insulate the foil shielding and exposed drain wire for each signal cable

with heat shrink tubing.

C. Conduit: 1. Provide conduits types on centrifuge skid as follows:

a. PVC coated rigid aluminum conduit: 1) PCS/SCADA system shall meet the requirements of NEMA RN-1 and

UL 6. b. Sealtight – liquid-tight flexible conduit (SLT).

D. SLT shall meet the requirements of UL 360.


2.04 CONTROLS

A. Control Requirements: 1. Provide all PLCs, HMI/LOI and networking components as specified herein. 2. Provide EtherNet/IP communication capability between centrifuge PLCs and

plant PLC. Ethernet cable to be provided by Contractor. 3. Provide native EtherNet/IP communication protocol for each HMI/LOI. 4. Provide native EtherNet/IP communication protocol capability for each of the

following: a. Pre-THP Centrifuge Starter Panel No. 1 AFD. b. Pre-THP Centrifuge Starter Panel No. 2 AFD. c. Pre-THP Centrifuge Starter Panel No. 3 AFD. d. Post-THP Centrifuge Starter Panel No. 1 AFD. e. Post-THP Centrifuge Starter Panel No. 2 AFD. f. Pre-THP Centrifuge Control Panel No. 1 PLC chassis and Managed

Ethernet Switch. g. Pre-THP Centrifuge Control Panel No. 2 PLC chassis and Managed

Ethernet Switch. h. Pre-THP Centrifuge Control Panel No. 3 PLC chassis and Managed

Ethernet Switch. i. Post-THP Centrifuge Control Panel No. 1 PLC chassis and Managed

Ethernet Switch. j. Post-THP Centrifuge Control Panel No. 2 PLC chassis and Managed

Ethernet Switch. 5. Provide a Vendor Control Panel package for each centrifuge consisting of a

Centrifuge Starter Panel (CSP) and Centrifuge Control Panel (CCP). a. The CSP shall contain the AFD and other electrical components. b. The CCP shall contain the PLC, HMI/LOI, managed Ethernet switch and

other control components. 6. Centrifuge PLC: Provide EtherNet/IP module on the chassis for each

Centrifuge PLC for connection to Ethernet Switch inside cabinet. 7. Connect each Centrifuge PLC and HMI/LOIs to a managed Ethernet switch

inside the CCP. 8. Ethernet cable to be provided by Contractor.

B. Centrifuge Starter Panel (CSP): 1. Starter panel components, AFDs, reduced voltage soft starters, and motor

starter assemblies shall meet requirements of Division 26. 2. NEMA 12 free-standing enclosure with pad-lockable 3-point latch painted

ANSI 49 or 61. Back panel shall be secured to enclosure with collar studs. 3. Electrical Service:

a. One 480 VAC, 3 phase, 60-Hz feeder provides power for main drive, backdrive, and all auxiliaries and controls in the CSP and CCP.

4. Flange mounted lockable power disconnect with minimum short circuit rating of 65 kAIC.

5. Control panel interior components include: a. Provide AFD assemblies for both the centrifuge motor and backdrive

motor. Each AFD shall be of the pulse width modulated (PWM) type. The manufacturer shall supply an 18-pulse bridge rectifier design.

b. Thermal overload trip reset pushbuttons shall only be resettable from inside the control panel.


c. Each motor starter disconnect assembly shall have a UL listed minimum RMS symmetrical short-circuit current rating of 65,000 amperes at 480 VAC.

d. Control transformer, terminal blocks, wiring, relays, signal converters, and all other components required.

e. Provide CAT 6 Ethernet cables for all cables within the CCP and CSP. f. Refer to Network Block Diagram 03N01 for more information.

6. Label control panel with a serialized UL label. 7. All internal component ratings per the requirements of the National Electrical

Code. 8. Hardwired emergency stop pushbutton.

C. Centrifuge Control Panel (CCP): 1. Provide one free-standing control panel per centrifuge unit to control and

monitor the operation of each centrifuge unit. 2. The CCP shall include a “Pause” and “Resume” push-button. The Pause

pushbutton, when depressed shall cause a temporary sludge pump and polymer pump shutdown to allow changing of trucks. The Resume button, shall reactivate the feed system. a. When a centrifuge has been paused for 10 minutes, the alarm horn shall

sound 3 times to draw attention to the “none processing” machine. This will continue for 30 minutes, at which time an auto stop sequence will be initiated.

3. The CCP shall include an automatic torque/differential speed control module that shall maintain process optimization within adjustable preset limitations and operate in differential speed or torque modes.

4. General Requirements and Arrangement for the Control Panel: a. Arrange panel internal components for external conduit and piping to

enter into panel either from above or below. b. Arrange panel instruments and control devices in a logical configuration

associating pushbutton and selector switches with related readout devices.

c. Mount internal control components on an internal back-panel. Devices may be mounted on the side-panel only by special permission from the Engineer.

d. All control panel mounted operator interface devices shall be mounted between 3 feet and 6 feet above finished floor.

5. Control panel component sizing is the responsibility of the Centrifuge Manufacturer.

6. NEMA 12 enclosure with pad-lockable 3-point latch painted ANSI 49 or 61, and thermostat-controlled cooling fan.

7. Back panel shall be secured to enclosure with collar studs. 8. Include mounting hardware. 9. Front Panel, Touch-screen HMI/LOI:

a. Minimum size: 12 inches. b. Color, TFT LCD. c. Enclosure rating: NEMA 12. d. EtherNet/IP communications as specified above. e. Manufacturer: Allen-Bradley PanelView Plus 7, no equal. f. Program HMI/LOI using the latest version of Rockwell Automation

FactoryTalk View ME programming software: 1) Provide graphic screens for each monitoring, control and alarm point.


2) Coordinate with the Contractor’s ICSC (Instrumentation and Control Sub-Contractor) for graphic standard during the pre-construction meeting.

10. The CCP shall accept dual 120 VAC, 1-phase, 60 Hertz electrical service. a. Use one circuit for lights, receptacles, and cooling fans. Provide a main

power circuit breaker. This shall be from the individual Centrifuge Starter Panel.

b. The second circuit shall have a main power circuit breaker, surge protection, 120 VAC UPS and a redundant 24 VDC power supply with a diode bridge. 1) Use UPS power source with individual circuit breakers for each of the

following: a) Each 24 VDC Power supply unit. b) PLC power supply. c) HMI/LOI (120 VAC or 24 VDC).

2) Use UPS-powered 24 VDC power source with individual fuses for each of the following: a) Managed Ethernet Switches (with redundant power input). b) PLC analog, discrete, and other miscellaneous I/O modules.

11. Programmable Logic Controller (PLC): a. PLC shall be Allen-Bradley ControlLogix L7 series, no equal. The PLC

shall meet the requirements specified Division 16. b. PLC shall be programmed by the latest version of Studio 5000

Programming software. Program the PLCs as indicated in this section. c. EtherNet/IP communications and DLR capability as specified above. d. Monitor the following status at the PLC:

1) 24 VDC PS 1 fail alarm. 2) 24 VDC PS 2 fail alarm. 3) 24 VDC diode bridge module fail alarm. 4) Cabinet high temperature alarm. 5) Managed Ethernet switch failed alarm. 6) Door Intrusion switches alarm.

12. Control relays. 13. Terminal points for interconnection. 14. All information monitored and displayed at the CCP HMI/LOI shall be available

for monitoring and display at the plant control system. 15. In addition to the control, monitoring, and display requirements specified

herein, the Contractor and Centrifuge Manufacturer shall coordinate to ensure that the following are capable of being input and/or controlled from the CCP HMI/LOI and the plant control system via EtherNet/IP: a. Dewatering Feed Pump Control Mode: Hand/Off/Auto. b. Dewatering Feed Grinder Control Mode: Hand/Off/Auto. c. Polymer Feed Pump Control Mode: Hand/Off/Auto. d. Sludge Conveyors Control Mode: Hand/Off/Auto. e. Dewatering Feed Grinder Start/Stop. f. Dewatering Feed Setpoint (gpm). g. Dewatering Feed Pump Speed Setpoint (rpm). h. Dewatering Feed Pump Start/Stop. i. Dewatering Feed Solids Concentration (percent solids). j. Neat Polymer Concentration (percent active polymer in neat polymer). k. Neat Polymer Specific Weight (lb/gal). l. Polymer Dose Setpoint (lb active polymer per dry ton).


m. Polymer Pump Speed Setpoint. n. Polymer Pump Start/Stop. o. Conveyors Start/Stop.

16. Power Loss Protection: a. Centrifuge will have the capability to operate without interruption during

brief power outages of 3 to 5 seconds duration. b. During longer duration power outages, the centrifuge will have the ability

to automatically generate sufficient power to complete a normal shutdown and cleanout of centrifuge. Lubrication system must also remain powered during coast down.

17. Panel wiring diagram laminated and affixed to the inside of the control panel. 18. Panel grounding lug; compression type. 19. Hardwired emergency stop pushbutton.

D. At a minimum, CCP functions shall provide for selection of the following for each centrifuge: 1. Hand/Off/Auto Mode. 2. System Maintenance Mode. 3. Backdrive Control Mode: Torque/Differential. 4. Centrifuge Pause. 5. Centrifuge Resume. 6. Centrifuge Start. 7. Centrifuge Stop. 8. Centrifuge Clean-in-Place (CIP) Cycle Start.

E. The CCP shall provide the following outputs via EtherNet/IP to the Plant SCADA system: 1. Centrifuge Control Mode: Local/Off/Remote. 2. Centrifuge Control Mode: System Maintenance Mode. 3. Centrifuge Control Mode: Pause Mode. 4. Centrifuge System ON/OFF Status. 5. Centrifuge System Main Drive AFD Running. 6. Centrifuge System Main Drive AFD Fail. 7. Centrifuge System Main Drive AFD Overload. 8. Centrifuge System Main Drive AFD High Temp. 9. Centrifuge System Main Drive AFD Speed. 10. Centrifuge System Back Drive AFD Running. 11. Centrifuge System Back Drive AFD Fail. 12. Centrifuge System Back Drive AFD Overload. 13. Centrifuge System Back Drive AFD High Temp. 14. Centrifuge System Back Drive AFD Speed. 15. Centrifuge Status: Start-Up Cycle/Idle/Production/Stop Cycle/Pause Cycle/CIP

Cycle/Off/Failed. 16. Centrifuge Cover Position Status: Opened/Closed. 17. Backdrive Control Mode: Torque/Differential. 18. Time until Lubrication System Oil Replacement Required. 19. Emergency Stop Pressed. 20. Clean in place Mode. 21. Controlled Shutdown. 22. Immediate Shutdown. 23. Lubrication Pump Running. 24. Lubrication Pump Fail.


25. Lubrication Pump Remote. 26. Lubrication Pump Overload. 27. Centrifuge Inlet Valve Open/Closed. 28. Centrifuge Inlet Valve Remote. 29. Plant Water Inlet Valve Open/Closed. 30. Plant Water Inlet Valve Remote. 31. Daily Totalized Centrifuge Energy Consumption (kWhr/day). 32. Centrifuge Vibration. 33. Centrifuge System Start Command. 34. Dewatering Feed Grinder Start/Stop Command. 35. Dewatering Feed Setpoint (gpm). 36. Dewatering Feed Pump Speed Setpoint (rpm) Command. 37. Dewatering Feed Pump Start/Stop Command. 38. Polymer Dose Setpoint (lb active polymer per dry ton). 39. Polymer Pump Speed Setpoint. 40. Polymer Pump Start/Stop Command. 41. Sludge Conveyors Start/Stop Command. 42. Operating Centrifuge Power Consumption (kWhr). 43. All other data recommended by manufacturer for safe operation.

F. The CCP shall accept the following inputs from the Plant SCADA system via EtherNet/IP: 1. Emergency Stop. 2. Polymer Feed Pump Control Mode: Hand/Off/Auto. 3. Sludge Conveyors Control Mode: Hand/Off/Auto. 4. Dewatering Feed Pump Control Mode: Hand/Off/Auto. 5. Dewatering Feed Grinder Control Mode: Hand/Off/Auto. 6. Dewatering Feed Pump Status: Running/Off/Failed. 7. Dewatering Feed Pump Speed (rpm or percent). 8. Dewatering Feed Solids Concentration (percent solids). 9. Dewatering Sludge Feed Flow Rate. 10. Dewatering Feed Grinder Status: Running/Off/Failed. 11. Polymer Pump Status: Running/Off/Failed. 12. Polymer Pump Speed (rpm or percent). 13. Neat Polymer Concentration (percent active polymer in neat polymer). 14. Neat Polymer Specific Weight (lb/gal). 15. Polymer Flow Rate. 16. Polymer System Failure. 17. Sludge Conveyors Status: Running/Off/Failed. 18. Dewatered Cake Silo High-High Level.

G. At a minimum, the CCP HMI/LOI shall display for each centrifuge: 1. Centrifuge Control Mode: Hand/Off/Auto or System Maintenance. 2. Centrifuge Status: Start-Up Cycle/Idle/Production/Stop Cycle/Pause

Cycle//CIP Cycle/Off/Failed. 3. Backdrive Control Mode: Torque/Differential. 4. Lubrication System Status: Running/Off/Failed. 5. Time until Lubrication System Oil Replacement Required. 6. Bowl Motor Amperage (amps). 7. Bearing Temperatures (degrees F): For all bearings. 8. Centrifuge Vibration Velocity (in/sec). 9. Scroll Motor Torque (as percent): Setpoint and Actual.


10. Scroll Motor Frequency (hertz). 11. Bowl Speed (rpm). 12. Scroll Speed (rpm). 13. Differential Speed (rpm): Setpoint and Actual. 14. Backdrive Gear Shaft Speed (rpm). 15. Centrifuge Sludge Feed Flow Rate (gpm): Setpoint and Actual. 16. Totalized Daily Centrifuge Sludge Feed (gallons). 17. Dewatering Feed Pump Speed (rpm and percent). 18. Polymer Flow Rate (gpm): Setpoint and Actual. 19. Polymer Pump Speed (rpm and percent). 20. Control mode of each of the following system components:

a. Dewatering Feed Pump: Hand/Off/Auto. b. Dewatering Feed Grinder: Hand/Off/Auto. c. Polymer Feed Pump: Hand/Off/Auto. d. Sludge Conveyors: Hand/Off/Auto.

21. Status of each of the following system components: a. Dewatering Feed Pump: Running/Off/Failed. b. Dewatering Feed Grinder: Running/Off/Failed. c. Polymer Feed Pump: Running/Off/Failed. d. Sludge Conveyors: Running/Off/Failed.

22. Operating Centrifuge Power Consumption (kW/hour). 23. Daily Totalized Centrifuge Power Consumption (kW/day). 24. All alarms. 25. Specific shutdown conditions causing centrifuge system to shut down and

result in Failed status. 26. All inputs/outputs (I/Os) sent to and received from Plant SCADA System. 27. All other data recommended by manufacturer for safe operation.

H. Control System Operation: 1. Hand/Off/Auto control shall be provided:

a. Under Hand: 1) When the centrifuge Hand/Off/Auto selector is in the Hand position

and the control status for all ancillary system components allows remote control, the operator shall be able to start/stop the centrifuge and ancillary system components at the HMI/LOI.

2) The operator shall also be able to send Start/Stop signals from the HMI/LOI to the Plant SCADA system for the centrifuge feed grinder, Dewatering feed pump, polymer pump, and sludge conveyors.

3) The speed of the feed pump and speed of the polymer pump shall be adjustable via speed controls at the HMI/LOI, which sends those signals to the Plant SCADA system.

b. Under Auto: 1) When the Hand/Off/Auto selector is in the Auto position, the

centrifuge shall be controlled automatically by the CCP PLC and ancillary system components shall be controlled automatically by the Plant SCADA system based on inputs/outputs from the CCP PLC.

2. System Maintenance Mode: a. Allows operation of centrifuge for troubleshooting purposes only without

initiating sludge feed or polymer feed. When in System Maintenance Mode, the sludge feed and polymer feed systems associated with the centrifuge shall be shut down and not allowed to start.


b. Under maintenance mode: 1) The lube oil pump (if provided and applicable) can be started at the

Start button on the maintenance screen and will remain active until expiration of a timer or upon release of Start button.

2) The main drive for the bowl can be started by pressing and holding the bowl main drive motor button on the maintenance screen.

3) The backdrive for the scroll can be started by pressing and holding the scroll backdrive motor button on the maintenance screen.

I. Start-up (Auto Sequence): 1. The operator sets the flow rate of the centrifuge feed pump and the polymer

dosage (pounds of active polymer per dry ton of sludge). 2. The operator presses the “Auto Start” key at the CCP HMI/LOI. 3. The PLC starts the flushing cycle for the out-of-spec sludge. 4. The PLC starts the lube oil pump and allows pre-lubrication to continue until

the pre-lube timer expires. 5. The PLC starts the backdrive motor and allows scroll to rotate until a timer

expires. 6. The PLC starts the centrifuge main drive motor, and the bowl begins to

accelerate. Backdrive motor ramps up until base differential is achieved between scroll and bowl.

7. If the centrifuge comes up to speed with no faults, the PLC shall send a “run” command to the Plant SCADA system to start the sludge cake conveyors.

8. After an adjustable, timed interval, during which the bowl has reached full operating speed, the centrifuge is ready to begin dewatering.

9. The PLC shall confirm that Dewatering feed grinder is running or send a “run” command to the Plant SCADA system to start the Dewatering feed grinder.

10. The PLC shall send a “run” command to the Plant SCADA system to start the polymer pump. The PLC shall then send a polymer feed rate signal to the Plant SCADA system. The Plant SCADA system shall vary the feed rate of the polymer pump based on the control signal.

J. Normal Stop (Auto Sequence): 1. A normal stop will be initiated when the operator presses the “Auto Stop”

pushbutton at the HMI/LOI. Upon initiation of “Auto Stop” by the operator at the HMI/LOI, the following shutdown sequence will start: a. The PLC shall send a “stop” command to the Plant SCADA system to stop

the centrifuge feed pump and the associated grinder system. b. If all centrifuge feed pumps are not running, the PLC shall send a “stop”

command to the Plant SCADA system to stop the centrifuge feed grinder. c. The PLC shall send a “stop” command to the Plant SCADA system to stop

the polymer pump. d. The PLC shall start the centrifuge shutdown timer. The PLC shall stop the

main drive motor and the bowl will coast to a stop. e. The PLC shall start the flush water sequence and flushing shall continue

until expiration of flushing water duration timer. Sequence shall include opening and closing of flush water valves by the PLC.

f. Once the centrifuge shutdown timer expires and the bowl speed is less than 25 rpm, the PLC shall stop the backdrive motor.

g. The PLC shall stop the oil lubrication system. h. The PLC shall send a “stop” command to the Plant SCADA system to stop

the conveyors after an adjustable time delay.


K. Clean-In-Place (CIP) System: 1. This system is used for optimal cleaning of the centrifuge and can be used

during shutdown. The operator can start the CIP run cycle anytime the main drive motor is at rest, as determined by the shutdown time, and all faults are cleared.

2. The operator presses a “CIP Start” key at the operator interface to begin the CIP cycle.

3. The PLC starts the flushing cycle. 4. Depending on unit supplied, one of the following will occur:

a. The PLC shall speed bowl up to a preset value for CIP cycle and then allow bowl to coast back to stop while differential speed is maintained at maximum. Once bowl speed drops below preset speed, PLC shall close flush water valve. Once bowl speed reaches zero, PLC sets differential speed back to normal operation. The scroll motor, lubrication system, and lubrication system cooling water system continue to run or remain open until a shutdown timer expires.

b. The backdrive is energized and begins to rotate in the reverse direction at a low speed for a pre-determined time. At the end of the set time, the backdrive toggles direction, causing a water “sloshing” effect within the centrifuge bowl and conveyor. The scroll motor, lubrication system, and lubrication system cooling water system continue to run or remain open until a shutdown timer expires.

5. The process continues until the pre-determined overall time ends, the operator presses the “CIP Stop” key, or a fault occurs. Any shutdown fault shall terminate the CIP cycle.

L. Pause Mode: 1. There is a “Pause” and “Resume” push-button located on the Main and Sludge

pump/polymer system setup screens. The Pause pushbutton, when depressed will cause a temporary sludge pump and polymer pump shutdown to allow changing of trucks. To reactivate the feed system, depress the appropriate “Resume” pushbutton. When a centrifuge has been paused for 10 minutes the alarm horn will sound 3 times to draw attention to a “none processing” machine. This will continue for 30 minutes, at which time an auto stop sequence will be initiated.

M. Controlled Shutdown: 1. A controlled shutdown will be initiated upon specific alarm conditions. 2. Alarm conditions that trigger controlled shutdown and a common failure alarm

to be transmitted to the Plant SCADA system for centrifuge failure: a. High-High Temperature for Liquid Side Main Bearing. b. High-High Temperature for Solids Side Main Bearing. c. High Bowl Speed. d. Low Bowl Speed. e. Low Differential Speed. f. High Lube Oil Filter Differential Pressure. g. High Lube Oil Return Temperature. h. Low Lube Oil Flow for Liquid Side. i. Low Lube Oil Flow for Solids Side. j. Lube Pump Breaker Tripped. k. Lube Pump Run Failure. l. Lube Pump Thermal Overload Tripped.


m. Main Motor Breaker Tripped. n. Main Motor AFD Fault. o. High Temperature for Main Motor Winding. p. High-High Torque. q. High-High Vibration. r. Dewatered sludge cake silo high-high level (from Plant SCADA system). s. Dewatering feed grinder failure (from Plant SCADA system). t. Dewatering feed pump failure (from Plant SCADA system). u. Polymer system failure (from Plant SCADA system). v. Polymer pump failure (from Plant SCADA system). w. Others as recommended by the Centrifuge Manufacturer.

3. Upon initiation of one of these alarm conditions, the following shutdown sequence will start: a. The PLC shall send a “stop” command to the Plant SCADA system to stop

the Dewatering feed pump. b. If all Dewatering feed pumps are not running, the PLC shall send a “stop”

command to the Plant SCADA system to stop the Dewatering feed grinder. If any other centrifuge feed pumps are running, the Dewatering feed grinder will remain operational.

c. The PLC shall send a “stop” command to the Plant SCADA system to stop the polymer pump.

d. The PLC shall start the centrifuge shutdown timer. The PLC shall stop the main drive motor and the bowl will coast to a stop.

e. The PLC shall start the flush water sequence and flushing shall continue until expiration of flushing water duration timer. Sequence shall include opening and closing of flush water valves by the PLC.

f. Once the centrifuge shutdown timer expires and the bowl speed is less than a specific value, the PLC shall stop the backdrive motor.

g. The PLC shall stop the oil lubrication system. h. The PLC shall send a “stop” command to the Plant SCADA system to stop

the conveyors after an adjustable time delay.

N. Immediate Shutdown: 1. An immediate shutdown will be initiated upon specific alarm conditions. 2. Alarm conditions that trigger immediate shutdown and a common failure alarm

to be transmitted to the Plant SCADA system for centrifuge failure: a. Backdrive Motor Breaker Tripped. b. Backdrive Motor AFD Fault. c. High Temperature for Backdrive Motor Winding. d. Backdrive Motor Run Failure. e. Others as recommended by the Centrifuge Manufacturer. f. Sludge conveyor failure (from Plant SCADA system). g. Centrifuge Cover Position Open.

3. Upon initiation of one of these alarm conditions, the following shutdown sequence will start: a. The PLC shall send a “stop” command to the Plant SCADA system to stop

the Dewatering feed pump. b. If all Dewatering feed pumps are not running, the PLC shall send a “stop”

command to the Plant SCADA system to stop the Dewatering feed grinder.

c. The PLC shall send a “stop” command to the Plant SCADA system to stop the polymer pump.


d. The PLC shall start the centrifuge shutdown timer. The PLC shall stop the main drive motor and the bowl will coast to a stop. The PLC shall stop the backdrive motor and the scroll will stop.

e. The PLC shall start the flush water sequence and flushing shall continue until expiration of flushing water duration timer. Sequence shall include opening and closing of flush water valves by the PLC.

f. Once the centrifuge shutdown timer expires and the bowl speed is less than a specific value, the PLC shall stop the oil lubrication system.

g. The PLC shall send a “stop” command to the Plant SCADA system to stop the conveyors after an adjustable time delay.

O. Emergency Shutdown: 1. Emergency shutdown will be issued with the E-stop pushbutton at the CCP,

CSP, or through the Plant SCADA system. All equipment associated with the system will be stopped instantaneously with no flush water.


A. Testing: Manufacturer shall submit a certified test report from a qualified independent laboratory demonstrating that the abrasion resistant materials used on the wear face meet the following requirements: 1. A typical full-size sample of the materials used to protect the tips of the

conveyor in the area from the feed zone to the solids discharge ports, the feed nozzle, and solid discharge inserts shall be submitted to a qualified laboratory. To be considered qualified, the laboratory must be independent, and have apparatus qualified in accordance with ASTM G 65.

2. The qualifying test procedure is ASTM G 65, Procedure A, Standard Practice for Conducting Dry Sand/Rubber Wheel Abrasion Tests. a. This procedure ranks materials in their relative order of merit in an

abrasion environment. Abrasion tests are reported as volume loss in cubic millimeters under a specific set of conditions. Materials of higher abrasion resistance have a lower volume loss.

3. Sintered tungsten carbide tiles shall be tested in accordance to ASTM G 65, Test Procedure A. a. The maximum volumetric loss not to exceed 3 cubic millimeters on the

scroll tile test specimen and 4 cubic millimeters on all other test specimens.

B. Factory Mechanical Performance Testing (non-witness test): 1. Shop testing shall be performed with the centrifuge to be provided, including

its own drive motor, backdrive system, lube system (if provided and applicable), and starter and control panels. a. Standard shop motors and starter and control panels are acceptable for

factory mechanical performance testing if initial testing is performed in Europe. Functional testing of the complete centrifuge system, including its own drive motor, backdrive system, lube system (if provided and applicable), and starter and control panels shall be performed at the manufacturer's U.S. factory before shipping.

2. Centrifuge Manufacturer shall provide written and certified Factory Mechanical Performance Test Report for review and approval.


C. Factory Instrumentation Acceptance Testing (non-witness test): 1. Provide a written and certified Factory Instrumentation Performance.

D. Instrumentation and Controls Meeting: 1. In addition to the field services required per the Sections, the Centrifuge

Manufacturer shall provide a qualified instrument and controls engineer to coordinate with Contractor’s ICSC during construction and the Pre-Construction Meeting. a. Meeting to coordinate all controls required from and to centrifuge vendor

control panels to Plant SCADA. Centrifuge Manufacturer shall share HMI screens with ICSC for duplication at Plant SCADA for monitoring.

b. Minimum 1 trip, 4 hours.

PART 3 EXECUTION

3.01 INSTALLATION

A. Centrifuges shall be installed in accordance with the manufacturer's installation instructions. 1. Contractor is responsible for the installation of the centrifuge system. 2. Contractor shall coordinate with Centrifuge Manufacturer during the installation

of the centrifuge system. 3. Centrifuges shall be installed under supervision of Centrifuge Manufacturer. 4. Contractor shall level machine and install vibration pads in strict accordance

with manufacturer’s written installation instructions. 5. The Contractor shall install all electrical, instrumentation, and piping

connections with supervision and inspection performed by the Centrifuge Manufacturer.

B. Operational Instructions and Training: 1. The Centrifuge Manufacturer shall provide the services of a factory-trained and

certified service representative to provide a minimum of 40 hours on site “hands on” training to the Owner’s personnel. The Centrifuge Manufacturer shall submit a course outline plan, 3 months before training starts, with proposed class material and class schedule to the Owner for approval. Training will begin only if the class material and class schedule have been reviewed and approved by the Owner.

2. Training will begin only after the first set of centrifuges are granted Substantial Completion status.

3. Subjects of instruction shall include the following: a. Start-up procedures. b. Shutdown procedures. c. Troubleshooting. d. Selection of proper polymer types and dosages. e. Operating adjustments for performance optimization. f. Preventative maintenance. g. Maintenance procedures. h. Emergency procedures. i. Record keeping. j. Mechanical unit function and description. k. Variable frequency drives.


l. System controls. 4. Two training sessions shall be provided, one for each shift. Each training

session shall be provided in 8-hour days with a 1-hour lunch break during regular work days, Monday through Friday, except holidays. A list of District holidays and shift schedules is available upon request.

5. Training sessions will be videotaped by the Owner.

The Centrifuge Manufacturer shall also provide five copies of the Engineer-approved Operations and Maintenance (O&M) Manuals 30 days prior to the training sessions.


A. Start-Up and GPAT: Each centrifuge shall undergo start-up and GPAT. Depending on the sludge availability, however, each centrifuge may undergo start-up and guaranteed performance acceptance testing simultaneously or separately, as determined by the Engineer. Contractor to coordinate field service work with the manufacturer’s service representative, Owner, and Engineer prior to initiation such work. The Centrifuge Manufacturer shall furnish the services of a factory-trained and certified service representative experienced in the installation and operation of dewatering centrifuge. Provide a minimum of the support requirements detailed in the tables below (exclusive of travel time):

Services Provided by Factory-trained and

Certified Service Representative

Minimum Number of

Trips Minimum Time on Site per

Centrifuge (Hours)

Centrifuge Installation 2 8

General Testing 2 8

Start-Up 2 40 (maximum 8 hours per day)

GPAT 2 40 (maximum 8 hours per day)

Training 1 Refer to Article 3.02, Paragraph C

B. Start-Up Testing: 1. The Centrifuge Manufacturer shall submit a start-up test procedure and

schedule to the Owner for approval. Start-up will begin only if the start-up test procedure and schedule have been reviewed and approved by the Owner. The Centrifuge Manufacturer, Centrifuge Manufacturer’s factory-trained and certified service representative, Owner’s personnel, and Engineer shall be present for start-up testing.

2. The Centrifuge Manufacturer’s factory-trained and certified service representative shall be available on site for the tuning, monitoring, inspection, optimization, and restarting of each centrifuge during the entire start-up test duration.

3. The start-up procedure shall include: a. To begin initial start-up, each centrifuge shall be tuned and adjusted to

undergo operation. For start-up, the Owner will provide (at the Owner’s expense) personnel, sludge feed, water, dewatered sludge hauling and disposal, and electrical power. Centrifuge Manufacturer shall provide all


emulsion polymer for start-up. Subsequent to proper tuning, an initial thorough inspection of all system components, including electrical and instrumentation controls, will be performed. Faulty components found during initial inspection shall be repaired and replaced within 48 hours by the Centrifuge Manufacturer at no cost to the Owner. Subsequent to initial inspection, each centrifuge shall be operated for a minimum of 24 hours (part-one) of aggregate operation. If no malfunctions occur during the 24 hours (part-one) of aggregate operation, the initial start-up testing shall be deemed complete. Subsequently operate each centrifuge for the remaining 16 hours (part-two) of aggregate operation. The intention of this additional 16 hours (part-two) of testing is for the Centrifuge Manufacturer to determine the optimum polymer dose, torque setting, and other parameters to make ready for the GPAT.

b. If malfunctions occur during the 24 hours of aggregate operations, the Centrifuge Manufacturer shall perform corrective action within 48 hours and restart the centrifuge for a minimum of 32 hours of additional aggregate operation (maximum 8 hours per day). If no problems are evident during the 32 hours of subsequent operation, the start-up testing shall be deemed complete.

c. If malfunctions occur during the 32 hours of subsequent aggregate operation, the Centrifuge Manufacturer shall once again perform corrective action within 48 hours and restart the centrifuge for a minimum of 32 hours of additional aggregate operation. This procedure shall be repeated until the "part-one" start-up testing has been completed successfully. All additional start-up tests shall follow the same procedures as specified above and be subject to Owner’s approval. The satisfactory completion of the start-up test shall be at the sole discretion of the Owner.

d. Before the GPAT is started, provide the sampling results and performance curves (described below) for the 16 hours of the "part-two" of the Start-up test. During the "part-two" testing operate each centrifuge to determine the driest cake, highest throughput, and optimum polymer dose. Upon approval of these results, GPAT will be started. The performance curves developed during the Start-up test will provide valuable information to allow successful GPAT.

C. GPAT: 1. The Centrifuge Manufacturer shall submit a detailed procedure for the GPAT

to the Owner for approval. 2. The GPAT will be subject to facility construction, shut down, water production,

and sludge availability. For the initial GPAT of each centrifuge, the Owner will provide (at the Owner’s expense) personnel, sludge feed, dewatered sludge hauling and disposal, water, and electrical power. The Centrifuge Manufacturer shall provide all test equipment, including instruments, analyzers, and containers to facilitate the testing of each centrifuge. Centrifuge Manufacturer shall provide all emulsion polymer for GPAT testing. The Centrifuge Manufacturer, Centrifuge Manufacturer’s factory-trained and certified service representative, the Owner’s personnel, and Engineer shall be present for the GPAT testing described as follows.

3. The GPAT shall be carried out on one centrifuge at a time. To begin GPAT, the Centrifuge Manufacturer shall operate each centrifuge for 8 continuous hours per day over a period of 7 working days. During this time period, the Centrifuge Manufacturer will document system performance.


4. The centrifuge system performance during GPAT shall meet or exceed the minimum performance requirements as defined within these specifications. The centrifuge system performance is defined as the average of all test results for raw sludge solids within the ranges specified.

5. If, in the opinion of the Engineer, the GPAT results do not meet the performance requirements, the Owner or his designated representative shall notify the Contractor in writing of the non-acceptable performance.

6. In the case of non-acceptable performance, the Centrifuge Manufacturer shall then have 15 days in which to perform, at his expense, any supplemental testing, equipment adjustments, changes, or additions and request additional retest of the non-acceptable system. The Contractor shall notify the Engineer 5 days prior to the commencement of the retest.

7. Emulsion polymers required for GPAT retests, shall be provided by the Centrifuge Manufacturer at his expense.

8. The cost of all laboratory tests necessary to confirm the dewatered sludge characteristics for the guaranteed performance acceptance tests for each centrifuge system shall be borne by the Centrifuge Manufacturer. All tests shall be carried out by a Texas Commission on Environmental Quality (TCEQ) certified laboratory. The testing data shall be submitted to the Engineer for approval.

D. Sampling and Analysis: 1. During "part two" start-up period, each centrifuge shall have its feed sludge,

centrate, and cake sampled every two hours per day (four total samples for 8 hour testing). Testing, calculations and analysis required for collected samples as described herein.

2. During each day of GPAT a minimum of five samples and related tests per centrifuge per day shall be required. Testing, calculations and analysis required for collected samples as described herein.

3. Data collected during each test run shall include, as a minimum: a. Run number. b. Date. c. Time. d. Feed sludge percent TS, %TS (daily composite). e. Sludge feed rate, gpm. f. Polymer name. g. Polymer percent active, %. h. Polymer density, lb/gal. i. Polymer feed rate (neat), gph. j. Bowl speed, rpm. k. Scroll speed differential, rpm. l. Torque, %. m. Amperage draw by the main drive, amps. n. Amperage draw by the scroll drive, amps. o. Centrate percent total solids, %TS (= Centrate Total Suspended Solids

Concentration in mg/L / 10,000 mg/L). p. Cake percent total solids, %TS.

4. Provide calculated values for the following: a. Solids throughput, lbs TS/hr. b. Polymer dosage, active lb/dry ton TS. c. G force, g’s and associated G-volume. d. Percent Solids Capture, %, calculated as defined above.


5. Solids concentrations shall be determined using “Standard Methods for the Examination of Water and Wastewater.” a. Method 2540 G. Total solids in solid and semisolid samples for % TS. b. Method 2540 D. Total suspended solids for TSS. c. Performance curves shall be developed based on the data generated

during the test. 1) Performance curves shall be developed based on the data generated

during both the Start-up test and GPAT. Submit the results of the "part-two" of the Start-up test before beginning the GPAT.

2) Performance curves shall show how dewatered sludge cake concentration and capture efficiency vary with polymer dose by plotting polymer dose (pounds of active polymer per dry ton of solids) on the x-axis, cake solids on the y-axis, and capture efficiency on the secondary y-axis. a) The feed rate and operating torque shall be constant. b) At least three curves shall be developed, each curve generated

during a different day of testing. At least five consecutive points shall be plotted for each curve.

c) Polymer dose shall be varied until the cake dryness and percent capture drop 20-percent below the minimum specified performance parameters and until cake dryness and percent capture exceed the minimum specified performance parameters by 10-percent.

3) Performance curves shall show how dewatered sludge cake concentration and capture efficiency vary with torque by plotting torque as a percentage of maximum torque on the x-axis, cake solids on the y-axis, and capture efficiency on the secondary y-axis. a) The feed rate and polymer dose shall be constant. Polymer

dose shall be set at that value required to achieve the minimum specified performance parameters for cake dryness and percent capture.

b) At least three curves shall be developed, each curve generated during a different day of testing. At least five consecutive points shall be plotted for each curve.

c) Torque shall be varied until the cake dryness and percent capture drop 20 percent below the minimum specified performance parameters and until cake dryness and percent capture exceed the minimum specified performance parameters by 10 percent.

E. Post-start-up field visit: 1. The Centrifuge Manufacturer shall coordinate with Owner to provide one Post-

Start-Up Field Visit within 90 days following Substantial Completion for the first set of centrifuges to be installed.


2. The Centrifuge Manufacturer shall furnish the services of a factory-trained and certified service representative experienced in the installation and operation of dewatering centrifuge for a post-start-up field visit. Provide a minimum of the support requirements detailed in the table below (exclusive of travel time.

Services Provided by Factory-Trained and

Certified Service Representative

Minimum Number of Trips

Minimum Time on Site (Hours)

Post-Start-Up Field Visit 1 8

END OF SECTION


SECTION 11392

SIDESTREAM DEAMMONIFICATION SYSTEM

PART 1 GENERAL

1.01 GENERAL CONTRACTOR SCOPE OF WORK

A. Installation of all equipment and materials as provided by the SYSTEM SUPPLIER.

B. Supply and installation of all sample pumps and sample piping as required for the instrumentation provided by the SYSTEM SUPPLIER.

C. Provide all labor, materials, supplies, and utilities as required for startup, adjustment and performance testing including laboratory equipment, laboratory facilities, analytical work and chemicals.

D. OWNER shall provide all chemicals, lubricants and other supplies required for equipment startup and adjustment.

E. Provide all anchor bolts for equipment and piping, including those provided by the SYSTEM SUPPLIER.

F. Assist the SYSTEM SUPPLIER with process startup activities.

G. Supply and installation of all insulation and heat tracing for all tanks and piping subject to freezing temperatures.

H. Provide and install all piping required to connect to the SYSTEM SUPPLIER’S equipment.

I. Provide all support beams and/or slabs, platforms, grating, floor plate, handrails, hatches, ladders and platforms as required.

J. The CONTRACTOR shall install and test all level floats, level transmitters, level alarms, and alarm communication devices prior to filling a process tank with media and water.

K. Supply and install all motor control centers, motor starters, panels (other than the Sidestream Deammonification System PLC panel which shall be supplied by the SYSTEM SUPPLIER and installed by CONTRACTOR), transformers and variable frequency drives (VFD's) in compliance with Division 16.

L. Installation of all control panels and instrumentation provided by the SYSTEM SUPPLIER in compliance with Division 16.

M. Supply and install all electrical power, control wiring and conduit to the Sidestream Deammonification System equipment, including wire, telephone lines, cable trays, cable, junction boxes, fittings, disconnects, conduit, etc. in compliance with Division 16.


N. The CONTRACTOR shall coordinate the installation and timing of all interface points such as piping and electrical tie-ins with the SYSTEM SUPPLIER.

O. Supply and installation of any embedded pipe sections or wall inserts, if applicable, for any penetrations including but not limited to those for drop pipes and instruments.

P. Video recording of any training activities.

Q. Concrete Tank Finish adhere to requirements of ACI 301 (2011) for form facing materials and as-cast finishes: 1. Form-Facing Materials:

a. Unless Otherwise specified or permitted, form face material in contact with concrete shall be lumber, plywood, tempered concrete-form-grade hardboard, metal, plastic, or paper that creates specified appearance and texture of concrete surface.

2. As-Cast Finishes: a. Use form facing materials meeting the above requirements. Produce as-

cast form finishes in accordance with contract documents. b. Patch voids larger than 3/4 in. wide or 1/2 in. deep. c. Remove projections larger than 1/8 in. d. Patch tie holes. e. Surface tolerance class A as specified in ACI 117. f. Provide Mockup of concrete surface appearance and texture.

R. All other work not included in the SYSTEM SUPPLIER SCOPE OF WORK.

1.02 SYSTEM SUPPLIER SCOPE OF WORK – ANITA MOX

A. The SYSTEM SUPPLIER shall furnish the process design, equipment, and process performance guarantee for a Sidestream Deammonification System, as shown on the Contract Drawings and specified herein. The Sidestream Deammonification System shall consist of a an integrated fixed-film activated sludge (IFAS) zone with media in two reactors, and a settling zone in an external clarifier. The process equipment shall include media, a medium bubble aeration system, positive displacement (PD) blowers, media retention screen assemblies, mixers, recycle pumps, clarifier mechanism, instrumentation and controls including a PLC control panel, field instrumentation, technology licenses and patent infringement indemnification. A single SYSTEM SUPPLIER shall supply the process equipment for the Sidestream Deammonification System in order to establish system performance responsibility.

B. Mechanical process equipment to be furnished under this section includes the following: 1. HDPE media. 2. Four (4) effluent screen assemblies (two per reactor). 3. Two (2) drain screens (one per reactor). 4. Twelve (12) Medium bubble aeration grids (six per reactor). 5. Two (2) dry-pit internal recycle pumps. 6. Six (6) submersible mixers (three per reactor). 7. Three (3) PD blowers (Two (2) Duty and One (1) stand-by). 8. Eight (8) airlift pumps (four per reactor). 9. Three (4) modulating control valves (plug).


10. One (1) modulating control valve (ball). 11. Two (2) modulating control valves (butterfly). 12. One (1) clarifier mechanism.

C. Instrumentation and Controls to be furnished under this section include the following: 1. One (1) PLC control panel. 2. One (1) ammonia nitrogen probe. 3. Two (2) dissolved oxygen (D.O.) sensors. 4. Two (2) pH meters. 5. Two (2) combination ammonia / nitrate nitrogen probes. 6. Two (2) High level float switches. 7. Two (2) Thermal mass flowmeters. 8. Six (6) Magnetic flowmeters.

1.03 QUALIFICATIONS

A. The SYSTEM SUPPLIER of the Sidestream Deammonification System shall be Veolia Water Technologies (dba Kruger) of Cary, NC; or an approved equivalent. 1. All alternate manufacturers must meet detailed specifications below to be

considered for equivalent status. 2. Requests for consideration of alternate equipment shall be submitted in writing

to the ENGINEER no later than fifteen (15) days prior to the originally scheduled bid opening. Requests for consideration shall be complete and shall contain the following information: a. A statement of compliance with the manufacturer’s qualification

requirements and a list of qualified projects including the following information: 1) Project name, location and equipment description. 2) OWNER’s name, address, contact person and telephone number. 3) Designing ENGINEER’s name, address and telephone number. 4) Evidence of five (5) years of municipal wastewater treatment system

supplier experience. 5) One (1) or more sidestream deammonification systems treating post-

THP sidestream at municipal plants in North America in successful operation meeting their design effluent limits.

b. A description of all proposed equipment including materials of construction and protective coatings.

c. Equipment layout drawings with dimensions and component sizing drawn to scale.

d. Calculations showing that the equipment complies with the requirements of this specification.

e. Complete catalog data for each item, including: 1) Detailed shop drawings. 2) Specification Data. 3) Catalog Cuts. 4) Brochures.

f. Any and all deviations from specification requirements. g. Proposed performance guarantee.


3. ENGINEER will consider all requests for deviations from these specifications and advise via an Addendum in which requests for deviations have been accepted and, if any, additional manufacturers have been approved. a. Pre-bid approval does not relieve any additionally named suppliers from

specifically complying with these specifications unless specific deviations are approved by the Addendum prior to the time for receiving bids.

b. The CONTRACTOR shall reimburse the OWNER for any engineering costs directly attributable to the change in manufacturers/suppliers from those listed under paragraph 1.04.A, such as: 1) Additional field trips for the ENGINEER. 2) Additional re-design drawings. 3) Additional review costs. 4) These costs will be billed at the ENGINEER’s usual hourly rate plus

expenses (minimum $1,000 per day). c. The CONTRACTOR shall also reimburse the OWNER for other costs

directly attributable to the change in manufacturers/suppliers, such as increased electrical requirements, changes in construction, piping, tankage, etc.

B. The SYSTEM SUPPLIER must have experience designing and starting up a minimum of 5 municipal wastewater Integrated Fixed Film Activated Sludge (IFAS) Treatment Systems and/or Moving Bed Bioreactor (MBBR) Systems and successfully operating in the United States for at least 3 years and designed for an average annual flow of 6mgd or greater.

C. The SYSTEM SUPPLIER must have experience designing and starting up a minimum of 3 municipal sidestream deammonification systems and successfully operating in the United States for at least 3 years.

D. All equipment furnished under this specification shall be new and unused, unless otherwise noted in this specification.

E. The CONTRACTOR shall assume responsibility for the satisfactory installation of the entire Sidestream Deammonification System.

1.04 SUBMITTALS

A. Submittals shall include the following: 1. Equipment drawings showing all important details of construction and

dimensions. 2. Descriptive literature, bulletins, and/or catalogs of the equipment. 3. Data on the characteristics, features, and performance of the equipment. 4. The total weight of the equipment including the weight of the single largest

item. 5. Motor drive data.

B. The SYSTEM SUPPLIER shall furnish operation and maintenance manuals. The manuals shall be prepared specifically for this installation and shall include all required catalog cuts, drawings, equipment lists, descriptions, and other information that is required to instruct operation and maintenance personnel unfamiliar with such equipment.



A. The installations shall conform to all applicable codes that are typical and reasonable for the type of installation.

B. Requirements of the following organizations shall be considered minimum: 1. OSHA - Occupational Safety and Health Act. 2. ANSI - American National Standards Institute. 3. ASTM - American Society for Testing and Materials. 4. AISI - American Iron and Steel Institute. 5. AIWC - American Institute of Steel Construction. 6. AWS - American Welding Society.

1.06 PATENTS

A. The SYSTEM SUPPLIER shall assume all costs of patent fees or licenses for equipment or processes it supplies under this agreement supplied by IFAS supplier under this agreement, and shall safeguard and save harmless the GENERAL CONTRACTOR, OWNER and ENGINEER and their agents from damages, judgments, claims and expenses arising from license fees or claimed infringements or any letters of patent or patent right, or because of royalty or fee for the use of any equipment or process; and the price stipulated for all such patent fees, licenses, or other costs pertaining thereto.

1.07 DESCRIPTION OF THE OVERALL SYSTEM

A. The IFAS zone of the Sidestream Deammonification System shall allow the media to move about freely within a reactor using the supplier’s standard aeration system for aerobic reactors. Screen assemblies shall be used to retain the carrier elements within each IFAS zone. Centrate (Influent) is fed to all the IFAS zones on a continuous basis. For complete treatment, effluent from the IFAS zones flows through the fixed screen assemblies to a clarification system where suspended solids are settled and the clarified effluent is discharged. Excess settled solids are wasted from the return activated sludge flow that is sent back to the IFAS zone.

B. The Sidestream Deammonification System shall be designed for operation in a reactor as indicated on the drawings. Equipment shall be designed for the following:

Parameter Units Values Number of Process Trains - 2 Number of Aerobic IFAS Reactors per Train - 1 Aerobic IFAS Reactor Dimensions (Each) ft 60 Dia. × 10 SWD Volume (Each) ft3 28,270 Total Volume (All Reactors, All Trains) ft3 56,540 Minimum Freeboard ft 2.5 Media Type: - K5 Fill of Biofilm Carriers % 35 Media Volume (All Reactors, All Trains) ft3 19,930


Parameter Units Values Aeration System Type - Medium Bubble Residual DO, Design Flow and Load mg/L 1.0 Total Process Air Requirement (All Reactors, All Trains) SCFM 4,020

Discharge Pressure (From Top of Drop Pipe) psi 4.3 Clarifier Quantity - 1 Dimensions (Each) ft 25 Dia x 10 SWD Volume (Each) ft3 4,906 Total Volume (All Reactors, All Trains) ft3 4,906 MLSS, Design Flow mg/L 3,500 RAS, Design Flow % 100

1.08 PROCESS GUARANTEE

A. Basis of Design: 1. OWNER/CONTRACTOR hereby agrees to the Basis of Design as defined

herein, confirms its accuracy and completeness, and agrees that it shall serve as the basis for the Process Performance Guarantee.

2. Basis of Design:

Parameter Units Values Centrate Flow, Max Month gpm 180 Hydraulic Flow, Maximum gpm 400 Particulate BOD5, Max Month lb/d 345 Soluble BOD5, Max Month lb/d 221 Particulate COD, Max Month lb/d 2,268 Soluble COD, Max Month lb/d 4,880 TSS, Max Month lb/d 4,865 NH3-N, Max Month lb/d 2,685 PO4-P, Max Month lb/d 2,924 Alkalinity(1) mg/L 1,500 Elevation ft 743 Design Temperature(2) °C 30 Notes: (1) If alkalinity to the system needs to be higher for proper performance, supplier to provide chemical feed system. (2) Temperature to be maintained by heating centrate discharge between centrifuges and sidestream tanks. Heating system to be provided by the system supplier.

3. In addition to the data provided in the Basis of Design, the following conditions shall apply: a. The wastewater shall contain sufficient alkalinity, either present in the

wastewater or by means of chemical addition by the SYSTEM SUPPLIER,


to maintain an alkalinity required by the system supplier for sufficient performance.

b. The SYSTEM SUPPLIER is responsible for providing the heating system to heat the centrate piping as needed to maintain a desired reactor temperature.

4. During the Commissioning Period (prior to the Performance Test), should the Influent criteria be out of compliance with the criteria specified in the Basis of Design, the Owner shall make all necessary adjustments upstream of the SYSTEM SUPPLIER’s process to bring the Influent into compliance. If this is not possible, the parties shall discuss in good faith and agree on the appropriate change order in order to take into account the impact of such variation with respect to the Basis of Design. The change order shall comprise any necessary adjustments, as appropriate, to the design, the Performance Guarantee, the Performance Test and remedies and modification of the Contract Price and the Contract schedule.

B. Process Guarantee Requirements: 1. The Process Guarantee shall be defined by the table(s) in this section. 2. The Process Guarantee is predicated on all conditions specified herein, in the

entirety of the Process Guarantee and Performance Test document. 3. The Process Guarantee shall be conclusively demonstrated through the

successful completion of the Performance Test, as described herein. 4. Process Guarantee Table(s). The Sidestream Deammonification System

design shall be based on meeting the target effluent limitations summarized in the table below at the design maximum month loading conditions and governing design operating conditions summarized above.

Parameter Units Values NH4-N (mg/L) %Removal 80 Total Inorganic Nitrogen (mg/L) %Removal 70

5. Conditions on the process guarantee: a. The running 7-day average reactor temperature shall not be lower than

the minimum design temperature. b. The 7-day average applied loads shall not exceed the design loadings by

more than 10 percent. 6. A Performance Test Protocol shall be prepared by SYSTEM SUPPLIER and

approved by ENGINEER prior to commencement of the Commissioning Period.

1.09 PERFORMANCE TEST

A. Timing of Performance Test: 1. Start of the Performance Test:

a. SYSTEM SUPPLIER shall provide the OWNER/CONTRACTOR written notice with the date when SYSTEM SUPPLIER believes the process has reached system stability and is ready for the Performance Test to start in accordance with the requirements described herein.


b. SYSTEM SUPPLIER’s determination with regard to system stability shall take into account factors that include, but are not necessarily limited to, the following: 1) The system appears to be acclimated to the material (water,

wastewater, biosolids, etc.) that it is intended to treat. 2) The system’s unit operations appear to be functioning at acceptable

operating conditions. 3) The system is being operated with proper pre-treatment, pre-

conditioning, or chemical conditioning as instructed by SYSTEM SUPPLIER.

c. The Owner/Contractor shall start the Performance Test within sixty (60) days after the date the process has achieved system stability as determined by SYSTEM SUPPLIER.

2. Duration of the Performance Test: a. In the event that the Performance Test is interrupted due to equipment

failure, at SYSTEM SUPPLIER’s discretion, only the remaining unfinished test period will be tested following modifications/repairs to the system.

b. The Performance Test shall consist of one 30-day Performance Test. 3. Performance Test Period Window:

a. Should conditions meeting the Basis of Design not be available within twelve (12) months of SYSTEM SUPPLIER’s determination of system stability, or the OWNER/CONTRACTOR is otherwise unable to complete the Performance Test within the twelve (12) month period after SYSTEM SUPPLIER’s determination of system stability, SYSTEM SUPPLIER’s total liability with regard to the Process Guarantee shall be discharged. See requirements for Certificate of Performance Test Acceptance.

B. Sampling and Analytical Parameters: 1. OWNER/CONTRACTOR shall take and analyze samples for the purposes of

determining system compliance with the Process Guarantee. OWNER/CONTRACTOR shall bear all costs for sampling and analysis. The following are the minimum parameters for sampling and analysis:

Sampling and Analytical Parameters Parameter Unit

Centrate Flow, Influent/Effluent gpm Hydraulic Flow, Influent/Effluent gpm TSS, Influent/Effluent mg/L Particulate BOD5, Influent/Effluent mg/L sBOD5, Influent/Effluent mg/L Particulate COD, Influent/Effluent mg/L sCOD, Influent/Effluent mg/L Total Kjeldahl Nitrogen (TKN), Influent/Effluent mg/L NH4-N, Influent/Effluent mg/L NO3-N , Influent/Effluent mg/L NO2-N, Influent/Effluent mg/L PO4-P, Influent/Effluent mg/L Dissolved Oxygen (DO), In Reactor(s) mg/L pH, Influent/Effluent SU


Sampling and Analytical Parameters Parameter Unit

Alkalinity, Influent/Effluent mg/L as CaCO3 Temperature, Influent/Effluent ⁰C

C. Sampling, Laboratory and Analytical Standards: 1. The OWNER/CONTRACTOR shall use the publication, Standard Methods for

Examination of Water and Wastewater, most recent edition; as the primary laboratory and analytical procedure source, unless otherwise agreed to by SYSTEM SUPPLIER. All other analyses, data reduction or tests not specified in that publication or otherwise specified shall be carried out by the OWNER/CONTRACTOR using procedures furnished or approved by SYSTEM SUPPLIER.

2. In the case of continuous reading instrumentation, OWNER/CONTRACTOR shall calibrate instrumentation at least once per test period. Calibration reports shall be available if requested by SYSTEM SUPPLIER.

3. OWNER/CONTRACTOR shall have all laboratory analyses performed at a state-certified laboratory where the project is located.

4. SYSTEM SUPPLIER reserves the right to witness the sampling and testing and to take portions of the samples for analysis in its own laboratories.

D. Responsibilities During the Performance Test: 1. OWNER/CONTRACTOR:

a. System Operations: 1) OWNER/CONTRACTOR shall be responsible for providing the

influent conditions as specified in Basis of Design. 2) OWNER/CONTRACTOR shall be responsible for furnishing all

personnel, influent, materials, utilities, services, chemicals, and all incidentals required for the operation of the complete facility, including SYSTEM SUPPLIER’s system.

3) Owner/ Contractor shall be responsible for operating SYSTEM SUPPLIER’s system in accordance with SYSTEM SUPPLIER’s O&M instructions, manuals and instructions, or SYSTEM SUPPLIER’s reasonable revisions of the same.

4) If required by SYSTEM SUPPLIER, OWNER/CONTRACTOR shall restore the system to the specified operating conditions before testing begins.

5) Should the OWNER/CONTRACTOR operate the system outside of the specified operating conditions, the Process Guarantee shall be deemed to have been met, and SYSTEM SUPPLIER shall have no further obligation or liability hereunder.

6) Should the OWNER/Operator already have operated the system outside of the specified operating conditions, and such operation damaged system equipment, the Process Guarantee shall be deemed to have been met, and SYSTEM SUPPLIER shall have no further obligation or liability hereunder.

b. Sampling and Analysis: 1) OWNER/CONTRACTOR shall be responsible and bear all costs for

collecting all samples, carrying out all laboratory analysis or other tests, and furnishing all necessary labor, laboratory equipment, and supplies.


c. Record Keeping and Copies of Records: 1) OWNER/CONTRACTOR shall record and maintain such detailed

records as may be necessary for determining whether the Process Guarantee has been met.

2) OWNER/CONTRACTOR shall retain such records until the Process Guarantee has been satisfied or until the expiration of the Performance Test Period Window, whichever occurs earlier.

3) OWNER/Operator’s records shall include all daily log sheets, operator notes, sample inspections, calibration reports, laboratory and analytical results, maintenance records, and instrument charts produced in operation of the plant.

4) OWNER/CONTRACTOR shall provide one (1) copy of such records to SYSTEM SUPPLIER at no charge upon SYSTEM SUPPLIER’s request.

5) OWNER/CONTRACTOR shall make such records available to SYSTEM SUPPLIER for inspection and for further copying at SYSTEM SUPPLIER’s expense.

d. Access to the System: 1) Owner/Operator shall provide full access to SYSTEM SUPPLIER’s

system, facility components upstream and downstream of the system that may impact system performance, and test results and records for SYSTEM SUPPLIER’s personnel or authorized subcontractor.

2. SYSTEM SUPPLIER: a. SYSTEM SUPPLIER shall provide the Owner/Operator O&M instructions

and manuals to advise the Owner/Operator, and reasonable revisions of the same, on system operation.

b. SYSTEM SUPPLIER shall have the right, but not the obligation, to: 1) Inspect the system prior to testing to ensure the system meets

SYSTEM SUPPLIER’s specified requirements for operation. 2) Provide technical personnel on-site to provide technical input and to

observe the Performance Test. 3) Witness sampling and analysis, and to take its own samples to a lab

of SYSTEM SUPPLIER’s choosing for analysis at SYSTEM SUPPLIER’s expense.

4) Carry out adjustments to the system to optimize or improve the system’s performance.

c. SYSTEM SUPPLIER shall consolidate the Performance Test data (data provided by OWNER/CONTRACTOR) and provide the OWNER/CONTRACTOR with the results in a Performance Test Report.

E. Determination of Performance Test Result: 1. Performance shall be based on a comparison of the Basis of Design and the

Process Guarantee Requirements. Measured values of the system performance shall be based upon: a. 24-hour composite sample results.

2. Upon receipt of test data confirming that the Process Guarantee has been met, the Performance Test shall have been deemed successful and SYSTEM SUPPLIER’s total liability under the Process Guarantee shall be discharged and the OWNER/CONTRACTOR shall have no further recourse against SYSTEM SUPPLIER or any claims for recovery with respect to the Process Guarantee.


3. SYSTEM SUPPLIER shall then execute and submit the Performance Test Report and the Certificate of Performance Test Acceptance.

4. OWNER/CONTRACTOR shall execute the Certificate of Performance Test Acceptance as specified elsewhere herein.

5. If OWNER/CONTRACTOR does not return the executed Certificate of Performance Test Acceptance within fourteen (14) calendar days, the Certificate shall be deemed to have been issued with the effective date being the date the Performance Test was completed.

F. Remedies in Event of Performance Test Failure: 1. If, during the Performance Test, it appears that the Process Guarantee is not

being met: a. SYSTEM SUPPLIER shall have the right to have the system operated at

such conditions as it may deem necessary or advisable for purposes of determining the nature or cause of the failure of the system to meet such guarantee, provided such operating conditions are in accordance with good engineering practices, OWNER/CONTRACTOR’s regulatory obligations, safety rules, operational restraints, and similar requirements.

b. SYSTEM SUPPLIER shall have the right to make or have made such adjustments as it deems necessary or advisable in order to meet such guarantee and to make or have made, at its own expense, such alterations or modifications to the SYSTEM SUPPLIER system as it deems necessary or advisable. It is understood and agreed that any mechanical corrective work necessary to cause the system to meet the Process Guarantee shall be performed by SYSTEM SUPPLIER, a SYSTEM SUPPLIER-authorized subcontractor, or the OWNER/CONTRACTOR as agreed upon by SYSTEM SUPPLIER. Corrective work shall be allowed to commence as soon as practical.

c. SYSTEM SUPPLIER shall have the right to conduct two (2) additional Performance Tests to meet the Process Guarantee at SYSTEM SUPPLIER’s expense. Prior to the start of any of these subsequent tests, SYSTEM SUPPLIER shall have the right to make any additional modifications to the system at SYSTEM SUPPLIER’s expense.

d. In the event that the system fails to meet the Process Guarantee, SYSTEM SUPPLIER’s sole obligation and OWNER/CONTRACTOR’s sole remedy shall be to replace or modify the system as SYSTEM SUPPLIER deems appropriate to enable the system to meet such Guarantee, subject to the following: 1) SYSTEM SUPPLIER shall not be accountable for failure to meet the

Process Guarantee during this necessary modification period. 2) The OWNER/CONTRACTOR shall allow for sufficient time for the

order and delivery of any necessary equipment for SYSTEM SUPPLIER to complete modifications to the system.

e. NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY, SYSTEM SUPPLIER SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES, AND SYSTEM SUPPLIER’S TOTAL LIABILITY ARISING AT ANY TIME FROM THE SALE OR USE OF THE EQUIPMENT SHALL NOT EXCEED THE PURCHASE PRICE PAID FOR THE EQUIPMENT. THESE LIMITATIONS APPLY WHETHER THE LIABILITY IS BASED ON CONTRACT, TORT, STRICT LIABILITY OR ANY OTHER THEORY.


f. THERE ARE NO GUARANTEES ESTABLISHED, EXPRESS, IMPLIED OR STATUTORY, EXCEPT THOSE SET FORTH HEREIN. IN NO EVENT, BE IT DUE TO A BREACH OF ANY GUARANTEE HEREIN OR ANY OTHER CAUSE, SHALL SYSTEM SUPPLIER BE LIABLE FOR OR OBLIGATED IN ANY MANNER TO PAY CONSEQUENTIAL, SPECIAL, PUNITIVE, OR INDIRECT DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFITS, SYSTEM DOWNTIME, FINES OR PENALTIES, OR SUITS BY THIRD PARTIES AGAINST THE OWNER/CONTRACTOR.

G. Mechanisms that Discharge the Process Guarantee: 1. Upon any of the following, SYSTEM SUPPLIER’s total liability for the Process

Guarantee shall be discharged: a. Successful completion of a Performance Test, as demonstrated by the

Performance Test results. b. OWNER/CONTRACTOR’s operation of the system at any time (prior to or

during the Performance Test) outside of the operating conditions as specified herein in a manner that does damage to the system’s equipment.

c. OWNER/CONTRACTOR’s operation of the system during the Performance Test outside of the operating conditions as specified herein.

d. Conditions meeting the Basis of Design are not available within twelve (12) months of SYSTEM SUPPLIER’s determination of system stability, or the OWNER/CONTRACTOR is otherwise unable to complete the Performance Test within the twelve (12) month period after SYSTEM SUPPLIER’s determination of system stability.

e. Any other conditions outside of SYSTEM SUPPLIER’s control, including but not limited to the following: 1) Noncompliance with the Basis of Design as specified herein.

a) If the OWNER is unable to provide Influent conditions in compliance with the Basis of Design, the non-compliant Influent shall be treated to the extent possible, while OWNER makes every effort to bring Influent into strict compliance with the Basis of Design. SYSTEM SUPPLIER shall assist OWNER and use commercially reasonable efforts to adjust equipment and controls settings and/or operating guidelines to optimize performance of the facility under the prevailing conditions. SYSTEM SUPPLIER and OWNER may agree on an extension of the Commissioning Period for the period of time reasonably estimated as necessary to bring Influent strictly into compliance and the Contract Schedule shall be adjusted accordingly.

b) All costs and expenses of SYSTEM SUPPLIER as a result of such efforts, including costs related to extension of the Commissioning Period and the costs of any Make-up Performance Tests shall be reimbursed by the OWNER to SYSTEM SUPPLIER. Reimbursement shall include at a minimum SYSTEM SUPPLIER’s standard labor rates, travel and living costs and expenses.

c) Should the efforts described above prove successful within the agreed extension period of time, a Make-up Performance Test will be conducted at the OWNER’s written request.


d) Should the Parties disagree on whether the Basis of Design (Influent) is compliant, SYSTEM SUPPLIER may take additional Influent and Effluent samples and conduct independent laboratory testing and the Commissioning Period shall be extended and the Contract Schedule adjusted accordingly until the results of such laboratory test are available. If the laboratory test results confirm that the Basis of Design (Influent) is out of compliance OWNER shall reimburse SYSTEM SUPPLIER for the costs and expenses associated with the sampling and laboratory testing and costs related to the extension of the Contract.

e) Should compliant Basis of Design (Influent) be unattainable within the Commissioning Period (including the extended period described in (d), the requirement to meet the Process Performance and Effluent Guarantee(s) shall be waived by the OWNER and the OWNER shall promptly execute a Certificate of Acceptance, with the last day of the Commissioning Period being the effective date.

2. Engineering design (other than that by SYSTEM SUPPLIER). 3. Materials and equipment (other than those specified or supplied by SYSTEM

SUPPLIER). 4. Workmanship and services (other than those provided by SYSTEM

SUPPLIER). 5. Defective materials or mechanical conditions, or deficient performance of

equipment or auxiliary parts (other than those supplied by SYSTEM SUPPLIER).

6. Defective conditions or performance of any materials, equipment (other than equipment supplied by SYSTEM SUPPLIER) or work supplied by or contracted for by anyone other than SYSTEM SUPPLIER.

7. Failure of the Contractor to furnish adequate utilities, such as, but not limited to, electricity, air, water, etc. as set forth in the O&M Manual and /or O&M training supplied by SYSTEM SUPPLIER, or SYSTEM SUPPLIER’s reasonable revisions of the same.

8. Failure of the OWNER/CONTRACTOR to provide adequate personnel. 9. Mechanical failure of any of the equipment or component parts thereof due to

ordinary wear and tear or any other cause. 10. Failure of the OWNER/CONTRACTOR to perform any of the responsibilities

and obligations specified herein. 11. Any other cause outside of a cause attributable to SYSTEM SUPPLIER,

including Force Majeure.

H. Certificate of Performance Test Acceptance: 1. A Certificate of Performance Test Acceptance shall be executed by both

parties upon discharge of the Performance Guarantee: a. Upon successful completion of the Performance Test, SYSTEM

SUPPLIER shall execute and submit the Performance Test Report and Certificate of Performance Test Acceptance to the OWNER/CONTRACTOR. OWNER/CONTRACTOR shall execute the Certificate of Performance Test Acceptance effective as of the date the Performance Test was completed, and return the Certificate to SYSTEM SUPPLIER within fourteen (14) calendar days of its receipt from SYSTEM SUPPLIER. If OWNER/CONTRACTOR fails to execute the Certificate of


Performance Test Acceptance within the fourteen (14) calendar days, the Certificate shall be deemed to have been issued with the effective date being the date the Performance Test was completed.

b. Should conditions meeting the Basis of Design not be available within twelve (12) months of SYSTEM SUPPLIER’s determination of system stability, or the OWNER/CONTRACTOR is otherwise unable to complete the Performance Test within the twelve (12) month period after SYSTEM SUPPLIER’s determination of system stability, the Certificate shall be deemed to have been issued with the effective date being the date the OWNER/CONTRACTOR notifies SYSTEM SUPPLIER that the OWNER/CONTRACTOR is unable to complete the Performance Test within the specified period, or the date twelve (12) months after SYSTEM SUPPLIER’s determination of system stability, whichever comes first.

c. Should the Performance Test and/or Process Guarantee be discharged for any of the other reasons as specified herein, the Certificate shall be deemed to have been issued with the effective date being the date that SYSTEM SUPPLIER determines the Process Guarantee is discharged.


1.10 CERTIFICATE OF PERFORMANCE TEST ACCEPTANCE

CERTIFICATE OF PERFORMANCE TEST ACCEPTANCE The undersigned representative of the SYSTEM SUPPLIER hereby certifies that the system

successfully completed the Performance Test on _____________________________________

and as required by the Contract between the SYSTEM SUPPLIER and ___________________

____________ for the named project.

System: IFAS_________________________________________________________________ Project Name: ________________________________________________________________ SYSTEM SUPPLIER Signed: _____________________________________________________________________ Printed or Typed Name: ________________________________________________________ Title: _______________________________________________________________________ Date: _______________________________________________________________________

ACCEPTANCE: OWNER/CONTRACTOR hereby agrees that the system has successfully completed the

Performance Test and the Process Guarantee is discharged as of the completion date shown.

OWNER/CONTRACTOR Signed: _____________________________________________________________________ Printed or Typed Name: ________________________________________________________ Title: _______________________________________________________________________ Date: _______________________________________________________________________


1.11 EQUIPMENT WARRANTY

A. SYSTEM SUPPLIER shall warrant to the OWNER that the Equipment shall materially conform to the description in SYSTEM SUPPLIER’s Documentation and shall be free from defects in material and workmanship. The warranty shall not apply to any Equipment that is specified or otherwise demanded by OWNER and is not manufactured or selected by SYSTEM SUPPLIER, as to which (i) SYSTEM SUPPLIER hereby assigns to OWNER, to the extent assignable, any warranties made to SYSTEM SUPPLIER and (ii) SYSTEM SUPPLIER shall have no other liability to OWNER under warranty, tort or any other legal theory. If OWNER gives SYSTEM SUPPLIER prompt written notice of breach of this warranty within 1 year from acceptance (the "Warranty Period"), SYSTEM SUPPLIER shall, at its sole option and as OWNERS’s sole remedy, repair or replace the subject parts or refund the purchase price therefore. If SYSTEM SUPPLIER determines that any claimed breach is not, in fact, covered by this warranty, the OWNER shall pay SYSTEM SUPPLIER its then customary charges for any repair or replacement made by SYSTEM SUPPLIER. SYSTEM SUPPLIER’s warranty is conditioned on OWNER’s (a) operating and maintaining the Equipment in accordance with SYSTEM SUPPLIER’s instructions, (b) not making any unauthorized repairs or alterations, and (c) not being in default of any payment obligation to SYSTEM SUPPLIER. SYSTEM SUPPLIER’s warranty does not cover damage caused by chemical action or abrasive material, misuse or improper installation (unless installed by SYSTEM SUPPLIER). THE WARRANTIES SET FORTH IN THIS SECTION ARE SYSTEM SUPPLIER’S SOLE AND EXCLUSIVE WARRANTIES. SYSTEM SUPPLIER MAKES NO OTHER WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE.

1.12 PERFORMANCE BOND

A. The SYSTEM SUPPLIER shall provide a Performance and Payment Bonds upon receipt of a fully executed contract and released in writing upon successful completion of Performance Testing, as outlined within Section 1.10 and further defined herein. The Performance and Payment Bonds shall be equal to 100 percent of the contract value. The Performance and Payment Bonds shall be outstanding for a period not to exceed 18 months. A letter of surety confirming the SYSTEM SUPPLIER’S ability to provide such bonds shall be provided with the Contractor bid.

PART 2 PRODUCTS

2.01 MANUFACTURERS/SYSTEM SUPPLIERS

A. The SYSTEM SUPPLIER shall be: 1. Veolia Water Technologies, Inc. (dba Kruger) of Cary, North Carolina. 2. World Water Works of Oklahoma City, OK.

2.02 GENERAL

A. The work shall generally comprise the supply of a Sidestream Deammonification System complete with process design, HDPE media, medium bubble Aeration System, stainless steel wedge wire Screen Assemblies, PD blowers, mixers,


recycle pumps, a clarifier mechanism, and all other related appurtenances required for a complete system.

B. License fees or royalties required in connection with use of the Sidestream Deammonification System shall be included in the Contract Price. The SYSTEM SUPPLIER shall indemnify and hold harmless OWNER against all claims, damages, losses and expenses arising out of any infringement of patent rights or copyrights of the equipment supplied by the SYSTEM SUPPLIER.

2.03 ROTARY POSITIVE DISPLACEMENT BLOWERS

A. General: 1. Positive displacement blower package including accessories as specified

herein. a. Quantity: 2 duty + 1 stand by. b. All equipment specified in this section shall be designed and furnished by

the blower manufacturer, who shall be responsible for the suitability and compatibility of all included equipment per this section.

2. Manufacturers’ Qualifications: a. All equipment furnished under this section shall be furnished by a single

manufacture certified in ISO 9001, who shall assume complete responsibility for the design and performance of the blower package.

b. All equipment furnished under this section shall be new, unused, and shall be the standard product of the manufacturer, who shall have a minimum of 10 years’ experience in producing blower packages and be able to produce evidence of at least 5 installations of similar size in satisfactory operation in the United States, if requested.

3. Factory Tests: a. Parts must be inspected as part of a strict ISO 9001:2008 quality control

program. b. All critical dimensions of the blower components provided by the

manufacturer shall be verified and documented prior to assembly. c. Each blower provided by the manufacturer shall be tested per ISO 1217,

Annex B. d. Each blower provided by the manufacturer shall be operated at its

maximum rated speed and differential pressure for fifteen (15) minutes. e. On completion of final assembly of the packaged blower and prior to

shipment, each packaged blower shall be mechanically run for a minimum of thirty (30) minutes.

f. Each blower package provided by the manufacturer shall be guaranteed to provide performance to ISO 1217, Annex C.

4. Reference Standards: a. American Society of Testing and Materials (ASTM). b. National Electrical Manufacturers Association (NEMA). c. Occupational Safety and Health Act (OSHA). d. National Electrical Code (NEC). e. American Gear Manufacturers Association (AGMA). f. Anti-Friction Bearing Manufacturers Association (AFBMA). g. International Organization of Standardization (ISO). h. International Electrotechnical Commission (IEC). i. German Institute for Standardization (DIN).


5. Furnish the following manufacturer’s recommended routine maintenance spare parts for each blower package provided: a. Two (2) integral inlet silencer filter elements. b. Lubrication for first year of operation. c. One (1) belt set. d. One (1) tube of motor grease (50HP or larger).

6. The manufacturer shall warrant all package components for a period of twelve (12) months from date of startup.

7. The contractor shall be responsible for proper storage of the equipment so as to remain in “as shipped” condition. If the equipment remains in storage at the job site for longer than six (6) months before installation, the contractor shall provide factory service personnel for a complete inspection of the equipment. Any work necessary to restore the equipment to “as shipped” condition shall be the responsibility of the contractor.

B. Products: 1. Manufacturer:

a. The equipment specified herein is intended to be standard equipment for use in low pressure air systems and be supplied by a single manufacturer or authorized sales representative to assure uniform quality, ease of maintenance, and minimal parts storage.

b. Manufacturer List: 1) Kaeser Compressors, Inc. 2) Aerzen USA.

c. Plan layouts, weights, and pertinent specification language used in the design have been based upon Kaeser Compressors, Inc. equipment. Any changes required to accommodate equipment other than the basis of design shall be provided by the Contractor at no additional expense to the Owner. Furthermore, a complete and detailed deviation list from the specification shall be provided with proposal.

2. Design Criteria: a. Standard Conditions for SCFM:

1) Elevation: 14.3 PSIA (743 ft elevation). 2) Temperature:68 deg F. 3) Relative Humidity: 50 percent.

b. Performance Data: 1) Flow required: 2,430 SCFM. 2) Blower Package Discharge Pressure: 5.5 PSIG. 3) Motor Horsepower: 100 HP.

a) Motor shaft power shall account for belt losses in addition to internal package losses.

b) The motor shall not operate in its service factor at design conditions.

c) VFD efficiency loss shall be accounted for. 4) Power supply voltage:

a) Main motor: 460v/ 3ph/ 60hz. b) Enclosure ventilation fan motor: 115v/ 1ph/ 60hz.

5) Blower Package Sound Level: 85 dB(A) at 3 feet* a) In accordance with ISO 2151, +/- 3 dB(A) at 1m, free field

conditions, with insulated piping. 3. Blower Package Configuration:

a. Installation Location: Indoors, Temperatures up to 110 deg. F.


b. Inlet Configuration: Ambient (pull from room). c. All components and instrumentation are to be mounted and pre-piped; no

field installation shall be required by the contractor. The manufacturer shall be responsible for all aspects of the engineering, from the blower package’s air inlet to its discharge connection.

4. Bare Blower Construction: a. Blower type:

1) The bare blower shall be mounted for vertical air flow, be of the oil-free, positive displacement, rotary three lobe type, designed for air or other inert gas service, and belt driven via electric motor.

2) The bare blower assembly must operate at the effective value for vibration velocity in frequency range A and B, according to VDI 3836.

b. Material: 1) AISI, ASTM, GJL, GLS, DIN, etc., numbers, types, and grades

specified are typical of material composition and quality, equivalent materials will be considered.

c. Housing: 1) The casing shall be made of high strength, close grained, cast iron,

and shall be adequately ribbed to prevent casing deflection and facilitate cooling. Casing shall be of EN GG 20 material.

2) The casing shall be precision machined to allow for minimum clearances.

3) The casing shall include channels integrated on the discharge to reduce blower pulsation and dampen noise.

4) The casing shall include threaded atmospheric vent ports between its air-side and oil-side labyrinth seals for safe separation of the conveying and oil chamber.

5) Inlet and discharge ports shall be drilled and tapped for studs to allow solid connection of mating surfaces. Through bolting shall not be allowed. Flange style blower ports, which may be subject to loading, causing cylinder distortion, shall not be allowed.

6) Bearing fits shall be precision machined to ensure accurate positioning of the rotors in the casing.

d. Rotors: 1) The rotors shall be precision machined out of a one piece casting

made of EN GGG 50 material. Stub shafts or two-piece impellers shall not be allowed.

2) The rotor assemblies shall be statically and dynamically balanced to ISO standard 1940/1- Q2.5 (turbine rotor). Modifications to the face of the rotors for balancing purposes are not acceptable.

3) The rotors shall be a tri-lobe design in order to minimize pulsation and noise.

4) The rotor must be solid or closed-end to prevent build-up of contaminants inside the rotor causing imbalance.

5) Cored rotors must be closed using threaded iron plugs which are permanently fixed. Impeller end caps of stamped sheet metal shall not be allowed.

6) The rotors shall have an integral sealing strip for improved efficiency. 7) The rotors shall operate without rubbing, liquid seals or lubrication in

the air chamber.


e. Cover Plates: 1) The gear-end and drive-end cover plates shall be high strength,

close grained, cast iron made of EN GG 20 material. Aluminum cover plates shall not be allowed.

2) The cover plates shall have a precision machined sealing face. 3) The drive-end cover plate shall include at least two precision

machined holes to allow for the use of fitting bolts to accurately align the opening for the input shaft seal.

f. Timing Gears: 1) The rotor timing gears shall be precision machined and ground from

alloy steel made from case hardened 16 MnCr5 material. 2) Each timing gear shall be straight cut and beveled to quality standard

5f 21, which will eliminate axial bearing loads and ensure long life as well as quiet operation. Helical gears, which cause axial loading, shall not be allowed.

3) Each timing gear shall be manufactured in accordance with: a) DIN 3960, Specifications for Spur Gear Sets. b) DIN 3961 & DIN 3962, Tolerances for Spur Gear Mesh. c) DIN 3964, Specifications for Shaft Centering.

4) The timing gear set shall be taper-mounted on the rotors. Keyed, hub mounted, taper-pinned, or splined shaft timing gear mounting designs are not acceptable.

g. Bearings: 1) All four rotor shaft support locations shall incorporate large, heavy-

duty, full complement, cylindrical roller bearings with PEEK cages, designed with at least 5-times the dynamic capacity of ball bearings. Ball bearings shall not be allowed.

2) The bearing maximum speeds must be at least two times the maximum recommended blower speed.

3) The bearings minimum acceptable L10 design life shall be as follows: a) At least 40,000 hours at blower’s maximum rated speed and

maximum rated differential pressure. b) At least 100,000 hours at design conditions.

h. Lubrication: 1) Both the gear end and the drive end of the blowers shall be oil splash

lubricated via a disc slinger for minimal maintenance and long service life. Grease lubricated bearings in the blower are not acceptable.

2) The lubrication design shall ensure adequate lubrication of the timing gears and bearings.

3) The drive-end and gear-end oil chambers must not be interconnected and each oil chamber shall have a domed design sight glass to allow visual inspection of oil level and oil condition, viewable from the front of the blower.

4) Blower to be factory filled with a synthetic lubricating fluid that is rated for the design conditions specified.

i. Rotor Seal Assembly: 1) Each rotor shall include one labyrinth seal assembly on each end,

four assemblies in total per blower. Each seal assembly shall consists of the following: a) Oil splash guard ring.


b) Shaft guide wear sleeve with vent holes located between the dual air and oil ring seals. Wear sleeve shall protect the blower casing.

c) Four piston ring type labyrinth seals made from heat treated GG/42CrMo4 material. Two seals located on the air side and two seals located on the oil side of the grooved rotor sleeve. The use of rubber lip seals shall not be allowed.

d) Grooved rotor sleeve which will protect the rotor shaft and be used to hold the four piston ring seals.

j. Input Shaft Seal Assembly: (Compak BBC, CBC, DBC, and EBC series): 1) The input drive shaft seal shall be a high temperature radial lip type

seal made from Viton elastomer. The seal shall prevent oil leakage from where the input shaft goes thru the drive end cover.

2) The seal design shall incorporate a replaceable wear sleeve on the input drive shaft. a) The sleeve exterior to be tungsten carbide coated to reduce

friction and wear. 3) The input shaft seal design must allow for the lip seal and the shaft

sleeve to be replaced without removing the drive end cover plate. k. Input Shaft Seal Assembly: (Compak FBC and HBC series).

1) The input drive shaft seal shall be a sliding ring type mechanical seal that will prevent oil leakage from where the input shaft goes thru the drive end cover plate.

2) The mechanical seal assembly shall consist of the following: a) Replaceable wear sleeve on the input drive shaft. b) Cover plate with a machined sealing surface. c) Mechanical sliding ring seal.

3) The input shaft seal design must allow for the mechanical seal assembly to be replaced without removing the drive end cover plate.

5. Motors: a. Drive Motor:

1) Motor shall be designed, manufactured, and tested in accordance with the latest revised editions of NEMA MG-1, IEC, DIN, ISO, IEEE, ANSI, and AFBMMA standards as applicable and shall be capable of continuous operation.

2) Motor must meet or exceed Energy Independence and Security Act (EISA 2007) standards for NEMA Premium efficiency. It shall also be marked with a Department of Energy Certification Compliance Number to assure compliance.

3) Motor shall comply with Low Voltage Directive 2006/95/EC or equivalent and be UL listed.

4) Motor must be inverter rated with impulse peak resistance in accordance with IEC 60034-1:2010 or equivalent for operation with an IGBT frequency converter or equivalent.

5) Motor horsepower nameplate rating shall not be exceeded at the design discharge pressure when operating at 60hz.

6) The temperature rise of the motor windings shall not exceed IEC and NEMA standards when the motor is operated continuously at the rated horsepower, rated voltage, and frequency in ambient conditions at 104ºF / 40ºC.


7) Motor shall be suitable for Full Load/Direct On-line starting, Solid State Ramp starting, VFD, and/or Wye-Delta reduced current starting.

8) Motor to be supplied, mounted and aligned by the blower package manufacturer.

9) VFD controlled motor (=>100HP) shall have an isolated non drive end “B-side” bearing. Methods of shaft insulation by means of brushes and/or grounding rings are not acceptable.

10) Motor shall confirm to the following: a) Motor voltage: 460v/ 3ph/ 60hz. b) Type: Squirrel cage induction. c) Speed: Single. d) Torque: Constant. e) Service factor: 1.15. f) Enclosure: TEFC. g) Mounting: Horizontal. h) Speed: up to 3,600 rpm at 60 hz (maximum). i) Design: A. j) Duty cycle: continuous (24 hours a day). k) Winding insulation: F. l) Temperature rise: B. m) Thermal motor protection: Positive Temperature Coefficient

(PTC) thermistors (one per winding) wired in series. The use of thermostats is not allowed. (1) Connection of the PTC thermistors to the control system

and signal processing is not part of the blower manufacturer’s scope of supply.

n) Conduit box location: Top. o) Wiring Connection: Terminal strip inside conduit box. Use of

wire nuts for connection of motor wiring to power source shall not be allowed.

p) Bearing L10 life: >40,000 hours. q) Bearing lubrication: Grease. r) Bearing type:

(1) ≤ 40HP: Permanently greased. (2) ≥ 50HP: Regreaseable.

(a) Lubrication fittings must be located towards the front of the blower package so that both bearings can be safely lubricated while the blower package is running.

(b) Grease drain holes to be closed for protection of the environment. A spent grease cavity in the bearing cover should be large enough to hold spent grease required for 40,000 operating hours.

s) Bearing design: Cantilever forces (belt drive). t) Condensation winding 110v heater: No.

11) Motor shall be as manufactured by Siemens. 12) Connection and control of the drive motor to the control system is not

part of the blower manufacturer’s scope of supply. b. Sound enclosure ventilation fan motor:

1) Motor voltage: reference Performance data – Power supply voltage. 2) Motor shall be UL listed.


3) Motor starter/ overload protection is the responsibility of the control system provider.

4) The fan motor should turn “on” when the main motor starts and turn “off” 10 minutes after the main motor stops. Controlling the fan motor via a thermostat shall not be allowed.

5) Connection and control of the fan motor to the control system is not part of the blower manufacturer’s scope of supply.

6. Blower Package: a. Drive:

1) The blower shall be driven by the drive motor through a V-belt drive assembly designed to meet the blower conditions specified with a 1.2 or larger service factor. a) V-belts shall have a XPZ/XPB profile with embedded low-stretch

polyester tension cords. The v-belts shall be designed for high rotational speeds and be heat and oil resistance. Ribbed, banded, or multi groove belts shall not be allowed.

b) Sheaves shall have a SPZ/SPB profile and be balanced to G16 for below 30m/s and G6.3 for sheaves above 30m/s.

c) Keyed taper bushing shall be used for easy installation and removal. QD type bushings shall not be allowed.

2) The blower drive must have a fully enclosed guard which protects the operator when the blower package enclosure is open while in operation. a) Belt guard shall be OSHA approved. b) The belt guard made from the manufacturer’s standard sheet

metal, shall be designed to duct the cooling air flow from the drive motor fan across the front of the blower to supplement blower input shaft seal cooling.

c) The mounting fasteners for the belt guard shall be retained on the housing to prevent loss during maintenance.

3) Belt tension shall be accomplished by the use of a motor swing base and automatic tensioning assembly. a) The drive motor shall be mounted on a pivoting swing base with

an axial adjustment for proper alignment of the v-belts. The weight of the drive motor shall provide the primary belt tension. The use of a sliding motor mount shall not be allowed.

b) A tensioning assembly consisting of a threaded rod with spring shall be used to adjust the v-belt tension to prevent belt slippage and efficiently transmit power to the blower. It shall include a visual indication showing whether or not the v-belt tension is within the correct belt tension range.

c) Adjustment of the tensioning assembly shall be accomplished without removal of the guard or loosening of the motor mounting bolts.

d) The design of the swing base with tensioning assembly shall prevent the swing base from falling and creating a personnel hazard in the event of a belt failure. The tensioning assembly adjusting nut shall raise the motor swing base facilitating v-belt changes without the use of pry bars or jacks.


b. Inlet Silencer: 1) An inlet silencer designed for the frequency range of the blower, shall

be provided to reduce the noise of the blower package as specified. a) The inlet silencer shall be of carbon steel construction and be of

the wear-free absorptive type, directly connection to the inlet port of the blower, and shall be mounted horizontally.

b) The inlet silencer shall be lined with replaceable polyether absorptive material.

c) The inlet silencer shall have an integral filter designed to protect the blower from particulates. It shall be located between the absorptive material and the blower inlet. (1) The filter element shall be a washable and reusable

polyester element for minimal pressure drop. (2) The filter efficiency shall meet ASHRAE 52.2 MERV7 50-

70 percent at 3-10 microns corresponding to EN779 G4. (3) The filter element integral to the silencer shall be supplied

no matter if the inlet configuration of the silencer is ambient or piped. If required on piped inlet configuration, any additional filtration or screening at the inlet location of the piped inlet air source is not the responsibility of the blower manufacturer.

(4) Filter element shall be removable without disconnecting the inlet duct.

d) The filter maintenance cover and element must be removable by hand (without the use of tools).

e) The pressure loss thru the inlet silencer assembly shall be accounted for in the motor horsepower selection of the blower package.

c. Base frame with integrated discharge silencer: 1) The blower base frame with integrated discharge silencer shall be

designed for the frequency range of the blower, shall be provided to reduce the noise of the blower package as specified. a) The blower base frame shall be of formed steel construction and

designed for horizontal mounting of blower with vertical air flow. Flange-mounting only of the bare blower to the blower base frame shall not be allowed, additional support by use of the base frame shall be required; preventing the loading of the blower casing and discharge silencer shell.

b) The blower base shall incorporate the pivoting motor swing base and tensioning assembly to insure proper alignment of the drive assembly.

c) The discharge silencer shall be an integral part of the base frame.

d) The discharge silencer type shall be a combination of absorption, reflection and diffusion. (1) The design of the discharge silencer shall incorporate a

solid outer and perforated inner cylinder with absorptive material in between the cylinders.

(2) Absorptive material shall be long, flexible, knotted polyester fibers to allow for lowering the noise and heat emissions inside the sound enclosure. The use of mineral wool shall not be allowed.


(3) The discharge silencer shall have connections ports for pressure relief, discharge pressure, and discharge temperature. Unused ports shall be capped or plugged.

e) The pressure loss thru the discharge silencer assembly shall be accounted for in the motor horsepower selection of the blower package.

d. Blower Sound Enclosure: 1) A sound enclosure shall be provided which fully covers the blower,

motor, drive assembly, inlet silencer, blower base frame with integrated discharge silencer, and be shipped fully assembled. a) The sound enclosure shall be the product of the blower

manufacturer to insure proper integration of blower package components.

b) The sound enclosure shall meet the sound level specified. c) The sound enclosure acoustic material shall comply to FMVSS

302 with a burning rate B or lower than 100 mm/min. d) The sound enclosure assembly shall be of self-supporting bolted

steel panel construction on a fabricated steel skid. (1) All maintenance removable panels or doors shall be located

in the front of the sound enclosure and must have a slotted key lock. A door key shall be provided. All maintenance panels shall meet OSHA weight requirements.

(2) The enclosure base shall be designed to enclose the full bottom of the sound enclosure and include fork lift guides for easy transportation and installation.

e) The sound enclosure ventilation cooling air circuit shall be separate from the process air circuit. Mixing of the two air circuits within the enclosure shall not be allowed.

f) The sound enclosure shall have a set of inlet louvers positioned on the blower-side of the enclosure to allow for the flow of ambient cooling air across the blower oil sumps.

g) A screened inlet louver shall be located on the back of the enclosure and designed to provide a laminar flow of ambient cooling air across the blower drive motor.

h) The sound enclosure ventilation air exhaust and the ventilation fan shall be located at the top of the sound enclosure. (1) The ventilation fan shall be sized to provide adequate

cooling of the blower package at all blower speeds. (2) The ventilation fan voltage shall be as specified and run

concurrent with the main motor. The ventilation fan shall not be controlled by a thermostat.

i) The back of the sound enclosure shall have predrilled holes with grommets for easy pass-thru of electrical wiring.

j) When installed outdoor, reference Blower Package Configuration Part 2.3. An outdoor stainless steel weather hood shall be installed on top of the enclosure to protect the unit from the elements. The weather hood shall be designed to allow access to the sound enclosure and panel mounted instruments.


e. Blower Package Accessories: 1) Pressure Relief Valve:

a) The relief valve(s) shall be factory installed within sound enclosure. Relief valve may not be shipped loose for field installation in the discharge piping.

b) The relief valve(s) shall be spring type and must be sized for 100 percent of the design flow specified. Weighted relief valves shall not be used.

c) The relief valve(s) shall be set to protect the blower from excessive differential pressure based on the design conditions specified. A seal shall be affixed that must be broken if set point is changed.

d) The relief valve(s) exhaust shall be vented out of the sound enclosure. Exhaust vented into the sound enclosure shall not be allowed.

e) The relief valve shall be ASME Section IIIV, UV, CE, and PED certified.

f) The relief valve shall be manufactured by Kunkle. 2) Check Valve:

a) A check valve to prevent back flow through the blower shall be factory installed and not shipped loose for field installation in the discharge piping.

b) The check valve flapper shall be swing type made from a steel disc embedded in a high temperature silicone elastomer. The valve shall be designed so that, in the event of failure, the valve element is retained in the valve housing. Split disc or center hinged designs shall not be used.

c) The check valve capacity shall exceed the blower package’s maximum discharge pressure and temperature.

3) Flexible Connector: a) An elastomeric compensator/flex connector shall be provided to

isolate the connection of the blower package to the self-supporting system piping. Restraining rods shall not be used. Flex connectors located between the bare blower and silencers shall not be allowed.

b) The flexible connector capacity shall exceed the blower package’s maximum discharge pressure and temperature.

c) Discharge connection: (1) 4 in. and smaller connection, a web reinforced silicone

rubber sleeve with corrosion resistant clamps shall be provided. (Compak BBC, CBC, and DBC series).

(2) 6 in. and larger connection, a ANSI/DIN flanged arch-type EPDM web reinforced connector shall be provided. (Compak EBC, FBC, and HBC series).

d) Piped Inlet connection – When required, Reference Blower Package Configuration 2.3. (1) 6 in. or smaller connection, a web reinforced silicone rubber

sleeve with corrosion resistant clamps shall be provided. (Compak BBC, CBC, DBC and EBC series).

(2) 8 in. and 10 in. piped inlet connection, a arch-type EPDM web reinforced sleeve with corrosion resistant clamps shall be provided. (Compak FBC series).


(3) 10 in. ANSI/DIN flanged inlet connection, a ANSI/DIN flanged arch-type EPDM web reinforced connector shall be provided. (Compak HBC series).

4) Blower instrumentation gauges: a) The following gauges shall be pre-piped and panel mounted on

the front of the sound enclosure. Gauges shall not be shipped loose for field installation.

b) Discharge pressure gauge: (1) The discharge pressure gauge shall measure the pressure

at the discharge of the blower. (2) The discharge pressure gauge shall be dual unit (English –

PSI / Metric – Bar) with a range of 0 – 23 psi (0 – 1.6 bar). Minimum dial diameter shall be 2 ½ in., made with a stainless steel case and be glycerin filled for pulsation dampening.

c) Discharge temperature gauge with adjustable switch: (1) The discharge temperature gauge shall measure the

temperature at the discharge of the blower package. (2) The discharge temperature gauge shall be dual unit

(English - ºF / Metric - ºC) with a range from 32 – 392ºF (0 – 200ºC) and include an adjustable set point dial. Minimal dial diameter shall be 2 ½ in., made with a black plastic case and have a liquid filled measuring system that is converted by a Bourdon tube into a rotary movement of the pointer. The rotary movement of the pointer spindle shall operate a SPDT microswitch through a lever system. Voltage rating up 220v, 5amps.

(3) The high temperature set point shall be as recommended by the blower manufacturer.

(4) Connection of the switch to the control system is not part of the blower manufacturer’s scope of supply. The switch shall be wired to shut down the blower package when actuated.

d) Filter differential pressure gauge: (1) The filter differential pressure gauge shall measure the

pressure difference from ambient to the back side of the filter that is integral to the blower package’s inlet silencer. When the filter starts to become dirty, the resistance shall be shown on a resettable red dial indicating when the filter shall be changed.

5) Oil Drains: a) An oil drain from the blower drive-end and gear-end lubricating

oil sumps shall be separately piped to the front of the blower base with flexible tubing. Common fill and drain shall not be allowed.

b) Each oil drain shall include a drain valve installed for ease of maintenance. The drain valves shall be 90° stainless steel ball valves and include a fully retained gasketed threaded cap to prevent accidental discharge of the blower lubricant.

6) Vibration isolators: a) Vibration isolators shall be provided between the base frame

with integrated discharge silencer and sound enclosure skid to prevent transmission of vibration to the foundation.


b) A ground wire shall be installed between the blower base and the sound enclosure base to allow for grounding of the complete blower package.

f. Nameplates: 1) The blower package shall have at least two weather proof adhesive

type nameplates which includes the manufacturer name, phone number, model number, year, capacity, max end pressure, max pressure difference, blower speed, equipment number, part number, serial number, voltage, phase, HP, motor Hz/ rpm, and FLA attached on the outside and inside of the blower package.

g. Anchor bolts and hardware: 1) Anchor bolts, washers, hex nuts, and all other fastening hardware

shall be stainless steel and be supplied by the contractor. h. Paint Specification:

1) The blower manufacturer is responsible for surface preparation, priming and finish coating of the blower package and components requiring paint in accordance with the manufacture’s standard procedures. Field painting of blower equipment or supplying components that are only prime painted is not acceptable. a) Cast parts are to be painted with a two part gray epoxy primer

and two part top coat. b) Fabricated parts are to be painted with a two part gray epoxy

primer and two part top coat. c) Sound enclosure parts are to be powder coated.

(1) Panels and base paint finish shall be pretreated by de-greasing and phosphate cleaning, then powder coated to a thickness of 70 µm -100 µm on both sides.

2) The blower package to be painted the blower manufacturer’s standard colors.

C. Execution: 1. Installation:

a. The blower package shall be handled and installed in accordance with the manufacturer’s recommendations and instructions as shown in the location on the drawings.

b. Contractor shall field verify all dimensions and elevations. The engineer shall be notified of any specific differences.

c. The blower package shall arrive on site ready for installation. Aligning, adjusting and filling the blower with lubrication shall not be required by the contractor.

2. Field Quality Control: a. Furnish the services of a manufacturer’s authorized representative for

proper installation to inspect and approve the installation, and to supervise a test run of the blower package.

3. After the installation and test run has been completed; the blower package shall be given a field test in the presence of the Engineer to verify that operation is satisfactory and in compliance with the Specification. If the blower package does not meet the Specification, corrective measures shall be taken or the package shall be removed and replaced with a package which satisfies the conditions of the Specifications.


4. Training: a. Furnish the services of a manufacturer’s authorized representative, who

will instruct plant personnel in the operation and maintenance of the blower package. All procedures shall be covered including preventive maintenance, method of controlling the blower package and troubleshooting.

2.04 MEDIUM SPEED GEAR REDUCED SUBMERSIBLE PROPELLER MIXERS

A. General: 1. Surface-mounted propeller mixers intended for use in IFAS applications,

including accessories as specified herein. a. Quantity: 3 per tank. b. Mixers with submersible motors, submerged bearings, sleeves, and wear

rings; or that rely on motor bearings to take loads will not be acceptable. c. All equipment specified in this section shall be designed and furnished by

the mixer manufacturer, who shall be responsible for the suitability and compatibility of all included equipment per this section.

d. Each mixer shall include, but not be limited to, the following items, which shall be supplied by the mixer manufacturer: 1) Mixers. 2) Motors. 3) Access bridges to span full diameter of sidestream tank.

2. Manufacturer qualifications: Manufacturer of proposed product for the following: a. Minimum 10 similar projects with satisfactory performance record. b. Minimum 5 municipal wastewater treatment projects with minimum 5

years satisfactory performance. c. Received approval to be used in IFAS applications. d. All equipment must be furnished from the same manufacturer.

3. Furnish the following manufacturer’s recommended routine maintenance spare parts for each mixer provided: a. One (1) complete set of bearings for each motor. b. One set of rubber buffers per installed mixer type. c. One shaft holder for each shaft diameter supplied. d. All lubricating oils required for the first year of operation shall be provided.

The products supplied shall be factory prefilled, in accordance with manufacturer's recommendations.

e. Spare parts shall be identical to and interchangeable with similar parts installed.

4. The manufacturer shall warrant all package components for a period of twelve (12) months from date of startup.

5. The contractor shall be responsible for proper storage of the equipment so as to remain in “as shipped” condition. If the equipment remains in storage at the job site for longer than six (6) months before installation, the contractor shall provide factory service personnel for a complete inspection of the equipment. Any work necessary to restore the equipment to “as shipped” condition shall be the responsibility of the contractor.


B. Products: 1. Manufacturer:

a. The equipment specified herein is intended to be standard equipment for use in IFAS applications and be supplied by a single manufacturer or authorized sales representative to assure uniform quality, ease of maintenance, and minimal parts storage.

b. Manufacturer List: 1) Stamo Agitation Solutions – Top mounted agitator.

C. Components: 1. General:

a. Configuration as required by the SYSTEM SUPPLIER. b. Geared motor with VFD speed control.

2. Mounting Base: a. The mounting base of each mixer shall consist of a gear base plate

mounted in rubber buffers connected permanently to the bridge/supports by bolted connection. The plate shall be able to be leveled using the threaded bolts, which can be adjusted in height.

b. The rubber buffers shall absorb start-up torque, prevent any transfer of vibrations to the bridge and constitute the galvanic separation of the mixer from its surroundings.

c. The mounting base shall include a fastening set for the metal bridge/walkway with bolted connections.

3. Access Bridges: a. Size and configuration of access bridges shall be as indicated on the

Drawings and acceptable to the Engineer. 1) Coordinate layout and details of access bridges and connections to

concrete with final configuration of other adjacent equipment and tank covers.

2) All components of bridges, including grating, guardrails, stairs, and equipment shields shall conform to applicable building code and OSHA requirements.

3) Access bridges shall have a minimum clear width of 5 feet, with at least 3 feet clear around mixer drive equipment at the inboard (cantilevered) end.

b. Materials: 1) Structural steel: Type 304 stainless steel. 2) Anchor bolts (to concrete): Type 316 stainless steel. 3) Frame assembly bolts: Type 304 stainless steel. 4) Welding: In accordance with AWS requirements. 5) Guardrails: Aluminum. 6) Grating: Aluminum.

4. Bolts: Type 304 stainless steel; following types: a. Assembly bolts. b. Anchor bolts for mounting static portions of frame to concrete wall. c. Expansion bolts, sized to accommodate mixer static and dynamic loads.

5. Local Control Panel (LCP): a. NEMA Type 4X enclosure suitable for Class I, Division 2, Group D

environment. b. Mountable on wall or as indicated on the Drawings. c. Provide remote inputs and outputs as indicated and as required by the

SYSTEM SUPPLIER.


d. Shall contain a visual and audible alarm to indicate failure of any component of the system.

e. Operator interface, provide as indicated below: 1) HAND/OFF/AUTO operation mode selector switch. 2) Red mushroom head Stop Button. 3) Red power on indicator. 4) Green AUTO ready status indicator. 5) Green system run indicator. 6) Red system alarm indicator. 7) Alarm silence button. 8) Alarm reset button.

6. Finishes: a. Coat machined, polished, and non-ferrous surfaces with corrosion

prevention coating.

D. The submersible mixers shall meet the following requirements:

Submersible Mixer Requirements Number of Mixers (per tank) 3 Propeller Diameter/ No. Blades As required by SYSTEM SUPPLIER Horsepower As required by SYSTEM SUPPLIER Voltage 460 V, 3 phase, 60 Hz Maximum Motor Speed 1,800 RPM Maximum Propeller Speed As required by SYSTEM SUPPLIER Motor Speed Control VFD Motor Service Factor 1.15 Motor NEMA Enclosure Type TEFC, Cl I, Div 2

E. Submittals: 1. Product data and shop drawings:

a. Shop drawings shall consist of a cover sheet indicating the drawing number and specification page and number to which referenced, intended use and data summary, outline drawings, cut-away drawings, parts lists, material specification lists, and all information required to substantiate that the proposed equipment meets the specifications. 1) Shop drawings submittals will not be considered complete if cut-away

or assembly drawings with part and material specification lists are not included.

b. General arrangement drawings showing the complete assembly, part number, and material list.

c. Detailed drawings: 1) Mixer. 2) Certified motor data sheets. 3) Gear reducers. 4) Shop primer and coating data. 5) Control system data, schematics, and wiring diagrams. 6) Spare parts lists. 7) Training course outlines. 8) Manufacturer’s experience and reference list as specified in Article

“Quality Assurance.”


d. Calculations. 1) Structural calculations for access bridges supporting mixers. 2) Verify conformance with specified structural design criteria. 3) Provide calculations sealed by a Professional Engineer licensed in

the State where the project is located. 2. Manufacturer’s installation instructions including anchor bolt layouts and

details, support details, and other drawings required for proper installation. 3. Operation and maintenance manuals:

a. Operation and maintenance manual submittals shall be complete in 1 comprehensive submittal. 1) Individual submittals for components of the system will not be

accepted for review. 2) Start-up of the system will not be permitted until operation and

maintenance manuals have been submitted and approved by the Engineer.

3) The submittal shall include the following: a) Operation and maintenance instruction bulletins for each

equipment item. b) Complete parts list. c) Schematic, physical wiring diagrams, and any as-built field

modifications. 4. Certificates: Manufacturer’s certification that the equipment was installed in

accordance with the manufacturer’s instructions, inspected by the manufacturer, serviced with the proper lubricants, and equipped with applicable safety equipment and controls.

5. Technician’s qualifications resume: Submit resume of technician to perform Manufacturers Field Service.

2.05 MEDIA

A. General: 1. The SYSTEM SUPPLIER shall provide media that meets the design quantity,

media dimension, and specific gravity, specified for the design conditions stated herein.

2. Media shall be contained in bags. The media in each bag shall be of known volumetric quantity such as to facilitate accurate inventory control during final placement of the media. Each bag shall have handles on the topside to assist in moving the bags from the storage location to above the basins for final placement of the media.

3. The CONTRACTOR shall install the media into the reactors and maintain an accurate inventory of the number of bags installed in each reactor. These records shall be made available to the ENGINEER or SYSTEM SUPPLIER upon request.

B. Biofilm Carrier Media: 1. The SYSTEM SUPPLIER shall provide a minimum of volume as identified in

Section 1.07 herein. 2. Material shall be an extruded, white, virgin high-density polyethylene.

Recycled materials will not be accepted.


2.06 AERATION SYSTEM (MEDIUM BUBBLE)

A. Definitions: 1. SCFM: A standard cubic feet per minute is understood to be air at 68 deg. F,

14.7 PSIA and 36 percent relative humidity flowing at a rate of 1 cubic feet per minute.

2. SOTR: Standard oxygen transfer rate is understood to be the rate of oxygen transferred to tap water (pounds of oxygen per hour) at standard conditions of 20 deg. C, 0.0 mg/L residual dissolved oxygen concentration, and a barometric pressure of 760 mm Hg (dry air).

3. SOTE: Standard oxygen transfer efficiency is understood to be the fraction of oxygen transferred under standard conditions of 20 deg. C, 0.0 mg/L residual dissolved oxygen concentration, and a barometric pressure of 760 mm Hg (dry air).

4. SWD: Side water depth is understood to be the overall dimension from the high point of the basin floor to the water surface.

B. General: 1. The CONTRACTOR shall furnish and install aeration grid(s) in the basin(s) as

shown and specified. The Equipment Manufacturer shall furnish the items listed below: a. Drop Pipe(s). b. In-Basin Manifold(s). c. Aeration Grids. d. Supports.

C. Equipment: 1. Drop Pipe:

a. A 304/304L stainless steel drop pipe(s) shall be provided for the aeration grid(s) to a point approximately 3 ft above the SWD. The drop pipe shall be schedule 10S pipe and connect to the CONTRACTOR supplied out-of-basin pipe. IFAS supplier's scope ends at the Straub coupling at the top of the drop pipe.

2. In-Basin Manifold (If necessary): a. A 304/304L stainless steel in-basin manifold shall be provided between

the drop pipe(s) and the aeration grid(s) as shown on the contract drawings. The in-basin manifold shall be schedule 10S pipe and connect to the in-basin equipment with 125lb plate flange with ANSI bolting pattern. Each in-basin manifold shall be supplied with all necessary gaskets and hardware.

3. Aeration Grids: a. A 304/304L stainless steel aeration grid(s) shall be provided for the

basin(s) as shown on the contract drawings. The aeration grid(s) shall be comprised of; an aeration grid manifold of schedule 10S pipe with Ø1” laterals of schedule 5 pipe. The laterals shall be uniformly spaced along the length of the aeration grid manifold. Each lateral will have a series of 4mm (5/32 in.) holes uniformly spaced along the bottom. The lateral pipe shall include a crimped drop pipe at the end, to provide for easy drainage, and to prevent entry of media. Each aeration grid shall be supplied with all necessary gaskets and hardware.


4. Supports: a. Drop Pipe Supports: Drop pipe supports to be fabricated from 304/304L

stainless steel. The supports shall be a minimum 3 in. x 3 in. x 1/4 in. angle with a minimum 1/4 in. thick anchor plate. The support shall be secured by two (2) 18-8 stainless steel threaded rods with a minimum diameter of 1/2 in. Each rod will be anchored to the concrete by chemical anchors. The drop pipes shall be secured to the support by a u-bolt. Supports shall have a maximum spacing of 9 ft.-0 in. All interconnecting hardware required to secure the support to the drop pipe shall be provided. No field welding shall be required.

b. Aeration Grid and In-Basin Manifold Supports: Aeration grid and in-basin manifold supports to be fabricated from 304/304L stainless steel. Each support shall consist of a minimum 2 in. bearing contact between the pipe and support. The support shall be secured by two (2) 18-8 stainless steel threaded rods with a minimum diameter of 3/4 in.. Each rod will be anchored to the concrete by chemical anchors. The aeration grid and in-basin manifolds shall be secured to the support by a u-bolt to prevent lateral movement. Supports shall be designed to allow for on-site height adjustment. Supports shall have a maximum spacing of 9 ft.-0 in. All interconnecting hardware required to secure the support to the aeration grid shall be provided. No field welding shall be required.

5. Construction: a. Welding: All welding shall conform to industry standard Welding

Fabrication Procedures for stainless steel. All factory welding shall undergo pickling/passivation to prevent rust and corrosion.

b. Bolting: Where nothing to the contrary is indicated, bolts, screws, nuts, and washers shall be 18-8 stainless steel.

c. Installation: The installation of the aeration equipment shall be such that upon completion of installation, all diffusers are level to ±1/8 in. of a common horizontal plane.

6. Design: a. Pressure at the top of the dropleg shall be as specified in Section 1.07

herein. b. The system shall be designed to be submerged within the tank basin

without deforming any component. c. All welded parts and assemblies shall be shop fabricated from 304L

stainless steel with a 2D finish. Unless otherwise specified, all non-welded parts and pieces shall be shop fabricated from type 304 stainless steel with a 2D finish.

d. All flanged joints shall have 45 to 55 durometer, Shore A, neoprene gaskets.

e. All aeration grid and in-basin manifold supports shall be designed to compensate for a maximum floor elevation difference of ±3 in.

f. All supports shall be designed to resist the load of the media in the event the tank is drained.


2.07 SCREENS

A. General: 1. The CONTRACTOR shall furnish and install cylindrical screen(s) for media

retention in the basin(s) as shown and specified. The Equipment Manufacturer shall furnish the items listed below: a. Cylindrical Screens. b. Flat Drain Screen to cover tank drain/RAS inlet. c. Supports.

B. Equipment: 1. Manufacturer:

a. Aqseptance. 2. Cylindrical Screen:

a. Cylindrical Screen (Perforated Plate): 304/304L stainless steel cylindrical screens shall be provided for the basins as shown on the contract drawings. The cylindrical screens shall be constructed of a minimum 14 gauge sheet and have a perforation pattern of a 5/8 in. dia. with 13/16 in. centers on a staggered spacing. Each screen will have a minimum 1/4 in. thick plate mounting flange with two sets of anchor holes for wall mounting.

3. Flat Drain Screen: a. A 304/304L stainless flat screen(s) shall be provided for the basin(s) as

shown on the contract drawings. The flat screen shall be constructed of a minimum 14 gauge sheet and have a perforation pattern of a 5/8 in. dia. with 13/16 in. centers, on a staggered spacing. Each screen shall fully cover the drainage/RAS inlet opening at the tank bottom.

4. Sparger Air Scour Piping: a. 1-inch diameter 304/304L stainless steel air scour piping will be provided

for each screen as shown on the contract drawings. The air scour piping shall be tapped from the main air line.

b. Sparger piping shall be rated for continuous operation. c. Airflow will be approximately 11 CFM per screen.

5. Construction: a. Welding: All welding shall conform to industry standard Welding

Fabrication Procedures for stainless steel. All factory welding shall undergo pickling/passivation to prevent rust and corrosion.

b. Bolting: Where nothing to the contrary is indicated, bolts, screws, nuts, and washers shall be 18-8 stainless steel.

c. Installation: Each screen shall be mounted by either (4) 18-8 stainless steel threaded rods with a minimum diameter of 1/2 in. (direct wall mounting), or with a minimum of (4) bolts (mating flange mounting). The installation of the screen shall be such that upon completion of installation, all cylindrical screens are level to ±1/4 in. of a common horizontal plane.

6. Design: a. The system shall be designed to be submerged within the tank basin

without deforming any component. b. All welded parts and assemblies shall be shop fabricated from 304L

stainless steel with a 2D finish. Unless otherwise specified, all non-welded parts and pieces shall be shop fabricated from type 304 stainless steel with a 2D finish.


c. Maximum headloss through the cylindrical screens shall not exceed 3 inches in each basin at peak hydraulic flows.

d. Provide 304L stainless steel supports for the screen as required.

2.08 ANCHORS

A. General: 1. The SYSTEM SUPPLIER SHALL furnish anchoring hardware for the supplied

equipment. 2. The CONTRACTOR shall furnish all epoxy and dispensing equipment for

chemical anchoring.

2.09 RECYCLE PUMPS

A. Description: Rotary lobe type positive displacement pumps with convoluted type tri-lobe rotors, motors, seals, couplings, base plates, guards, supports, anchor bolts, taps, lifting eyes, stands, and other items as specified and as required for a complete and operational system.

B. Submittals: 1. Data to be submitted:

a. The Contractor shall submit detailed installation drawings for the units which are being proposed to supply, showing: Brake Horsepower, Power Input to Electric Drive Motor and design discharge flowrate for the various conditions under which the units are to operate, together with descriptive data and specifications describing in detail the construction of the complete units.

b. Operation and maintenance manuals shall be submitted in accordance with Section OR-01170 - Closeout Procedures.

2. Dimensional Data: a. The successful bidder shall submit to the Engineer for approval, within 45

days after the award of the Contract, shop drawings certified as correct, showing all weights and dimensions necessary for the installation of foundations, anchor bolts, brackets and mast support system.

b. Submit anchor bolt sizes, setting depth, shear, and pullout strength for approval.

C. Quality Assurance: 1. Factory Testing: Each pump shall be factory tested as follows prior to

shipment: a. Mechanical and electrical integrity established by physical inspection and

by use of a megger. b. Power leads shall be applied and motor started to verify proper rotation. c. Pump shall be run in the design condition to verify amp draw, starting

capability, mechanical, and electrical integrity. d. The unit shall be removed and checked by megger and by physical

inspection to determine electrical and mechanical integrity.

D. Manufacturers: 1. Pumps: One of the following, or equal:

a. Boerger, LLC. b. Vogelsang USA, LTD.


E. Design requirements: 1. Pump performance characteristics:

a. As specified in the Pump Schedule. b. Pumps shall be suitable for installation as specified in this Section and as

indicated on the Drawings. 2. Motor characteristics: As specified in Pump Schedule.

F. Materials: 1. General: Materials in the Pump Schedule shall be the type and grade as

specified in this Section. 2. Cast iron: ASTM A48, Class 30 minimum. 3. Gray iron casting: ASTM A278, Class 30. 4. Buna-N: Synthetic rubber with a minimum Durometer hardness of 70 in

accordance with ASTM D2240 test methods. 5. Steel: ASTM A283, Grade D or ASTM A516 Grade 70. 6. Stainless steel: ASTM A276, Type 316 stainless steel; nickel - chrome - boron

coating as scheduled. 7. Carbon steel: ASTM A470. 8. All elastomers shall be Buna-N.

G. General Pump Construction: 1. Type: Industrial, heavy duty, positive displacement, rotary lobe type pumps

meeting performance requirements and features as scheduled and as specified.

2. Service: Pumping units shall be designed to convey return activated sludge. Normal solids concentrations will range from 0.3 to 1 percent. Other service requirements shall be as scheduled.

3. All equipment shall be designed and built for 24-hour continuous service at the rated design condition without overheating, without cavitation, and without excessive vibration or strain.

4. All working parts of the pumps and motors, such as bearings, wearing rings, shaft, sleeves, etc., shall be standard dimensions built to limit gauges or formed templates, such that parts will be interchangeable between like units and such that the Owner may obtain replacement and repair parts for those furnished in the original machines at any time in the future.

5. All lubrication fittings shall be brought to the outside of all equipment so that they are readily accessible from the outside without the necessity of removing covers, plates, housings, or guards.

6. Pump shall be capable of temporarily running dry without damage and operate in either direction.

H. Pump Casing: 1. Materials:

a. Pump casing: As scheduled. b. Pump top and bottom housing: As scheduled: minimum 750 Brinell

hardness. c. Front and end covers: Same as pump casing. d. Wear plates: As specified.


2. Top and bottom pump housing: Top and bottom segments of the pump shall be adjustable based on wear up to 6 millimeters. The adjustment shall be accomplished by simply moving stainless steel shims from one hole to the next in the pump housing, allowing for the closing of tolerance around the rotors. This adjustment must be available a minimum of 2 times from factory tolerance. a. In lieu of providing adjustable top and bottom segments, manufacturer

may provide radial wear plates on the casing walls that utilize the same philosophy as the front and rear wear plates.

b. The radial wear plates shall be designed to allow the Owner to replace the worn component and bring the radial casing back to factory tolerance.

3. Front cover: a. The removable front cover shall be mounted to the pump with 4 individual

bolts. b. The front cover shall permit removal of the rotors without disturbing piping,

bearings, and mechanical seals. c. The front cover shall be machined to accept a reversible wear plate.

4. End cover: a. The removable end cover shall be flush with no recesses or dead pockets

where solids can accumulate. b. The end cover shall be sealed with Buna-N o-ring and provide complete

access to the pump chamber without disconnecting pipe work glands or bearings.

5. Wear plates: Wear plates shall be constructed of Hardox 500 material, or equal, with a minimum Brinell hardness of 550 and a finished, hardened, reversible surface of 700 Brinell.

6. Port connections: Provide ANSI Class 150 raised face flanges. Connections shall be suitable for field coating.

I. Pump Rotors: 1. Materials:

a. Rotor core: As scheduled. b. Rotor (and/or rotor tip) coating: As scheduled.

2. Construction: a. The pump shall utilize 2 tri-lobe rotors, which are driven through positive

timing gears running in oil. b. Rotor cores shall be covered with a rotor coating as scheduled. c. The geometry of the rotor core shall be the same as that of the finished

rotor. d. Rotor vane geometry shall be convoluted to provide pressure-pulse free

operation. e. Designs with rotor vanes parallel to the shaft centerline will not be

accepted. f. The convoluted rotor shall be specifically designed for pumping sludge

containing organic solids, small inorganic particles, and grit. g. Rotors shall be positioned on the shaft by replaceable hardened key ways

and secured to the shaft by internal/external expansion clamp sleeves and flush discs requiring no recesses in the end cover.

3. In lieu of providing solid rotors, rotors may be provided with replaceable tips. Rotor, rotor tip, and rotor coating material shall be as specified.

4. Stacking of lobes is not acceptable.


J. Shafts: 1. Materials:

a. Shaft: As scheduled. b. Shaft sleeve: As scheduled: ceramic coated.

2. Construction: Pump shafts shall be designed to provide sufficient stiffness to operate without distortion, damaging vibration, or excessive wear throughout the range of operation specified.

3. Sludge wetted rotor/shaft connections are not acceptable. 4. Stuffing Boxes:

a. Construction: 1) A blocking chamber located behind the mechanical seal and in front

of the bearing housing lip seal shall be molded into the casting of the pump. a) This chamber shall be suitable for oil fill through the top and

bottom of the pump. b) This chamber will have an external pressurized oil bottle

mounted above the pump from the fill nipples to view the status of the mechanical seals.

2) The external oil bottle will be located in view of the operator. Oil-quench shall provide lubrication and cooling of the seal, allow detection of seal failures, and provide a buffer zone to the sealed timing gear. Seal water flush systems are not acceptable. a) In lieu of providing an external pressurized oil bottle mounted

above the pump, manufacturer may provide a plastic stopper on the chamber that is vented to the atmosphere, which will allow fluid to escape as an indication of seal failure.

b. Shaft seal type: As scheduled. c. Design of the pump shall allow removal and replacement of the seal via

the front cover. 1) Seal designs that open during rotor replacement are not acceptable.

d. Oil drain gearbox and intermediate chamber shall be easily accessible. 1) Oil drain under the pump is not acceptable.

K. Gear Reducers: 1. Gear reducers and couplings shall meet the requirements as specified in the

Project Technical Requirements. 2. Provide NEMA C face connection between motor and gearbox. 3. Provide helical reduction gears, rated for AGMA Class II service with a

1.5 service factor. 4. Provide oil bath lubrication.

L. Support Pedestals and Baseplates: 1. Materials: Same as pump casing or ASTM A283 steel, hot-dip galvanized after

fabrication and coated as specified in Section 09960 - High-Performance Coatings.

2. Pump, driver, and intermediate bearing support strength: Able to withstand minimum 1.5 times maximum imposed operating loads or imposed seismic loads, whichever is greater.

3. Configuration: a. Support pump, gear reducers, and motor on a common structural steel

baseplate.


b. Pumping unit shall be furnished in a piggyback arrangement, belt driven with motor overtop of pump.

c. Belt drive shall be as specified in the Project Technical Requirements. 4. Anchor bolts: Designed by the pump manufacturer:

a. 3/4-inch minimum diameter. b. As specified in the Project Technical Requirements.

M. Equipment Guards: 1. Provide safety guards.

N. Drivers: 1. Horsepower:

a. As scheduled. b. Listed driver horsepower is the minimum to be supplied.

1) Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout.

2) When scheduled driver is a motor, increase motor horsepower if required to prevent operation in the service factor.

3) Make all structural, mechanical, and electrical changes required to accommodate increased horsepower.

2. Motors: Provide motors as specified in Section 16222 - Low Voltage Motors up to 500 Horsepower and as specified in this Section. a. Revolutions per minute: As scheduled. b. Enclosure: As scheduled. c. Electrical characteristics: As scheduled. d. Efficiency, service factor, insulation, and other motor characteristics: As

specified in Section 16222 - Low Voltage Motors up to 500 Horsepower. e. Motor accessories: As specified in Section 16222 - Low Voltage Motors

up to 500 Horsepower and in this Section. f. Coordinate motors with the variable frequency drive manufacturer to

ensure compatibility between the motor and variable frequency drive. 3. Other drivers: As scheduled and as specified in sections listed in the

Schedule. 4. Non-reverse ratchets: When scheduled, provide driver with non-reverse

ratchets or pin mechanism to prevent reverse rotation of the pump and driver in the event of discharge valve failure.

O. Spare Parts and Special Tools: 1. Spare parts: Deliver the following for each type or size of pump:

a. 1 spare rotor set or set of replaceable rotor tips. b. 1 set of mechanical seals. c. 1 set of o-rings. d. 1 set of wear plates (front, back, and radial).

2. Special tools: For each type or size of pump specified, provide 1 set of all special tools required for complete assembly or disassembly of the pump system components.

P. Commissioning: 1. Manufacturer services:

a. Provide certificates: 1) Manufacturer’s Certificate of Source Testing.


2) Manufacturer’s Certificate of Installation and Functionality Compliance.

b. Manufacturer’s Representative onsite requirements: 1) Installation: 1 trip, 3-day minimum. 2) Functional Testing: 1 trips, 2-day minimum each.

c. Training: 1) Maintenance: 2 hours per session, 1 session. 2) Operation: 2 hours per session, 1 sessions.

d. Process operational period: 1) As required by Owner or Contractor.

2. Source testing: As specified in Pump Schedule. 3. Functional testing: As specified in Pump Schedule.

Q. Pump Schedule:

General Characteristics: Service Return Activated Sludge Quantity 2 Maximum Noise, dBA at 3 feet 85 Torsional Analysis Not Required Minimum Pumped Fluid degrees Fahrenheit 68 Normal Pumped Fluid degrees Fahrenheit 75 Maximum Pumped Fluid degrees Fahrenheit 95

Pump Characteristics: Impeller Type Positive Displacement, Rotary Lobe Minimum Sphere Size, Inch 3 Shaft Seal Type Single Mechanical Coupling Type Spacer Speed Control Variable Frequency Drive Maximum Pump rpm 600 Suction Flange Diameter, Inches 8 Discharge Flange Diameter, Inches 6

Rated Design Point (at Maximum Revolutions per Minute): Flow, Gallons per Minute 400 Head, Feet 6.75

Maximum Rated Head Condition (at Maximum Revolutions per Minute): Flow, Gallons per Minute 600 Head Range, Feet 8

Normal Operating Range: Flow, Gallons per Minute 300 Head Range, Feet 6 to 6.5

Other Conditions: Minimum NPSHa at Every Specified Flow, Feet 32


Pump Materials: Casing Gray Cast Iron Top and Bottom Pump Housing Gray Cast Iron Rotor Core Gray Cast Iron Rotor Coating (including rotor tip coating) Buna-N Shaft Carbon Steel Shaft Sleeve 316 Stainless Steel, Ceramic Coated Nuts and Bolts 316 Stainless Steel

Driver Characteristics: Driver Type Motor Drive Arrangement Inline Minimum Driver Horsepower 10 Maximum Driver rpm 1,800

Motor Characteristics (when motor is driver type): Inverter Duty Rated Yes Motor Voltage/Phases/Hertz 460/3/60 Enclosure Type TEFC

Source Testing: Test Witnessing Not Witnessed Performance Test Level 1 Vibration Test Level 1 Noise Test Level 1

Functional Testing: Performance Test Level 1 Vibration Test Level 1 Noise Test Level 1

2.10 CLARIFIER MECHANISM

A. General: 1. Specification of equipment for installation in circular secondary clarifiers of

center feed, peripheral overflow design.

B. System Description: 1. Nominal clarifier dimensions:

a. Diameter: As indicated on the Drawings. b. Side water depth: 10 feet. c. Bottom slope: As indicated on the Drawings.

2. Sludge collector mechanism: a. Supply as a complete and operational system by a single manufacturer. b. Equipment to include, but not be limited to, the following components:

1) Walkways and access bridges with handrail and grating. 2) Center column. 3) Influent well. 4) Flocculating well. 5) Center drive cage. 6) Sludge collector truss arms.


7) Scum skimming system. 8) Segmented scraper blades. 9) Center drive mechanism. 10) Drive motor. 11) Electrical controls. 12) Overload devices and alarms. 13) Other components necessary to provide a complete system.

c. Process description: 1) Mixed liquor enters the clarifier through a center column and is

discharged into the influent well through openings in the center column.

2) The influent well dissipates the kinetic energy of the influent mixed liquor flow. Peripheral outlet ports in the influent well create a controlled discharge of the mixed liquor into the flocculating well to enhance flow distribution and flocculation.

3) The flocculating well promotes flocculation of the mixed liquor suspended solids and allows for a gradual redirection of the flow velocity into the clarifier.

4) A central drive mechanism mounted on a center column supports and rotates a center cage with 2 truss arm assemblies, each supporting segmented, plow style scraper blades and 2 surface skimming arms.

5) Clarifier connected directly to RAS pump suction: a) Sludge is transported by the segmented scraper blades toward

a center sludge hopper. b) Sludge removal is accomplished by the combined action of the

continuously rotating sludge collection mechanism and the return activated sludge pumping system.

6) The scum skimming system consists of 2 full radius skimming arms that collect secondary scum from the surface of the clarifier and deposit it into the full radius scum collection trough cantilevered from the tank wall.

C. Design requirements: 1. Operating parameters:

a. Process flows:

Parameter (Per Clarifier) Average Maximum Peak Effluent Flow, million gallons per day (mgd)

88 125 200

Return Activated Sludge (RAS) Flow, mgd

88 125 200

Total Mixed Liquor (ML) Flow, mgd 176 250 400

b. Maximum allowable headloss through the center column, the influent well, and the flocculating well at peak flow = 4 inches.

c. Mixed liquor suspended solids concentration range = coordinate with the SYSTEM SUPPLIER.

2. Mechanical design: a. Design for a continuous running torque of 25,000 foot pounds. b. Design collector mechanism to operate at a tip speed, measured at the

ends of the truss arms, of approximately 8 feet per minute.


c. Use no chains, sprockets, bearings, or gears below the water surface for the sludge collector mechanism.

3. Structural design: a. Design the sludge collector mechanism in accordance with AISC 360,

except: 1) Provide a 1/4 inch minimum thickness for all members, except where

specifically modified for specified equipment components. 2) Include stresses caused by bending and twisting due to eccentricities

of members of all joints. b. Slenderness Ratio (Kl/r) using K Value of 1.0 shall not exceed the values

specified below: 1) Tension members-not greater than 240. 2) Compression members-not greater than 200.

c. Corrosion allowance: 1) For all structural members and center column, add 1/8 inch to the

thickness used for the final design calculations to check member stresses and buckling.

2) This corrosion allowance is to be applied to the design thickness and not to the minimum member thickness specified.

3) The final member thickness shall be the greater of the specified minimum thickness or the sum of the design thickness and the corrosion allowance.

d. Base member weights used for design on final full member thickness. e. Full member thicknesses may be used for performing deflection

calculations. f. Design the center cage and the truss arms as an integral structure.

Design the center cage and the connections to the truss arms for the reactions from the truss arms.

g. Do not include live load where its inclusion results in lower stresses in a member under investigation.

h. Load combinations: Design each structural member of the sludge collector mechanism for the most critical load combination resulting from the following load combinations: 1) Dead load plus live load plus continuous running torque. 2) Dead load plus live load plus continuous running torque plus seismic

load. a) Seismic load shall include seismic load from the water inside the

clarifier acting on members of the clarifier mechanism. b) For elements of the clarifier such as the center column, the

influent well, and the flocculating well, impulsive and convective seismic loads from the water shall be applied appropriately on both the inside and outside surfaces.

c) These seismic loads shall be in addition to the seismic loads due to the dead loads of the elements.

3) Dead load plus live load plus torque due to screeding grout topping on slab using sludge collector mechanism.

4) Dead load plus live load plus torque due to cutout torque test. 5) Other load combinations selected by the manufacturer.


6) Truss arm load cases: Use the following load cases on the truss arms for load combinations: a) Equal uniform horizontal load along the full length of both truss

arms which results in a combined torque equal to the continuous running torque.

b) Uniform horizontal loads along the full length of both truss arms which results in 70 percent of the torque from 1 truss arm and 30 percent of the torque from the other truss arm for a combined torque equal to the continuous running torque.

c) Load on truss arms due to spreading grout topping on slab using sludge collector mechanism.

d) Load on truss arm due to cutout torque load test. i. Deflections:

1) The horizontal deflection of the truss arm, due to truss arm deflection plus rotational deflection of the center cage for load cases which contain continuous running torque, shall not exceed a deflection equal to the radius of the clarifier divided by 400 (L/400). a) Not more than 60 percent of the total horizontal deflection shall

be due to center cage rotation. b) Horizontal deflection of the truss arm shall be measured at the

end of the truss arm furthest from the center column. 2) The vertical deflection of the truss arm due to equipment dead load

shall not exceed the length of the truss arm divided by 800 (L/800). j. Seismic design criteria: As specified in Basis of Design Report.

D. Submittals: 1. Submit product data and shop drawings, operation and maintenance manuals,

and test reports. 2. Product data and shop drawings:

a. Shop drawings shall consist of a cover sheet indicating the drawing number and specification page and number to which referenced, intended use and data summary, outline drawings, cut-away drawings, parts lists, material specification lists, and all information required to substantiate that the proposed equipment meets the specifications. 1) Shop drawing submittals will not be considered complete if cut-away

or assembly drawings with part and material specification lists are not included.

b. General arrangement drawings showing the complete assembly, part numbers, and materials list.

c. Detailed drawings: 1) Sludge collector mechanism indicating dimensions, member sizes

and thicknesses, welding, and connection details. 2) Drive mechanism showing sizes, dimensions, and arrangement of

each drive component. 3) For gears, except those contained in the gearmotor speed reducer,

detailed drawings with the following minimum data for each gear: a) Number of teeth. b) Net face width. c) Outside diameter of external gears. d) Inside diameter of internal gears. e) Normal diametral pitch or axial pitch for worms. f) Normal generating pressure angle.


g) Lead angle (for worms). h) Operating center distance. i) Addendum modification coefficient. j) Tooth thickness or pin or span measurements. k) Quality numbers in accordance with AGMA 915-1, 915-2, 2009,

2011, 2015-1 and 2015-2. l) Material alloy. m) Type of heat treatment. n) Tooth surface hardness. o) Tooth core hardness. p) For case hardened gears, effective case depth to Rc 50. q) Lubricant type (mineral/synthetic EP). r) Lubricant viscosity.

d. Certified motor data sheets. e. Shop primer and coating data. f. Control system data, schematics, and wiring diagrams. g. Spare parts list. h. Qualifications and resume of installation engineer. i. Training course outlines. j. Manufacturer’s experience and reference list as specified under Quality

Assurance. 3. Manufacturer's installation instructions. 4. Calculations: Include, without necessarily being limited to:

a. Structural calculations: 1) Calculations shall be prepared and signed by a professional civil

engineer licensed in the state where the Project is located demonstrating compliance with structural criteria specified in this Section and seismic design criteria as specified in Basis of Design Report.

2) Submit design calculations with complete shop drawings. b. Mechanical calculations: Performed by a professional civil or mechanical

engineer licensed in the state where the Project is located. Calculations are intended to: 1) Substantiate continuous running torque loading and overload torque

rating of each component of drive mechanism. a) Calculations shall be in accordance with AGMA 908. b) Calculations shall clearly specify all design parameters used in

developing the ratings, including materials in accordance with AGMA 2004.

c) All ratings in accordance with AGMA 2001 and AGMA 6034. 2) Demonstrate that each bearing in drive mechanism complies with life

requirements of this Section. 5. Reference list: Include the following information as a minimum:

a. Name and location of installation. b. Name and telephone number of the person in direct responsible charge of

the equipment. c. Name and contact information for equipment fabricator. d. Name and contact information for manufacturer’s engineer responsible for

structural design. e. Month and year the equipment was placed in operation. f. Size of equipment. g. Number of units installed.


h. Service. 6. Quality control submittals:

a. Welder’s certificates. b. Submit manufacturer's or designated contract fabrication facility’s

structural steel fabrication qualifications and information. c. Engineer’s qualifications to complete structural analysis and design.

7. Fabrication certification report: a. Provide fabrication certification report prior to equipment delivery to

project site. 8. Test reports:

a. Method of conducting cutout torque test and verification that method of testing will not impose stresses in any member which exceeds maximum allowable stresses specified in this Section.

b. Results of field torque tests on sludge collector mechanism. 9. Operation and Maintenance Manuals.

a. Include Scum Trough Flushing Device flushwater volume adjustment chart and graph.

10. Certificates: Manufacturer's certification that equipment was installed in accordance with the manufacturer's instructions, inspected by the manufacturer, serviced with the proper initial lubricants, and equipped with applicable safety equipment and connections.

11. Technician's Qualifications Resume: Submit resume of technician to perform Manufacturers Field Service.

E. Quality Assurance: 1. Manufacturer qualifications:

a. Experience: Demonstrate minimum 5 years experience in the manufacture and fabrication of plow-type segmented scraper sludge collectors which have been successfully utilized in domestic wastewater applications. 1) Experience of fabricator, if manufacturer does not self-perform

fabrication, shall meet or exceed that required of manufacturer. 2) Submit substantial information as necessary to establish

qualifications of fabricator, if manufacturer does not self-perform fabrication, including location (address), experience, qualifications, and certifications of all fabricator’s staff to be utilized.

3) Manufacturer’s engineer responsible for structural design shall also demonstrate minimum 5 years experience designing sludge collectors to withstand operational and seismic loads, including sloshing of tank contents on sludge collection mechanism.

2. Welding and welder qualifications: a. Perform welding and qualify and certify welders in accordance with AWS

D1.1, and D1.6 if applicable. b. Welds:

1) Use shielded arc welding. 2) Conform to requirements of design loads. 3) Conform to information indicated on the Drawings. 4) Use continuous watertight seal welds. 5) Use a minimum weld size of 1/4 inch. 6) Field welding is permitted only for bridge splice (if required). 7) Engineer may check materials, equipment, and qualifications of

welders.


8) Remove welders performing unsatisfactory Work, or require to requalify.

9) Engineer may use gamma ray, magnetic particle, dye penetrant, trepanning, or other aids to visual inspection to examine any part of welds or all welds.

10) Manufacturer shall bear costs of retests on defective welds. 11) Manufacturer shall also bear costs in connection with qualifying

welders. 3. Steel fabrication:

a. Manufacturer’s Authorized Representative shall be present during fabrication of equipment.

b. Manufacturer’s authorized representative shall provide a fabrication certification report complete with certified fabrication drawings, a journal of the fabrication work process, photo documentation of the shop assembly of all components required to be field erected, and a certification that the fabricated equipment is complete and ready for installation by the Contractor.

4. Equipment subassemblies: a. Each component subassembly requiring field erection shall be test

assembled and documented at the manufacturer’s fabrication facility. b. Digital photographic evidence of assembly shall be submitted as part of

the fabrication certification report. c. Mark parts with erection matchmarks for ease of field erection. d. Lubricate moving parts before shipment. e. When necessary to disassemble parts for shipping, coat uncoated

exposed machine surfaces with suitable, easily removable, rust-preventive compound before shipping.

F. Maintenance: 1. Spare parts: Furnish the following spare parts suitably packaged and marked.

Include a price list and name, address, and telephone number of local supplier: a. 2 sets of scum skimmer blade wear strips. b. 1 set of squeegees for each segmented scraper mechanism furnished. c. 4 sets of shear pins. d. 1 set of scum skimmer wipers. e. 1 set each of oil seals for the worm shaft and pinion shaft.

2. Special tools: Provide the following special tools: a. Tools required to assemble, disassemble, repair, and maintain equipment,

and that have been specifically made for use on the equipment. b. Necessary eyebolts, hooks, and rods for handling equipment parts. c. List of tools with the maintenance and operation data describing the uses

of the tools.

G. Warranty: 1. The manufacturer shall warrant all package components for a period of twelve

(12) months from date of startup.

H. Manufacturers: 1. Sludge collector mechanism:

a. All equipment components of the sludge collector mechanism including the walkways and access bridges, center column, influent well,


flocculating well, center drive cage, sludge collector truss arms, scum skimming system, segmented scrapers, center drive mechanism, drive motor, electrical controls, and overload devices and alarms, shall be furnished by the same manufacturer.

b. Some equipment may require modification from the manufacturer’s standard.

c. Exercise care to assure that the electrical, mechanical, structural, and miscellaneous systems comply with the requirements specified or in other referenced sections.

d. Manufacturer: One of the following: 1) Ovivo USA. 2) Westech, Inc. 3) Walker Process Equipment.

I. Density current baffle: 1. Manufacturer: The following or equal:

a. Nefco, Inc.

J. MATERIALS: 1. For all components unless specified otherwise the materials of construction

specified below. 2. Structural steel:

a. In accordance with ASTM A36 for clarifier bridge construction, and for all other components.

b. Grind all edges of steel members to approximately 1/16 inch minimum radius using standard workmanship and a grinder.

3. Anchor bolts: Type 316 stainless steel. 4. Weir plate: Fiberglass reinforced plastic as specified in the Project Technical

Requirements. 5. Scum baffles: Fiberglass reinforced plastic as specified in the Project

Technical Requirements. 6. Fasteners and washers: Type 304 stainless steel, except for bolts which will

be removed during installation and any high strength bolts. 7. High strength bolts: In accordance with ASTM F3125, Grade A325 hot-dip

galvanized high strength bolts in attaching truss arms to cage, and cage to center drive gear casting.

8. Do not use cadmium plated parts and fasteners. 9. Dissimilar metals: All aluminum components shall be isolated from steel

components as specified in the Project Technical Requirements, to prevent electrolysis.

K. EQUIPMENT COMPONENTS: 1. Walkways and access bridges:

a. Materials: 1) Welded steel beam construction.

b. Design: 1) Composed of 2 main members laterally braced together. 2) Minimum live load of 100 pounds per square foot. 3) Maximum deflection not to exceed span length divided by 360

(L/360) for dead plus live loads. 4) Support light standards and fixtures as indicated on the Drawings.


5) Supported using: a) Center column at one end and the outer concrete clarifier wall at

the other as indicated on the Drawings. b) Make allowance at outer concrete wall for expansion and

contraction of walkway due to temperature changes: (1) Use self-lubricating bearings. (2) Do not use non-lubricated metal-to-metal slide plates or

direct metal-to-concrete bearing. (3) Prevent lateral movement of bridge at outer wall.

6) Provide additional structural supports as required to support scum spray and other piping on the bridge as indicated on the Drawings.

c. Platform at the center turntable: Provide a minimum clearance of 2 feet 6 inches around all sides of drive mechanism and allow uninhibited access to all parts of the drive unit.

d. Guardrail with kickplate: 1) On both sides of walkway and all around center turntable platform. 2) Guardrail and kickplate as specified in the Project Technical

Requirements and matching other railing supplied for Project. e. Walking surface:

1) Materials: Hot-dip galvanized steel treadplate. 2) Location: Over entire bridge and center turntable platform.

2. Center column: a. Materials:

1) Vertically mounted, cylindrical steel column: a) Inside diameter: As indicated on the Drawings. b) Wall thickness: 1/4-inch minimum.

b. Design: 1) Support the entire sludge collector mechanism including inboard end

of bridge. 2) Size and anchor the center column to be capable of resisting design

loads when the tank is empty or full. c. Center column anchorage: Mount the center column over the influent port

at the center of the clarifier floor. Connect the base flange of the center column to the concrete foundation using anchor bolts: 1) Use a rigid steel template to of minimum 1/4-inch thickness

accurately locate anchor bolts for the center column during concrete placement.

2) Supplier shall coordinate with the Contractor to ensure proper anchor bolt location.

3) Center column base anchor bolts: a) Not less than 8 in number. b) Not less than 15 bolt diameters of embedment length. c) Not less than 3/4 inch in diameter. d) Use a minimum edge distance for anchor bolts of the larger of

6 inches or 6 anchor bolt diameters, and as required to clear reinforcing bars located around opening.

4) Center column base mounting flange: a) Size and reinforce using gussets or other stiffeners as

necessary to adequately transfer loads from the sludge collector mechanism to clarifier structure.

b) Bolt holes in flange to accommodate anchor bolts shall not exceed 1/8 inch plus bolt diameter.


d. Center column outlet ports: Provide outlet ports in the upper end of the center column to disperse influent flow into the influent well. Provide the following: 1) A total of 4 ports. 2) Appropriately reinforced port openings. 3) Port dimensions: As indicated on the Drawings.

e. Flange and stiffen the top of the center column for supporting the sludge collector mechanism, the drive mechanism, and the access bridge: 1) Attach the center column to the drive assembly using bolts.

f. Drain holes: Provide two 2-inch holes at bottom to allow column to drain into the tank.

3. Influent well: a. Materials:

1) Structural steel plate and members. 2) Reinforced with steel stiffening angles where necessary.

b. Design: 1) Closed-bottom tub concentric with the center column. 2) Supported around the outside of the center drive cage. 3) Diffuse influent flow into the clarifier tangentially, evenly, and

efficiently without excessive disturbances. 4) Center column outlet ports:

a) Shall direct and control flow into the clarifier. b) Dimensions: As indicated on the Drawings.

5) Dimensions: As indicated on the Drawings. 6) Provide two 2-inch orifices in the bottom to allow the well to drain as

the clarifier is emptying. 4. Flocculating well:

a. Materials: 1) Structural steel plate and members. 2) Reinforced with steel stiffening angles where necessary.

b. Design: 1) Dimensions: As indicated on the Drawings. 2) Equip with a minimum of 4 baffled slots as indicated on the Drawings

to allow for removal of floating material in the well. 3) Support from center cage using rigid connection:

a) Other methods of connection such as swinging supports or breakaway supports are not permitted.

5. Center drive cage: a. Materials:

1) Structural steel members. b. Design:

1) Use box truss design. 2) Design to carry load from the truss arms plus its own dead load. 3) Fasten center drive cage to spur gear assembly using bolted

connection. 4) Design the center drive cage to support and rotate the truss arm

assemblies with the segmented scrapers and the surface-skimming arm.

6. Sludge collector truss arms: a. Materials:

1) Structural steel truss arms.


b. Design: 1) Use truss design. Tie rods not permitted. 2) Design truss arm with sufficient structural strength to screed in a

layer of grout on the clarifier bottom under its own power. 3) Maintain width of the truss arm the same as the width of center drive

cage to ensure alignment and proper connection. 4) Rigidly connect truss arm to the center drive cage. 5) Conform truss arm to slope of tank floor. 6) Use the truss arm to support the segmented scrapers.

7. Segmented scrapers and squeegees: a. Scraper blades: Setting similar for each truss:

1) Structural steel construction. 2) Sized and spaced so entire circular portion of tank is scraped twice

for each revolution of mechanism. 3) Having a minimum depth of 9-1/2 inches. 4) Having adjustable squeegees.

b. Squeegees: 1) Constructed of brass not less than 26 gauge thickness. 2) Spring type. 3) Projecting approximately 2 inches below the bottom of the

segmented scraper blades. 4) Having a 2-inch adjustment in the vertical plane. 5) Attached using bolted hardware.

8. Scum skimming system: a. Materials:

1) Skimmer support arms: Structural steel. 2) Scum deflector blades: Structural steel plate. 3) Scum skimmer wipers: Oil resistant neoprene. 4) Wear block: Polyvinyl chloride. 5) Wear block spring enclosure: Welded steel or cast iron housing. 6) Springs, threaded fasteners: Type 18-8 stainless steel. 7) Scum trough and scum beach:

a) Fabricated from 1/4 inch minimum thickness steel plate. b) Supported from clarifier wall by structural steel members.

b. Design: 1) Space scum skimmer supports brought up from the truss arm at not

greater than 10 feet apart. 2) Scum trough:

a) Width: as indicated on the Drawings. b) Standard pipe flanged connection for scum discharge pipe size

and location as indicated on the Drawings. c) No internal stiffeners or structural members which obstruct scum

flow. 3) Scum beach (inclined ramp):

a) Length: As indicated on the Drawings. 4) Skimming device: Attach a scum deflector blade to the collector

mechanical arm to move floating scum outward to a circumferential scum baffle. The scum deflector blade shall extend from the flocculating well to the hinged scum skimmer: a) Attach hinged scum skimmer to the deflector blade. b) Attach inner end of skimmer tangentially to the flocculating well

where practicable. Otherwise, provide maximum angle of


approach of skimming device scum deflector blade to the scum in order to drift the scum to circumferential baffle.

5) Provide an inclined approach ramp (scum beach) and trough with the beach shaped to contain scum as it is moved up the incline to the trough by the scum skimmer.

c. Elements: 1) Scum skimmers:

a) Provide scum-skimming device on the outer end of the scum deflector blade to trap scum for discharge into scum trough: (1) Scum skimming device shall be the full length of the scum

trough. b) Maintain continuous contact and proper alignment with scum

baffle and inclined scum ramp to positively rake scum to the scum trough.

c) Use a hinged blade with replaceable scum skimmer wipers on the bottom inner and outer edges to seal the entrapped scum and water when moving up the inclined approach ramp to the scum trough: (1) Hinged blade adjustable vertically to control the dewatering

of scum as it travels up the inclined ramp to the scum trough.

(2) Hinged blade adjustable vertically over the length to ensure contact with the scum trough even though the trough may not be level.

(3) Hinged blade capable of being raised and locked out above the water level or held horizontally against the circumferential baffle when skimming is not required.

d) Equipment manufacturer shall size and locate counterweights to be installed by the Contractor.

e) Do not support scum skimmers from the scum baffle. 2) Wear block:

a) Provide a replaceable wear block on the outer edge of each hinged scum-skimming device.

b) Wear block constantly forced against circumferential scum baffle to keep baffle clean using a coiled spring arrangement: (1) Force between baffle and wear block adjustable between 1

to 5 pounds. (2) Coiled springs enclosed to protect them from the weather. (3) Spring enclosures: Bronze bushed and grease lubricated

for easy movement of hinged blades. 9. Center drive mechanism: Provide a center drive mechanism consisting of a

primary speed reducer driven by electric motor, through either a roller chain or shaft coupling using an intermediate gearset consisting of a cylindrical-worm and helical-wormgear or a cycloidal reducer, and a low speed gearset consisting of a spur pinion and internal spur gear supported within a cast or ductile iron housing by a circular main bearing. Center drive mechanisms utilizing steel housings and/or grease are not acceptable: a. Primary speed reducer:

1) Provide speed reducer using cylindrical-worm or helical-wormgear motor or cycloidal reducer: a) Planetary gear units will not be acceptable.

2) All gears supported by anti-friction bearings.


3) Speed reducer in accordance with AGMA 6013 and 6034. 4) Provide minimum speed reducer service factors as follows:

a) 2.0 minimum based on continuous running torque. 5) Connect speed reducer output shaft to drive sprocket of chain drive,

or to intermediate speed reducer using shear pin coupler. 6) Provide speed reducer with overhung load rating (if applicable)

exceeding the chain pull (based on continuous running torque) by 1.50 minimum.

7) Oil bath lubrication: a) Provide oil fill, drain, and oil level indicator devices. b) Lubricant in accordance with AGMA 9005. c) Oil bath protection seal: Felt.

b. Intermediate gearset: 1) Type A: Cylindrical-worm and wormgear:

a) Materials: (1) Worm: Alloy steel, hardened, ground, and polished. (2) Wormgear: Centrifugally cast bronze. (3) Washers: Hardened steel to prevent embedding of bolt

head or nut. (4) Bushings: Bronze. (5) Housing: Cast iron in accordance with ASTM A48, Class 30

minimum. b) Load capacity: Rated in accordance with AGMA 6034. c) Service factor: Minimum of 1.25 based on continuous running

torque. d) Wormgear shaft:

(1) Drives pinion of low-speed gearset. (2) Support shaft by anti-friction bearings or combination of

anti-friction bearings and bushing. e) Wormgear: In accordance with AGMA 6022. f) Worm shaft: Support shaft by anti-friction bearings. If the

wormgear is bolted to a drive hub, it shall be piloted for concentricity.

g) Worm and wormgear shaft: Anti-friction bearings shall have ABMA 9, L-10 life of 180,000 hours minimum based upon continuous running torque.

h) Provide oil bath lubrication: i) Lubricant in accordance with AGMA 9005. j) Provide oil fill, drain, and oil level indicator devices.

c. Type B: Cycloidal Reducer: 1) Materials:

a) Ring gear: High carbon chromium bearing steel. b) Cycloidal disks: High carbon chromium bearing steel. c) Housing: Cast iron in accordance with ASTM A48, Class 30

minimum. 2) Service factor: Minimum of 1.5 based on continuous running torque. 3) Provide oil bath lubrication:

a) Lubricant in accordance with AGMA 9005. b) Provide oil fill, drain, and oil level indicator devices.

d. Low-speed gearset: 1) Provide low-speed gearset using spur pinion and internal spur gear.


2) Spur pinion shall be: a) Integral with its shaft or keyed to a shaft:

(1) If keys are used, the pinion shall be secured to the shaft with a shrink fit.

(2) Set screws will not be acceptable. b) Welded spur pinion and shafts will not be acceptable. c) Keyed spur pinions shall have a wall thickness above the

keyway equal to 1 tooth whole depth minimum: (1) Keyway and keyseat shall have 0.02-inch minimum inside

radii. (2) Keys shall have 0.04-inch minimum chamfer on all edges.

d) Manufactured to have a minimum AGMA Quality Class 8 in accordance with AGMA 915-1, 915-2, 2015-1, and 2015-2.

3) Provide full depth teeth in accordance with AGMA ISO 53: a) Stub pitch gear teeth will not be accepted. b) Undercut gear teeth will not be accepted.

4) Load capacity rated in accordance with AGMA 2001. 5) Power rating based on continuous service and the lower of the:

a) Pitting resistance for the pinion and gear. b) Bending strength for the pinion and gear.

6) Minimum service factor of 1.25 based on continuous running torque. 7) Overload torque capacity (based on yielding of the pinion or gear

teeth) exceeding the momentary peak torque by 1.8 minimum. 8) Internal spur gear:

a) Material: Ductile (nodular) iron in accordance with ASTM A536 or cast steel in accordance with ASTM A148, or forged 4140 heat-treated alloy steel.

b) Bolted to the center drive cage. c) Minimum AGMA Quality Class 6 in accordance with AGMA 915-

1, 915-2, 2015-1, and 2015-2. 9) Turntable base:

a) Material: (1) Ductile (nodular) iron in accordance with ASTM A536 or

cast iron in accordance with ASTM A48, Class 40 minimum.

(2) Fabricated steel bases will not be accepted. b) Bolted to the center column to provide support for the internal

spur gear, entire rotating collector mechanism, and one end of the access bridge.

e. Raceways, ball bearings, and oil bath: 1) Provide replaceable annular raceways or 4 point precision bearing to

support vertical and horizontal forces transmitted by ball bearings on turntable base and internal spur gear: a) Raceway 40 inches minimum in diameter.


b) Size the raceways using the following equation:

q = 59,466 3/1

2D*NP

Where: q = Contact stress, pounds per square inch (maximum = 300,000 pounds per square inch). P = Total rotating (hung) load, pounds, including truss arms, center cage, internal spur gear, influent well, flocculating well, skimmers, segmented scrapers, counterweights, and any other rotating weight. N = No. of balls. D = Ball diameter, inches.

2) Design raceway and ball bearings for ABMA 9, L-10 life of 200,000 hours minimum.

3) Provide oil bath for turntable base and internal spur gear: a) Include felt seal and dust shield protection. b) Provide oil fill, oil drain, and oil level indicator devices in readily

accessible locations. c) Lubricant in accordance with AGMA 9005.

f. Chain drive (if used): 1) Provide standard roller chain in accordance with ASME B 29.1M

connecting drive sprocket of the gear motor speed reducer to the driven sprocket.

2) Provide drive sprocket having minimum of 12 teeth. 3) Provide roller chain and sprockets enclosed in weatherproof

fabricated steel guard with service openings. 4) Provide chain having:

a) Minimum tensile strength greater than 4 times chain pull based on momentary peak torque.

b) Power rating exceeding the transmitted power (based on continuous running torque) by 1.50 minimum.

g. Drive motor: 1) Type: Drive motor shall be a squirrel-cage induction type. 2) As specified in Section 16222 - Low Voltage Motors up to

500 Horsepower. 3) Motor characteristics:

a) Minimum continuous horsepower not less than 3/4. b) Voltage: 480-volts. c) Phase: 3. d) Frequency: 60-hertz. e) Insulation: Class B, moisture resistant. f) Service factor: 1.15. g) Maximum ambient temperature: 40 degrees centigrade. h) Enclosure: TEFC, Class I Division 2 compliant. i) Synchronous speed: 1,800 revolutions per minute.

4) Nameplate: Include all information listed for "Motor Characteristics": 10. Electrical controls:

a. Local control panel: 1) Enclosure: NEMA Type 4X. 2) Mount local control panel near drive mechanism on guardrail as

indicated on the Drawings. b. Electrical wiring as specified in the Project Technical Requirements.


c. Overload device and alarms: 1) Torque overload device: Incorporate into drive assembly:

a) Mechanical overload device shall be actuated by torque from the rotation of the wormgear acting on the linear motion of the worm, or the rotational displacement of the cycloidal speed reducer, as appropriate.

b) Torque indicator: (1) Provide a visual torque indicator oriented so that it may be

read from the walkway at all times during operation. (2) Calibrate torque indicator from 0 to 160 percent of the

continuous running torque. c) Include with the overload device, 2 independently adjustable

switches as follows: (1) Alarm switch: An alarm switch that shall be adjusted to

activate an alarm when load reaches 90 percent of the continuous running torque.

(2) Cutout switch: A cutout switch that shall be adjusted to shut off the motor when load reaches 100 percent of the continuous running torque.

(3) Alarm circuit to sound an alarm horn and illuminate a red lamp, both mounted at the local control panel.

(4) Alarm contacts of the maintained type rated at 10 amps continuous pilot duty.

(5) Overload device indicating meter enclosure: Weather proof steel, NEMA Type 4X.

d) Provide electrical supply to overload device as indicated on the Drawings. Include: (1) Electrical components of overload device compatible with

alarm devices. (2) Other electrical requirements as indicated on the Drawings.

2) Additional protection: a) Provide shear pins in the drive assembly for additional

protection above the shut-off torque rating. (1) This additional protection device shall function at

approximately 125 percent of continuous running torque. (2) Shear pins: Corrosion resistant material.

b) Provide limit switch or motion sensor that indicates breakage of the shear pin due to any circumstance. Shear pin fail indication shall be interlocked with motor controls to prevent mechanism from operating with a broken shear pin: (1) Materials: Corrosion resistant. (2) Electrical enclosure: NEMA Type 4X.

3) Alarm horn: a) Suitable for outdoor installation. b) Manufacturers: The following or equal:

(1) Federal Horn, Catalog Number 350W. 4) Alarm lamp:

a) Provide vapor-tight red alarm lamp suitable for outdoor installation.

5) Equipment identification plates: Provide 16-gauge stainless steel identification plate, securely mounted on equipment in readily visible location, bearing equipment identification tag number.


L. CLARIFIER ACCESSORIES: 1. Density current baffle:

a. The baffle system shall consist of a series of baffle panels which are attached to the wall of the clarifier and form an inclined, shelf-like surface around the entire inner periphery of the tank.

b. Construct panels of corrosion-resistant, UV-treated fiberglass-reinforced plastic: 1) For the resin, use an isophthalic polyester with corrosion-resistant

properties, 33-402 resin, or equivalent, which is typically used in submerged wastewater treatment applications.

2) Do not use any fillers in the resin except as required for viscosity control, for which, up to 5 percent by weight of a thixotropic agent may be added.

3) Treat the resin to provide ultraviolet suppression. c. Glass reinforcement to consist of chemically bonded surfacing mat and

copped strand roving, with the glass contents of the finished laminate to be not less than 30 percent by weight.

d. The nominal thickness of each baffle panel shall be 3/16 inches minimum. e. Attach the panels to the clarifier wall at a reinforced mounting flange and

support them at the proper angle with a triangular shaped bracket: 1) The brackets may be molded as an integral part of each panel, or

separate brackets may be supplied. 2) If separate brackets are supplied, the brackets shall be fabricated of

Type 316 stainless steel. f. Design the baffle to withstand a buoyant force load equal to the weight of

the water displaced from the volume beneath the baffle: 1) In addition, design the baffle to withstand common wind and snow

loads where applicable. 2) Provide sufficient pitch and width of the angle’s working surface of

the baffle to divert the flow and create a self-cleaning action of the baffle.

g. Include provisions to vent gases which may form beneath the baffle through the installation of vents located in the panel.

h. Manufacturer shall furnish certified test reports of the physical and mechanical properties of the product. Each panel shall have the following minimum physical properties:

Tensile Strength 5,000 psi per ASTM D638 Flexural Strength 16,000 psi per ASTM D790 Hardness Barcol 60 per ASTM D2583

i. Manufacturer shall also furnish certified design calculations and drawings showing details of installation.

j. Install the baffle as indicated on the Drawings and in accordance with the manufacturer’s recommendations: 1) For attachment of the baffle panels, use concrete expansion anchors

with neoprene-backed fender washers, lock washers and hex nuts. 2) Use Type 316 stainless steel for all the installation fasteners.

2. Equipment identification plates: Provide 16-gauge stainless steel identification plate, securely mounted on equipment in readily visible location, bearing equipment identification tag number.


M. SPARE PARTS AND SPECIAL TOOLS: 1. Spare parts: Furnish the following spare parts suitably packaged and marked.

Include a price list and name, address, and telephone number of local supplier: a. 2 sets of scum skimmer blade wear strips. b. 1 set of squeegees for each segmented scraper mechanism furnished. c. 1 set each of upper and lower sludge collection center manifold seals. d. 4 sets of shear pins. e. 1 set of scum skimmer wipers. f. 1 set each of oil seals for the worm shaft and pinion shaft (if used).

2. Special tools: Provide the following special tools: a. Tools required to assemble, disassemble, repair, and maintain equipment,

and that have been specifically made for use on the equipment, including jacking bolts and hardware, removable gussets, blocking, and any other components needed to remove main gear bearing from drive housing.

b. Necessary eyebolts, hooks, and rods for handling equipment parts. c. List of tools with the maintenance and operation data describing the uses

of the tools.

N. INSTALLATION: 1. Field welding:

a. Field welding is permitted only for the bridge splice. b. Field weld components as required for installation as indicated on the

Drawings. c. Use welding procedures, welders, and welding operators qualified and

certified in accordance with AWS D1.1. d. Shielded arc welding is required for all field welding and shall conform to

the shop drawing requirements. 2. Finishes:

a. Protect motors prior, clean equipment prior to coating. b. Coating systems:

1) As specified in Section 09960 - High-Performance Coatings. 2) Submerged surfaces: High solids epoxy. 3) Other surfaces: Epoxy-polyurethane. 4) Shop apply or field apply primer.

c. Shop applied primer: Use shop-applied primer compatible with the specified field coating system: 1) Smooth welds and prominences with power tools before applying

coatings. 2) Provide SSPC SP 5 (White Metal Blast Cleaning) to achieve a

uniform surface profile between 2.0 and 2.5 mils before coating. 3) Visit coating plants to observe and approve surface preparation

procedures and coating application of items to be shop primed: a) Coordinate plant visits with Owner's inspector. b) Notify Owner a minimum of 2 weeks prior to shop priming and

plant visits. 4) Provide NACE III inspector's reports from visits to coating plants to

observe and approve surface preparation and primer application. 5) Provide data sheets identifying the shop primer to on-site coating

application personnel. 6) Perform adhesion tests on the shop primer.


7) Field preparation of shop-primed surfaces: a) Smooth welds and prominences with power tools. b) Remove and recoat damaged, deteriorated, and poorly applied

shop coatings. c) Clean and dry shop-primed ferrous metal surfaces and

fabricated assemblies before applying field coats. d) Prepare shop epoxy primed surfaces with light abrasive blasting

or abrading and then vacuum before applying finish coats. 8) Damaged shop primer or rust bleeding: Clean in accordance with

SSPC SP1 (Solvent Cleaning), spot blast in accordance with SSPC SP 10 (Near-White Metal Blast Cleaning) to achieve a uniform surface profile between 2.0 and 2.5 mils before recoating.

d. Field primer: apply in the field. e. Finish coats: apply finish coats in the field.

3. Guardrailing with kickplate: Install on both sides of walkway and around center turntable as specified in the Project Technical Requirements.

4. Scum skimming system: Install counterweights designed and located by the manufacturer.

5. Center column: Mount center column vertically over influent port at center of basin floor.

O. COMMISSIONING: 1. As specified in Section OR-01757 - Commissioning and this Section. 2. Manufacturer services:

a. Provide certificates: 1) Manufacturer’s Certificate of Installation and Functionality

Compliance. b. Manufacturer’s Representative onsite requirements:

1) Installation: 1 trip, 1-day minimum. 2) Functional Testing: 1 trip, 1-day minimum each.

c. Training: 1) Maintenance: 2 hours per session, 2 sessions. 2) Operation: 2 hours per session, 2 sessions.

3. Functional testing: a. Clarifier drive:

1) Test witnessing: Witnessed. 2) Cutout torque test:

a) The manufacturer shall propose a method of conducting this test and shall verify that the method of testing will not impose stresses in members that exceed allowable stresses.

b) Perform cutout torque test prior to placement of grout topping on concrete slab.

c) Provide test results. 3) Adjustments and settings to overload device:

a) Adjustments and settings: Perform necessary adjustments and settings to overload device to ensure that sludge collector mechanism will sound an alarm and switch off drive motor when specified overload conditions occur in tank.

b) Test run: Perform test run following completion of adjustments and settings of overload device to confirm effectiveness of overload device.


4) Dry test run of equipment: a) Special attention: Give attention during dry test run of equipment

to operation of scum skimming device. b) Settings of skimmer boom to scum box lip and rubber wiping

and sealing strips: Set as required to ensure that adequate volume of scum is discharged under normal operating conditions.

2.11 AIRLIFT PUMPS

A. Manufacturer shall size the eductor tube, inlet and air supply sizes based on the design conditions provided by the sidestream manufacturer.

B. Airlift pump shall have a cast iron or stainless steel eductor tube with an easily removable top cover to allow tube to be cleaned in place.

C. The pump shall discharge at rates adjustable, by controlling the air supply valve.

D. The air line shall include a quick-disconnect coupling and an air supply control valve.

E. The pump and control valve shall be located so that it can easily be reached from the walkway.

F. SUBMITTALS: 1. Shop Drawings:

a. Detail drawings and manufacturer's literature to indicate compliance with the specified requirements.

b. Dimensional drawings. 2. Product Data. 3. Operation and Maintenance Manuals. 4. Manufacturer's Installation Instructions.

G. MANUFACTURERS: 1. One of the following or equal:

a. Walker. b. Hitech. c. Sanitaire.

H. MATERIALS: 1. Manufacturer shall furnish all stainless steel supports, anchor bolts, nuts,

washers and gaskets necessary for anchorage of airlift pump.

2.12 IFAS CONTROL PANEL – GENERAL

A. A.The IFAS supplier shall provide a PLC-based control panel to monitor and control the IFAS process. The PLC-based control panel shall include the PLC, operator display, control relays, push buttons and selector switches, indicating lights, power supplies, incoming power surge protector, analog isolators, signal conditioners, circuit breakers, and terminal strips.


B. The Contractor shall furnish and install all required equipment, including signal wiring, piping, terminations, incidental conduits, and necessary mounting and accessory equipment to provide a complete and operational system.

C. Quality Assurance: 1. All wiring and piping shall be installed in compliance with the best standard

practices and in accordance with the recommendations as set forth by the IFAS Supplier.

D. The Contractor will terminate all wiring within instrument cabinets at terminal blocks.

2.13 PLC CONTROL PANELS

A. Control Panel System Cabinets: 1. The IFASCP shall be located in climate controlled room at the WWTP and

shall be supplied in a NEMA 12 carbon steel enclosure suitable for inside use. The front panel of the cabinet shall contain operator interface and push buttons, as detailed within this specification. The PLC based control panel shall also include an operator interface display mounted on the front of the control panels. The internal portion of the cabinet shall contain all rack mounted PLC equipment, power supply, processor and interface cards. Relays, terminal strips and surge suppressors shall also be contained within the cabinet. Terminal strips for all field wiring shall be furnished within the panel. The panels shall be manufactured by Saginaw, or an approved equivalent.

2. An alarm horn shall be provided loose with the IFASCP. The contractor shall mount this horn adjacent to the IFASCP. The horn shall be manufactured by Federal Signal or an approved equivalent. A horn disconnect switch/circuit breaker shall be provided inside the IFASCP panel.

3. Circuit breakers shall be provided within the panel. A duplex outlet and fluorescent panel light shall be included within the panel.

4. One surge suppression device on the 120 VAC main supply line shall be installed. The power surge suppressor shall be equivalent to part #2856702 by Phoenix Contact.

5. On all analog input signals, current isolators shall be installed to galvanically separate external and internal 4-20 mA current loops. Current Isolators shall be equivalent to Phoenix Contact part #2864150.

6. All analog inputs and outputs shall also be protected from surges. The surge-arresting module shall combine coarse, medium and fine protection elements such as gas filled arrestors, varistors and suppressor diodes. The surge arresting modules shall be plug-in style allowing replacement of arrestors without removing field or panel wires. The analog surge arrestors shall be equivalent to Phoenix Contact part # 2838228.

7. Field I/O shall be terminated to field terminal blocks located inside the IFASCP. Terminal blocks shall be double level configuration, rated for 600VAC, 30Amps and accommodate wires sized 26AWG to 10AWG. The terminal blocks shall be Phoenix Contact UTTB4 3044814.

8. All digital outputs shall be provided with isolated relay contacts.


B. Devices for Operator Interface: 1. External face mounted devices for operator interface shall be as follows:

a. Push buttons and selector switches shall be SQ-D class 9001 30 mm, Telemecanique XB2 22 mm, or Allen Bradley series 800.

b. A Color Touchscreen Operator Interface Display shall be included and mounted on the front of the enclosure. The Display shall allow the operator to view and modify system variables within the PLC. The display shall be a minimum of 6 in., and be capable of communicating via Ethernet to the PLC located within the IFASCP. The unit shall include a real-time clock with battery back-up, color touchscreen or keypad / touchscreen combination, color active matrix thin film transistor display, and minimum resolution 320 x 240 pixels. The unit shall be manufactured by Allen Bradley or approved equivalent.

C. PLC-based Control Panel I/O Field Interface Signals: 1. All PLC ladder logic shall reside within the PLC based control panel. The PLC

ladder logic shall perform all necessary process monitoring and control for the Oxidation Ditch System and associated equipment.

2. All necessary I/O cards shall be supplied to monitor and control the field signals listed within the IO list at the end of this specification. All PLC and I/O racks shall be supplied with 10 percent spare I/O.

D. Control Panel Components: 1. The PLC-based Control Panel supplied shall consist of the following

components: a. NEMA 12 freestanding control panel. b. PLC CPU Card. c. PLC I/O Racks. d. PLC Field Interface Cards. e. Operator Interface Display. f. Power Supply. g. Alarm Horn. h. Signal Isolators. i. Surge Protectors. j. Circuit Breakers. k. Terminal Strips. l. Miscellaneous Wire and Panduit.

2.14 PROGRAMMABLE LOGIC CONTROLLER SUBSYSTEM

A. Programmable Logic Control System Submittals shall include: 1. Block Diagram: A diagram showing all major PLC components. Identify

components by manufacturer and model number. Show interconnecting cables diagrammatically.

2. Bill of Materials: A list of all PLC components. Group components by type and include: a. Component manufacturer, model number and part number. b. Component description. c. Quantity supplied. d. Reference to component catalog information.


3. Descriptive Information: Catalog information, descriptive literature, performance specifications, internal wiring diagrams, power and grounding requirements, power consumption, and heat dissipation for all elements of the PLCS. Clearly mark all options and features proposed for this project.

4. Interconnecting Wiring Diagrams: Diagrams shall show all PLC elements, their interconnecting cables, wiring terminations, and terminations to all interacting elements and subsystems. Terminations shall be numbered. Terminations for circuits extending outside PLC assemblies and/or having housing panels shall be labeled with circuit names corresponding to the Circuit and Raceway Schedule. The external circuit portion of this diagram shall be coordinated with the Electrical Subcontractor and shall bear his mark showing that this work has been done.

5. Outline Drawings: Equipment envelope drawings showing: external dimensions, enclosure materials, conduit connections, and installation requirements.

6. Installation Details: Any modifications or further details as may be required to supplement the Contract Documents and adequately define the installation of the PLC elements.

7. Input/Output List: For each I/O point list point type, tag number of the source or final control element, equipment description, PLC number, PLC terminal identification, and PLC address.

B. Factory Testing: 1. All non-loop specific functions shall be tested, including, but not limited to:

a. Failure mode and backup procedures: power failure, auto restart, disk backup and reload, and retentive outputs.

b. Operator Interface (Located at IFASCP). c. All IO (Analog Inputs, Analog Outputs, Digital Inputs, and Digital Outputs)

will be confirmed for proper operation form the PLC to the terminals within the PLC Control Panel.

d. Programming and documentation methods and features.

C. Functional Requirements: 1. The PLC system shall be used for monitor and control of the Oxidation Ditch

process. The operations described herein are intended to identify minimum acceptable performance. The Contractor shall provide all hardware and software features required to make the PLC panel totally operational.

D. Manufacturers: 1. Allen-Bradley. 2. Substitutions with Engineer’s approval only.

E. Product Description: 1. Programmable Logic Controller with the required memory and functional

capacity to perform the specified sequence of operation with the scheduled input and output points.

F. Common Hardware Ratings: 1. Operating Temperature of range of 0 degrees to +60 degrees C (+32 degrees

to +140 degrees F). 2. Storage Temperature range of minus 40 degrees to +85 degrees C. 3. Humidity range of 5 to 95 percent non-condensing.


4. Vibration Rating of 2.0G maximum peak acceleration for 10 to 500Hz. 5. Operating shock rating of 30G peak for 11 milliseconds. Storage shock rating

of 50G for 11 milliseconds. 6. Hazardous Environmental Rating: Class 1, Division 2.

G. Configurations: 1. The controller’s programming environment must be a pure “tag-based”

environment, not requiring the use of controller memory addressing. The programmer must not be burdened with mapping/organizing memory addresses.

2. The “tag-based” environment must be created only once, and available to the HMI/EOI interface not requiring any import/export.

3. The development environment should automatically create device (I/O and network devices) and logic instruction “tag structures”, consisting of related command, status, and diagnostic information.

4. One must be able to access a device on a network(s) multiple levels removed without having to develop communication logic or network tables.

5. The programmable controller, associated I/O, chassis and powersupplies shall be of a modular design. The programmable controller and I/O modules shall mount into the chassis. Fixed block control modules are not acceptable.

6. Processor Systems shall include processor, power supply, input/output modules, communication modules and remote interface modules as required to meet system requirements.

7. Remote Input/Output Units shall include input/output modules, interface modules, communication modules, and power supply to meet system input and output requirements.

8. Modules are to be supplied as specified unless system requirements dictate the use of alternative modules.

H. Selection: 1. The programmable controller shall be selected from a family of programmable

controllers with memory capability ranging from 64Kbytes to 7.5Mbytes. 2. All system and signal power to the Controller and support modules shall be

distributed on a single motherboard or backplane. No interconnecting wiring between these modules via plug-terminated jumpers shall be acceptable.

3. All system modules including the processor shall be removable from the chassis or inserted in to the chassis while power is being supplied to the chassis without faulting the processor or damaging the modules.

4. All system modules, local and remote chassis shall be designed to provide for free airflow convection cooling. No internal fans or other means of cooling, except heat sinks, shall be permitted.

5. Modules shall be designed to plug into a chassis and to be keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules as well as safeguard against the insertion of a module into the wrong slot or chassis via an electronic method for identifying a module. Electronic keying shall perform an electronic check to insure that the physical module is consistent with what was configured.

I. Programming Language: 1. Ladder Logic.


J. Programming Software: 1. Include one licensed programming package for use with general purpose

microcomputer and Microsoft Windows NT, Windows 2000 or Windows XP operating systems.

2. Provide one licensed communication package. 3. Programming Package: RSLogix5000 Standard, CD ROM. 4. Communication Package: RSLinx for Allen-Bradley, CD ROM. 5. Network Package: RSNetWorx for ControlNet.

K. Minimum Programming Instruction Set: 1. Language Characteristics: Ladder diagram. 2. Logic Operations: AND, OR, XOR, NOT. 3. Register Operations: Store, recall. 4. Math Operations: Addition, subtraction, multiplication, division, square root,

matrix operations. 5. Process Control: Proportional-Integral-Derivative.

2.15 PROCESSOR UNIT

A. Manufacturer: 1. Allen-Bradley Model 1756. 2. Substitutions: Not Permitted.

B. Processor Memory: 1. Program memory of 64 Kbytes to 7.5 Mbytes Words. 2. The CPU shall be a self-contained unit providing control program execution

and supporting remote or local programming. This device shall supply I/O scanning, inter-processor communication functions and peripheral communication functions.

3. Base memory shall be available for user program and data. The base memory will exclusively contain all I/O tags even if expansion memory is installed. Non I/O tags and ladder logic shall be stored in base memory and optional expansion memory.

4. Memory capacity shall be configurable to allow for the most economical match to the intended application. It shall be possible to upgrade to a processor with a larger memory size simply by saving and downloading the program to the new system without having to make any program changes.

5. The operator should be able to backup volatile memory, including data and program logic onto a personal computer storage disk.

6. All user memory in the processor not used for program storage shall be allocable from main memory for the purpose of data storage.

C. Performance: 1. The Programmable Controller shall use multiple independent, asynchronous

scans. These concurrent scans shall be designated for processing of input and output information, program logic, and background processing of other processor functions. Input and output devices located in the same backplane (local I/O) as the CPU will produce at the rate of configured RPI Requested Packet Interval), and for inputs enabled for Change Of State (COS), at the time any point changes state.

2. Bit Execution Time of less than 0.15 microseconds.


3. Proportional Integral Derivative Control with an execution time between 310 to 425 microseconds.

4. Online programming including runtime editing. 5. The Programmable Controller system shall have the ability to communicate

with multiple remote I/O racks or devices configured with multiple I/O modules. The remote I/O networks shall include RIO, Ethernet, ControlNet, and DeviceNet.

6. The Programmable Controller shall have the ability to support multiple data communications links by using Ethernet, DH+, ControlNet, and DeviceNet modules.

7. The user program and data shall be contained in non-volatile battery backed memory. The operating system shall be contained in non-volatile firmware. The memory containing the operating system shall be field updateable via a separate update tool.

8. The Programmable controller shall have the ability to be updated electronically to interface with new modules.

D. Features: 1. The program storage medium shall be of a static battery backed RAM type. 2. The front panel of the Controller shall include a holder and a connector for a

lithium battery. The battery shall provide power backup for user programs and data when the main power supply is not available.

3. The front panel of the Controller shall include a mounted keyswitch with the following control modes: a. RUN – No control logic edits possible, program always executing. b. PROGRAM – Programming allowed, program execution disabled. c. REMOTE – Programming terminal can make edits and change processor

mode, including test mode, whereby the logic executes and inputs are monitored, but edits are not permanently active unless assembled.

4. The front panel on the Controller shall include color indicators showing the following status information: a. Program or Run mode of the controller. b. The fault status of the controller. c. Input and output status. d. RS-232 activity. e. Battery status.

5. The CPU within the system shall perform internal diagnostic checking and give visual indication to the user by illuminating a “green” (OK) indicator when no fault is detected and a “red” indicator when a fault is detected.

6. The front panel of the Controller shall include a 9-pin D-shell serial RS232 port, which supports DF1.

7. Real Time Clock. 8. Processor shall be capable of supporting a back-up scheme if specified.

2.16 CHASSIS-BASED DISCRETE INPUT AND OUTPUT MODULES



B. Selection: 1. All digital input and output modules shall be manufactured and supplied by the

manufacturer of the programmable controllers. 2. Modules shall support producer / consumer communications. Digital modules

shall multicast their data either upon Change of State or periodically depending upon configuration.

3. Digital input and output modules shall provide ON/OFF detection and actuation. They shall utilize the producer consumer network model to produce information when needed while providing additional system functions.

4. The controller shall not poll digital input modules; instead, the modules shall multicast their data either upon Change of State or periodically based upon configuration. The frequency shall depend upon the configuration and where in the control system that input module physically resides.

5. When a digital output module receives data from the controller, it shall immediately multicast the output commands to the rest of the system. The digital output modules shall utilize Output Data Echo (the output module shall echo the output data as input data and multicast it back out onto the network.)

C. Module Features: 1. Modules shall be connected directly to the ControlBus backplane via a

ControlBus Connector. 2. Modules shall have a locking tab to anchor the removable terminal block

(RTB) or Interface Module (IFM). 3. Modules shall have slots for mechanically keying the RTB to prevent making

the wrong wire connections to the module. 4. Modules shall be designed to be installed or removed while chassis power is

applied. 5. Modules shall have indicators to display the status of communication, module

health and input / output devices. 6. Each module shall have the following status indicators:

a. Yellow display to indicate the On/Off state of the field device. b. Green display to indicate the module’s communication status. c. This display shall be available on diagnostic modules to indicate the

presence or absence of various faults. 7. Each digital module shall maintain the following identification information:

a. Modules product type such as analog or digital. b. Modules catalog number. c. Modules major revision number. d. Modules minor revision number. e. Module manufacturer vendor. f. Module serial number.

8. Each digital module shall maintain the following status information: a. Controller ownership. b. Configuration status. c. Device specific status information. d. Minor and major recoverable and unrecoverable faults.

9. Each digital module shall provide the following fault reporting. a. On diagnostic modules, hardware indication shall be provided through. b. module’s LED fault indicator.


c. Modules shall have an input data tag, Fault, which indicates that a point is faulted and input data or output data for that point may be incorrect. If communication to the module is lost, then all points for the module will be faulted.

d. The programming package shall graphically display the fault and shall include a fault message describing the nature of the fault.

10. Module features shall be enabled or disabled through the I/O configuration portion of the programming package.

11. Programming package shall be capable of interrogating any module in the system to retrieve serial number, revision number, catalog number, vendor identification, error/fault information and diagnostic counters.

12. Electronic Keying shall be available through configuration to allow the system to control what modules belong in the various slots of the configured system. The following keying options shall be available.

D. Module Specifications (120 V AC Diagnostic Input Module): 1. Quantity of eight, sixteen or thirty-two inputs. 2. On-State Voltage Range of 79-132V ac, 47-63Hz. 3. Nominal Input Voltage of 120V ac. 4. On-State Current of 16mA at 132V ac, 47-63Hz maximum. 5. Maximum Off-State Voltage of 20V. 6. Maximum Off-State Current of 2.5mA. 7. Maximum Input Impedance of 8.25kOhm at 60Hz. 8. Input Delay Times:

a. Off to On - Programmable Filter, 1ms and 2ms. b. Hardware Delay - 10ms maximum plus filter time. c. On to Off - Programmable filter, 9ms and 18ms. d. Hardware Delay - 8ms maximum plus filter time.

9. Diagnostic Features: a. Open Wire - Off state leakage current of 1.5mA minimum. b. Loss of Power - Transition range 46 to 85V ac. c. Time Stamp Diagnostics of +/- 1ms. d. Change of State - Software Configurable. e. Time Stamp of Inputs of +/- 200 microseconds. f. Fault Data Tag to indicate that point is faulted.

10. Isolation Voltage: a. Group to Group - 100 percent tested to 2546V dc for 1s. b. User to System - 100 percent tested to 2546V dc for 1s.

E. Module Specifications (120 V AC Isolated Input Module): 1. Quantity of eight, sixteen or thirty-two individually isolated inputs. 2. On-State Voltage Range of 79-132V ac, 47-63Hz. 3. Nominal Input Voltage of 120V ac. 4. On-State Current of 15mA at 132V ac, 47-63Hz maximum. 5. Maximum Off-State Voltage of 20V. 6. Maximum Off-State Current of 2.5mA. 7. Maximum Input Impedance of 8.8kOhm at 60Hz. 8. Input Delay Times:

a. Off to On - Programmable Filter, 1ms and 2ms. b. Hardware Delay - 10ms maximum plus filter time. c. On to Off - Programmable filter, 9ms and 18ms. d. Hardware Delay - 8ms maximum plus filter time.


9. Diagnostic Features: a. Change of State - Software Configurable. b. Time Stamp of Inputs of +/- 200 microseconds. c. Fault Data Tag to indicates that point is faulted.

10. Isolation Voltage: a. Group to Group - 100 percent tested to 2546V dc for 1s. b. User to System - 100 percent tested to 2546V dc for 1s.

F. Module Specifications (120 V AC Diagnostic Output Module): 1. Quantity of eight or sixteen Outputs. 2. Output Voltage Range of 74-132V ac, 47-63Hz. 3. Output Current Rating.

a. Per Point - 1A maximum at 30 degrees C; 0.5A maximum at 60 degrees C; Linear Derating.

b. Per Module - 8A maximum at 30 degrees C; 4A maximum at 60 degrees C; Linear Derating.

4. Surge Current Per Point of 8A for 43ms each, repeatable Every 2s at 30 degrees C; 5A for 43ms each, repeatable every 1s at 60 degrees C.

5. Minimum Load Current of 10mA per point. 6. Maximum On-State Voltage Drop of 2.5V peak at 0.5A and 3V peak at 1A. 7. Maximum Off-State Leakage of 3mA per point. 8. Output Delay Time:

a. Off to On - 9.3ms at 60Hz, 11ms at 50Hz. b. On to Off - 9.3ms at 60Hz, 11ms at 50Hz.

9. Diagnostic Features: a. Short Trip - 12A for 500microseconds minimum. b. No Load - Off state detection only. c. Output Verification - On State detection Only. d. Pulse Test - On and Off State Detection. e. Field Power Loss - Detects at 25V peak minimum. f. Time Stamp Diagnostics - + / -1ms. g. Fault Data Tag to indicate that point is faulted and data may be incorrect.

10. Configurable States: a. Fault Per Point - Hold Last State, ON or OFF. b. Program Mode Per Point - Hold Last State, ON or OFF.

11. Scheduled Outputs - Synchronization within 16.7s maximum, reference to CST.

12. Isolation Voltage: a. Group to Group - 100 percent tested at 2546V dc for 1s. b. User to System - 100 percent tested at 2546V dc for 1s.

G. Module Specifications (Contact Output Module): 1. Quantity of eight or sixteen (Individually Isolated) Outputs. 2. Output Voltage Range of 10-265V ac, 47-63Hz. 3. Output Current Rating:

a. Resistive - 2A at 125V ac. b. Inductive - 2A Steady State, 15A make at 125V ac.

4. Power Rating (Steady State) of 250VA maximum for 125V ac inductive output. 5. Maximum Off-State Leakage of 1.5mA per point. 6. Output Delay Time:

a. Off to On - 10ms maximum. b. On to Off - 10ms maximum.


7. Diagnostic Feature - Fault Data Tag to indicate that point is faulted and data may be incorrect.


9. Scheduled Outputs - Synchronization within 16.7s maximum, reference CST. 10. Isolation Voltage:

a. Group to Group - 100 percent tested at 2546V dc for 1s. b. User to System - 100 percent tested at 2546V dc for 1s.

2.17 CHASSIS-BASED ANALOG INPUT AND OUTPUT MODULES


B. Selection: 1. All digital input and output modules shall be manufactured and supplied by the

manufacturer of the programmable controllers. 2. Modules shall support producer / consumer communications. Digital modules

shall multicast their data either upon Change of State or periodically depending upon configuration.

3. Analog input modules shall convert an analog signal that is connected to the module’s screw terminals into a digital value. The digital value representing the magnitude of the analog signal shall be transmitted on the backplane. Analog output modules shall convert a digital value that is delivered to the module via the backplane into an analog signal on the module’s screw terminals.

C. Module Features: 1. Modules shall be connected directly to the ControlBus backplane via a

ControlBus Connector. 2. Modules shall have a locking tab to anchor the removable terminal block

(RTB) or Interface Module (IFM). 3. Modules shall have slots for mechanically keying the RTB to prevent making

the wrong wire connections to the module. 4. Modules shall be designed to be installed or removed while chassis power is

applied. 5. Modules shall have indicators to display the status of communication, module

health and input / output devices. 6. Each analog module shall have the following status indicators:

a. Calibration Status – Indicates when your module is in the calibration mode.

b. Calibration Status – Indicates when your module is in the calibration mode.

7. Each analog module shall maintain the following: serial number, vendor, product type, catalog number, major revision and minor revision.

8. Each analog module shall provide both hardware and software indication when a module fault has occurred. Each module shall have an LED fault indicator and the programming software shall display the fault information.


9. Electronic Keying shall be available through configuration to allow the system to control what modules belong in the various slots of the configured system. The following keying options shall be available. Each digital module shall maintain the following identification information. a. Exact match – Parameters (Vendor, Product Type, Catalog Number,

Major Revision and Minor Revision) must be an exact match for the module.

b. Compatible match – Parameters (Vendor, Product Type, Catalog Number and Major Revision) must be an exact match for the module to allow a connection to the controller. The parameter minor, revision must be greater than or equal to that of the configured slot.

c. Disable keying – The inserted module will accept a connection to the controller regardless of its type.

10. Analog modules shall be software configurable through the I/O configuration portion of the programming software.

11. Modules shall be capable of being configured to access the controllers system clock to timestamp input data or to output echo data when the module multicasts to the system.

12. Analog modules shall multicast status / fault data to the owner / listening controllers with their channel data. The following tags shall be capable of being examined in ladder logic. a. Module Fault Word – Provides fault summary reporting. b. Channel Fault Word – Provides under-range, over-range and

communications fault reporting. c. Channel Status Words – Provides individual channel under-range and

over-range fault reporting for process alarm, rate alarms and calibration faults.

D. Module Specifications (Isolated Analog Input Module): 1. Quantity of six (Individually Isolated) Inputs. 2. Input Range of +/-10.5V, 0-10.5V, 0-5.25V, 0-21mA. 3. Resolution of approximately 16 bits across range. 4. Input Impedance of Greater than 10Mohms Voltage, 249Ohms Current. 5. Open Circuit Detection - Positive full scale reading within 5s. 6. Overvoltage Protection:

a. Voltage Range - 120V ac/dc. b. Current Range - 8V ac/dc with on-board current resistor.

7. Normal Mode Rejection of 60dB at 60Hz. 8. Common Mode Noise Rejection of 120dB at 60Hz, 100dB at 50Hz. 9. Isolation Voltage:

a. Channel to Channel - 100 percent tested at 1700V dc for 1s based on 250V ac.

b. User to System - 100 percent tested at 1700V dc for 1s based on 250V ac.

E. Module Specifications (Isolated Analog Output Voltage Module): 1. Quantity of six (Individually Isolated) Outputs. 2. Output Voltage Range of +/- 10.5V maximum. 3. Voltage Resolution of 13 bits across 10.5V; 14 bits across 21V. 4. Data Format - Integer mode; Floating Point IEEE 32 bit. 5. Open Circuit Detection – None. 6. Output Overvoltage Protection - 24V ac/dc maximum.


7. Output Short Circuit Protection - Electronically current limited. 8. Calibration Accuracy of - Better than 0.1 percent of range. 9. Calibration Interval - 12 months typical. 10. Isolation Voltage:



F. Module Specifications (Isolated Analog Current Voltage Module): 1. Quantity of six (Individually Isolated) Outputs. 2. Output Current Range of 0 to 21mA. 3. Current Resolution of 13 bits across 21m. 4. Data Format - Integer mode; Floating Point IEEE 32 bit. 5. Open Circuit Detection – None. 6. Output Overvoltage Protection - 24V ac/dc maximum. 7. Output Short Circuit Protection - 21mA or less (electronically limited). 8. Calibration Accuracy - Better than 0.1 percent of range from 4mA to 21mA. 9. Calibration Interval - 12 months typical. 10. Isolation Voltage:



2.18 CHASSIS-BASED HIGH SPEED COUNTER MODULE


B. Selection: 1. The high-speed counter module shall provide high speed counting. 2. The high-speed counter module shall interface to the controller through the

ControlNet network.

C. Module Feature: 1. The module shall periodically multicast its status to the controller. The owner

controller shall not scan the high-speed counter module. 2. Utilizing the programming software, it shall be possible to configure additional

controllers in a “Listen Only” mode for the high-speed counter module. In this mode the controllers shall be capable of receiving the data multicast from the high-speed counter module.

D. Module Specification: 1. Quantity of two counters. 2. Inputs Per Counter - Three (3) – A, B, Z for Gate/Reset). 3. Maximum Input Frequency:

a. 1 MHz in counter modes (A Input). b. 500KHz in rate measurement mode. c. 250KHz in encoder mode. d. 50Hz with debounce filter enabled.


4. Count Range of 0 – 16,777,214. 5. Input Voltage Range of 4.5-5.5V dc for 5V inputs; 10-26.4V dc for 12-24V

inputs. 6. Input Current - 15mA (Typical); 4mA (Minimum). 7. Number of Outputs - Four (Two Outputs/Common). 8. Output Voltage Range of 4.5-5.5V dc; 10-31.2V dc. 9. Output Current Rating of 20mA per point at 4.5-5.5V dc ; 1.0A per point at

10-31.2V dc. 10. Surge Current Rating of 2A for 10 ms every 1s at 60 degrees C. 11. Minimum Load Current of 3mA per point for 5V operation; 40mA per point for

12- 24V operation. 12. Maximum On-State Voltage of 0.55V (Drop/Output). 13. Maximum Off-State Leakage of 300 microAmp/point (Current/Output). 14. Output Delay Time:

a. Off to On - 20 microseconds typical; 50 microseconds max. b. On to Off - 60 microseconds typical; 300 microseconds max.

15. Current Limit of Less than 4 Amps. 16. Output Short Protection – Electronic. 17. Reverse Polarity Protection – Yes. 18. Isolation:

a. Group to Group - 100 percent tested at 1700V dc for 1s. b. User to System - 100 percent tested at 1700V dc for 1s.

2.19 POWER SUPPLIES


B. Selection: 1. All power supplies, in local and remote chassis, shall be mounted on side of

chassis. 2. Choose the power supplies to meet the current requirement based on the

maximum draw of the modules plus (10) percent spare. 3. The modules shall include processors, all input / output modules, specialty

modules and spare requirements.

C. Features: 1. Line Voltage rating of 85 to 265Vac, 47-63Hz. 2. Automatically shut down the Programmable Controller system whenever its

output power is detected as exceeding 125 percent of its rated power. 3. Provide surge protection, isolation, and outage carry-over up to 2 cycles of the

AC line. 4. Provide a failsafe fuse that is not accessible by the customer. 5. Green LED indicator that is ON during normal operation. 6. Accept number 14 AWG (single wire only)per terminal maximum.

2.20 CHASSIS



B. Selection: 1. Provide panel mounted chassis as required for the project. 2. A maximum of (2) chassis configurations shall be utilized on the project.

C. Features: 1. Panel Mount Chassis Size: 4, 7, 10, 13 or 17 slot as required to meet Project

Requirements. 2. No tools shall be required for insertion of modules.

2.21 COMMUNICATION INTERFACES

A. Controlnet Network : 1. Each I/O and Controller chassis shall interface to the ControlNet network

through a ControlNet Interface Module located in the chassis. 2. The module shall provide connection to a redundant ControlNet network. 3. The module shall meet the following minimum specifications.

a. The module shall be capable of being located in any slot in the chassis. b. The module shall have two (2) BNC connectors for redundant media

operation. c. The module shall have one Network Access Port (RJ-45, 8–pin with

shield). d. The acceptable cable shall be Quad-shield RG-6 coaxial cable.

B. Devicenet Network: 1. When required for DeviceNet network communications, provide a DeviceNet

Interface Module mounted in the chassis. 2. The module shall communicate with a ControlLogix controller via the chassis

backplane. 3. The module shall communicate with DeviceNet devices over the network.

a. The module shall read and write inputs and outputs to and from a device. b. The module shall download configuration data to a device. c. The module shall monitor operational status of a device.

4. The module shall meet the following minimum specifications. a. The module shall support 125Kbps, 250Kbps or 500Kbps communications

rates. b. The module shall allow for two (2) connections to a dedicated

ControlLogix controller. c. The module shall have an operating shock rating of 30g peak for 11ms. d. The module shall have a storage shock rating of 50g peak for 11ms. e. The module shall have a vibration rating of 10 to 150Hz, 5.0G maximum

peak acceleration.

C. Ethernet Network: 1. When required for Ethernet network communications provide an Ethernet

Interface Module mounted in the chassis. 2. The Ethernet module shall support gateway communications of control and

Information through Ethernet to the ControlNet network. 3. The module shall support AUI, 10 Base-T media, and 100 Base-T media. 4. The module shall use standard TCP/IP protocol. 5. The module shall support gateway communications to and from other modules

in the same chassis. 6. The module shall mount in an I/O chassis.


7. There shall be no limit on the number of modules per chassis. 8. The module shall meet the following minimum specifications:

a. Ethernet Connection shall be provided by an AUI or RJ45 connector. b. Conductors shall be 802.3 compliant, twisted pair or AUI, Category 2. c. Communication shall be Standard TCP/IP, BOOTP Enabled, SNMP

protocol at the MIB II level. d. Configuration shall be done through Gateway Configuration Software. e. Indicators shall be provided to indicate Module Status, Data Transmission

and Data Reception. f. The module shall have an unpackaged shock rating of 30g operational

and 50g non-operational. g. The module shall have an unpackaged vibration rating of 5g from

10-150Hz.

D. Remote I/O and Data Highway Plus Networks: 1. When required for Remote I/O and Data Highway Plus communications,

provide a Data Highway Plus and Remote I/O Communication Interface Module.

2. The module shall support messaging between devices on Data Highway Plus networks and those on Ethernet, ControlNet or DeviceNet.

3. The module shall act as a Remote I/O scanner to allow for transferring discrete and block-transfer data to and from Remote I/O devices.

4. The module shall meet the following minimum specifications. a. The module shall support a communication rate of 57.6Kbps for Data

Highway Plus and communication rates of 57.6Kbps, 115Kbps or 230Kbps for Remote I/O.

b. The module shall allow for (32) connections per Data Highway Plus channel.

c. The module shall allow for (32) logical rack connections per Remote I/O channel and (16) block-transfer connections per remote I/O channel.

d. The module shall have an operating shock rating of 30g peak for 11ms. e. The module shall have a storage shock rating of 50g peak for 11ms. f. The module shall have a vibration rating of 10 to 150Hz, 5.0G maximum

peak acceleration.

E. RS-232 Network: 1. When required to communicate with RS-232 devices, provide an RS-232

Interface Module. 2. The module shall support custom application C language programming to

enable the module to send, receive and process ASCII strings to an RS-232 device.

3. The module shall be capable of being installed in any location in the chassis. Remote mounted devices are not acceptable.

4. The module shall meet the following minimum specifications. 5. The module shall have one (1) non-configurable RS-232 port. 6. The module shall have two (2) RS-232 ports configurable for RS-232/RS-

422/RS-485. 7. The module shall have the following status indicators:

a. The module shall have Port Activity status indicators to indicate if serial activity is detected at a port. Indicators shall exist for each port.

b. The module shall have a quantity of two (2) user definable status indicators.


c. The module shall have an indicator to indicate if the battery voltage is low. d. The module shall have an indicator to indicate that either Power is ON,

Power is OFF or the Module has failed. e. All indicators shall be LED.

8. The module shall have an operation shock rating of 30g and a non- operational rating of 50g.

9. The module shall have a vibration rating of 2g from 10 to 500Hz.

2.22 DISTRIBUTED I/O - DISCRETE INPUT AND OUTPUT MODULES

A. The Distributed I/O Sub-System shall be networked to the Control Processor over ControlNet, Devicenet or Ethernet/IP.

B. Manufacturer: 1. Allen-Bradley Model 1734 (Point I/O). 2. Substitutions: Not Permitted.

C. Selection: 1. All digital input and output modules shall be manufactured and supplied by the

manufacturer of the programmable controllers. 2. Modules shall be designed to support DeviceNet, ControlNet and Ethernet/IP.

The Distributed I/O System shall support producer / consumer communications, and shall support Change of State reporting to the POINT I/O network interface (adapter).

3. Digital input and output modules shall provide ON/OFF detection and actuation. They shall support producer consumer network model (via the 1734 adapter) to produce information when needed while providing additional system functions.

4. The ControlNet adapter shall not poll digital input modules; instead, the modules shall report their data upon Change of State.

D. Module Features: 1. Modules shall be connected directly to the Control Logix network via a POINT

I/O Control Net Adapter with Redundant media (using COS, change of state) or a POINT I/O DeviceNet Adapter with configurable POINT Bus communications, or a POINT I/O Ethernet/IP Adapter (using COS, change of state).

2. Modules shall have a locking tab to anchor the removable electronics module. 3. Modules shall have slots for mechanically keying the electronic module to

prevent inserting an incorrect electronic module. 4. Modules shall have electronic IDs for electronic keying the electronic module

to prevent the operation of a module inserted incorrectly into a slot where the mechanical keying has been incorrectly set.

5. Modules shall be designed to be installed or removed while I/O system power is applied (Removal and Insertion Under Power – RIUP).

6. Modules shall have indicators to display the status of communication, module health and input / output devices.

7. Each module shall have the following status indicators. a. Yellow display to indicate the On/Off state of the field device. b. Green/Red display to indicate the module’s communication status. c. Green/Red display to indicate the module’s fault status.


d. This display shall be available on all modules to indicate the presence or absence of various faults.

8. Each digital module shall maintain the following identification information. a. Modules product type such as analog or digital. b. Modules catalog number. c. Modules major revision number. d. Modules minor revision number. e. Module manufacturer vendor. f. Module serial number.

9. Each digital module shall maintain the following status information. a. Controller ownership. b. Configuration status. c. Device specific status information. d. Minor and major recoverable and unrecoverable faults.

10. Each digital module shall provide the following fault reporting. a. On diagnostic modules, hardware indication shall be provided through

module’s LED fault indicator. b. Modules shall have an input data tag, Fault, which indicates that a point is

faulted and input data or output data for that point may be incorrect. If communication to the module is lost, then all points for the module will be faulted.

c. The programming package shall graphically display the fault and shall include a fault message describing the nature of the fault.




14. Field wiring shall be connected to the digital input modules through a wiring system provided by the manufacturer of the modules. Fault protected (reverse polarity, short circuit) interface modules shall be provided as standard. If protected interfaces are not available for the specified module, feed-through interface modules shall be provided. The wiring system shall consist of the following. a. Protected/Current Limiting Digital Interface Module. b. Thermally activated current limiting devices. c. Current Limiting active indication. d. Diagnostic bit available to the controller. e. UL Component Recognition. f. Wire Range of #22 to #14 AWG.

E. Module Specifications (24 V DC Diagnostic Input Module): 1. Quantity of eight, sixteen or thirty-two inputs. 2. On-State Voltage Range of 10-28.8V dc. 3. Nominal Input Voltage of 24V dc. 4. On-State Current of 4mA nominal at 24V dc or 6.3ma nominal at 24Vdc. 5. Maximum Off-State Voltage of 5V dc. 6. Minimum Off-State Current of 1.5mA. 7. Nominal Input Impedance of 3.6kOhm.


8. Input Delay Times: a. 0.5 millisecond hardware filter plus 0ms to 64ms programmable digital

filter. 9. Diagnostic Features – LEDs:

a. Input status. b. Module Status. c. POINTBus Status.

10. Diagnostic Features – LEDs: a. Input status. b. Module Status. c. Fault Status.

11. Isolation Voltage: a. User to System - 100 percent tested to 1250V rms/V ac. b. Group to Group - not required on 2 and 4 point modules.

F. Module Specifications (120 V AC Diagnostic Input Module): 1. Quantity of eight, sixteen and thirty-two inputs per electronic module. 2. On-State Voltage Range of 65-132V ac, 60Hz. 3. Nominal Input Voltage of 120V ac. 4. On-State Current of 6.9mA nominal at 120V ac, 60Hz maximum. 5. Maximum Off-State Voltage of 43V ac. 6. Maximum Off-State Current of 2.5mA. 7. Nominal Input Impedance of 10.6kOhm at 60Hz. 8. Input Delay Times:

a. Off to On - Programmable Filter, 1ms to 64ms, increments of 1ms. b. Hardware Delay - 20ms maximum plus filter time. c. On to Off - Programmable Filter, 1ms to 64ms, increments of 1ms. d. Hardware Delay - 20ms maximum plus filter time.

9. Diagnostic Features: a. Change of State – Pre-programmed. b. Fault Data Tag to indicate that point is faulted.

10. Isolation Voltage: a. Group to Group - 100 percent tested to 2546V dc for 1s. b. User to System - 1250V rms/V for 1 second.

G. Module Specifications (24 V DC Diagnostic Output Module): 1. Quantity of eight, sixteen or thirty-two Outputs. 2. Output Voltage Range of 10 to 28.8V dc. 3. Output Current Rating:

a. Per Point - 1Amps maximum per output. b. Per Module – 2Amps maximum per module.

4. Surge Current Per Point of 2A for 10ms each, repeatable every 3 seconds. 5. Minimum Load Current of 1.0mA per point. 6. Maximum On-State Voltage Drop of 0.2V. 7. Maximum Off-State Leakage of 0.5mA per point. 8. Output Delay Time:

a. Off to On – 0.1ms. b. On to Off – 0.1ms.

9. Diagnostic Features: a. Short Circuit for On State. b. Open Circuit for Off State. c. Over Current for On State.


d. Fault Data Tag to indicate that point is faulted and data may be incorrect. 10. Configurable States:

a. Fault Per Point - Hold Last State, ON or OFF. b. Program Mode Per Point - Hold Last State, ON or OFF.

11. Isolation Voltage: a. User to System - 1250V rms/V ac.

H. Module Specifications (120 V/ 220 V DC Diagnostic Output Module): 1. Quantity of eight or sixteen Outputs. 2. Output Voltage Range of 74 to 264V ac. 3. Output Current Rating:

a. Per Point - .75Amps maximum per output. b. Per Module – 1.5 Amps maximum per module.

4. Surge Current Per Point of 16A for 100ms each, repeatable every 10 seconds. 5. Minimum Load Current of 10.0mA per point. 6. Maximum On-State Voltage Drop of 1.0V Maximum at .75A. 7. Maximum Off-State Leakage of 2.75mA per point. 8. Output Delay Time:

a. Off to On – ½ cycle maximum. b. On to Off – ½ cycle maximum.

9. Diagnostic Features: a. Short Circuit for On State. b. Open Circuit for Off State. c. Over Current for On State. d. Fault Data Tag to indicate that point is faulted and data may be incorrect.


11. Isolation Voltage: a. User to System - 1500V rms/V ac dc for 1 second.

I. Module Specifications (Contact Output Module): 1. Quantity eight or sixteen Form C (Individually Isolated) Electromechanical

Outputs. 2. Output Voltage Range of 5-141V dc; 120/220 V ac. 3. Output Current Rating:

a. Resistive - 2A at 125V ac. b. Inductive - 2A Steady State.

4. Power Rating (Steady State) of 250VA maximum for 125V ac inductive output. 5. Maximum Off-State Leakage of 2.0mA per point at 240V ac. 6. Output Delay Time.

a. Off to On - 10ms maximum. b. On to Off - 10ms maximum.

7. Diagnostic Feature – LED: a. Module Status. b. Network Status. c. Channel Status.

8. Configurable States. a. Fault Per Point - Hold Last State, ON or OFF. b. Program Mode Per Point - Hold Last State, ON or OFF.

9. Isolation Voltage: a. Group to Group - 100 percent tested at 2550V dc for 1s.


b. User to System - 100 percent tested at 2546V dc for 1s.

2.23 DISTRIBUTED I/O - ANALOG INPUT AND OUTPUT MODULES

A. The Distributed I/O Sub-System shall be networked to the Control Processor over ControlNet, Devicenet or Ethernet/IP.

B. Manufacturer: 1. Allen-Bradley Model 1756. 2. Substitutions: Not Permitted.

C. Selection: 1. All analog input and output modules shall be manufactured and supplied by

the manufacturer of the programmable controllers. 2. Modules shall be designed to support the DeviceNet, ControlNet and

Ethernet/IP networks. Modules shall support producer / consumer communications. Analog modules shall support Change of State.

3. Analog input modules shall convert an analog signal that is connected to the module’s screw terminals into a digital value. The digital value representing the magnitude of the analog signal shall be transmitted on the backplane. Analog output modules shall convert a digital value that is delivered to the module via the backplane into an analog signal on the module’s screw terminals.

D. Module Features: 1. Modules shall be connected directly to the Control Logix network via a POINT

I/O Control Net Adapter with Redundant media, via a POINT I/O DeviceNet Adapter with configurable POINT Bus Communications, and a POINT I/O Ethernet/IP Adapter.

2. Modules shall have a locking tab to anchor the removable electronics module. 3. Modules shall have slots for mechanically keying the electronic module to

prevent inserting an incorrect electronic module. 4. Modules shall have electronic IDs for electronic keying the electronic module

to prevent the operation of a module inserted incorrectly into a slot where the mechanical keying has been incorrectly set.

5. Modules shall be designed to be installed or removed while I/O system power is applied (Removal and Insertion Under Power – RIUP).

6. Modules shall have indicators to display the status of communication, module health and input / output devices.

7. Each module shall have the following status indicators. a. Yellow display to indicate the On/Off state of the field device. b. Green/Red display to indicate the module’s communication status. c. Green/Red display to indicate the module’s fault status. d. This display shall be available on all modules to indicate the presence or

absence of various faults. 8. Each analog module shall maintain the following identification information.

a. Modules product type (such as analog or digital). b. Modules catalog number. c. Modules major revision number. d. Modules minor revision number. e. Module manufacturer vendor. f. Module serial number.


9. Each analog module shall maintain the following status information: a. Controller ownership. b. Configuration status. c. Device specific status information. d. Minor and major recoverable and unrecoverable faults.

10. Each analog module shall provide the following fault reporting. a. On diagnostic modules, hardware indication shall be provided through

module’s LED fault indicator. b. Modules shall have input data tags, Status Byte Channel, that indicates

that a point is faulted and input data or output data for that point may be incorrect. All possible faults shall be supported as follows: Fault (general), Calibration, Low Alarm, High Alarm, Low Low Alarm, High High Alarm, Under range and Over range. If communication to the module is lost, then all points for the module will be faulted.

c. The programming package shall graphically display the fault and shall include a fault message describing the nature of the fault.




14. Field wiring shall be connected to the analog input modules through a wiring system provided by the manufacturer of the modules. Anomaly detection Loss of field power, Open Wire, Calibration Status, short) shall be provided as standard.

E. Module Specifications (Non-Isolated Analog Input Modules): 1. Quantity of eight or sixteen (single-ended, differential) Inputs. 2. Input Range of Current Input: 4-20mA, 0-20mA; voltage input: 0-10V, +/- 10V. 3. Resolution: 16 bits across range. 4. Input Impedance of Greater than 100K Ohms Voltage, 60 Ohms Current. 5. Open Circuit Detection. 6. Normal Mode Rejection of -60dB. 7. Common Mode Noise Rejection of 120dB. 8. Isolation Voltage.

a. User to System – 1250V rms/V ac.

F. Module specifications (Non-Isolated Analog Output Module): 1. Quantity of four or eight Outputs. 2. Output Range:

a. Current Output: 4-20mA, 0-20mA. b. Voltage output: 0-10.5V, +/- 10.5V.

3. Voltage Resolution of 13 bits (plus sign) across 10.5V; 13 bits across 21mA. 4. Open Circuit Detection. 5. Calibration Accuracy of - Better than 0.1 percent of full scale. 6. Calibration Interval - 12 months typical. 7. Isolation Voltage User to System – 1250V rms/V ac 2.09.


2.24 FIELD VALVES AND INSTRUMENTATION

A. Dissolved Oxygen, pH, Ammonia Nitrogen, and Combination Ammonia / Nitrate Nitrogen Probes: 1. Manufacturer.

a. HACH. b. Endress + Hausser.

2. The interface unit shall convert the sensed dissolved oxygen concentration to an analog electrical signal.

3. The wetted probe shall sense the dissolved oxygen concentration via a luminescent sensor. The signal from the sensor shall be tied to the interface unit that will convert the sensor signal to a 4 to 20 mA signal that will interface with the PLC. The dissolved oxygen transmitter shall be utilized for monitoring the dissolved oxygen concentration in the tank.

4. The measuring principle shall be based on luminescent material that is sensitive to oxygen.

5. Sensor replacement shall not require factory service personnel to be present. Calibration shall be accomplished in free air and will not require special chemical baths.

6. The interface unit shall be housed in a NEMA 4X/IP66 metal enclosure with a corrosion-resistant finish. The panel must be complete with terminal strips and wire ducts (if needed).

7. Operation characteristics: a. The dissolved oxygen probe shall be a continuous-reading probe that

utilizes luminescent sensor technology. b. The probe will not require calibration more frequently than once ever y six

months. c. The probe material shall be formed Noryl® and 316 Stainless Steel. All

parts of the probe shall be corrosion resistant and fully immersible. d. The sensor material shall be polybutyl mehoacrolate. e. The measurement range shall be 0.00 to 20.00 mg/L dissolved oxygen. f. The operation of the analyzers shall not be affected by H2S, pH, K+1, Na+1,

Mg+2, Ca+2, NH4+1, Al+3, Pb+2, Cd+2, Zn+2, Cr (total), Fe+2, Fe+3, Mn+2, Cu+2, Ni+2, Co+2, CN-1, NO3-1, SO4-2, S-2, PO4+3, Cl-1, anion active tensides, crude oils, or Cl2.

g. The probe shall provide electrolyte-free operation without the requirements of sample conditioning.

h. The probe shall be furnished with a mounting kit.

B. Thermal Mass Flowmeter: 1. Manufacturer:

a. FCI. b. Endress + Hausser.

2. The Thermal Mass Flowmeters shall use thermal dispersion technology to provide direct mass flow measurement.

3. The unit shall be installed in line sizes ranging from 2 inches to 24 inches with a 1/2 in. or 3/4 in. NPT connection.

4. The sensor shall generate a 4-20mA analog output that will directly correlate to the measured flow. The transmitter can be configured in two standard configurations, integral transmitter with local display or remote transmitter with display.


5. The Thermal Mass Flowmeter shall be capable of measuring air, compressed air and nitrogen, with a range of 0.75 SFPS to 400 SFPS, with an accuracy of +/- 2 percent of reading, +/-0.5 percent of full scale.

6. The Flow Element shall be insertion type, thermal dispersion method, 316 stainless steel body with Hastelloy C thermowell sensors, 316 stainless steel compression fitting with Teflon or stainless steel ferrule 150 psig. Maximum operating pressure for stainless steel ferrule 500 psig, Teflon ferrule 150 psig. Maximum operating temperature: stainless steel ferrule 0°to 250°F, Teflon ferrule 0° to 200°F. The insertion length shall be field adjustable lengths: 1 in. to 6 in., 1 in. to 12 in. or 18 in.

7. The Thermal Mass Flowmeter Transmitter shall be NEMA 4X aluminum, and dual conduit ports.

8. The Transmitter will have two (2) 4-20mA outputs user assignable to flow rate and/or temperature.

9. The Transmitter shall operate with input power of 18-36VDC (6 Watt Maximum) or 85-265VAC (12 Watt Maximum), and operating temperature 0° to 140°F.

10. The Transmitter digital display +/- 9999 counts LCD, 0.45”H characters, user scalable to flow rate units or as 0-100 percent.

11. The unit shall be rated non-incendive for use in Class 1, Division 2, Groups A, B, C and D.

12. The SYSTEM SUPPLIER shall provide four (4).

C. Magnetic Flow Meter.

D. Float Switch: 1. The unit shall be a direct acting float switch, non-mercury switch, switch

contacts rated for 5 Amps at 125/250VAC. 2. The float switch contacts shall have the ability to be wired for either normally

open or normally closed activation. 3. The float switch housing shall be polypropylene or an equivalent material, and

shall be for use in potable water as well as non-potable water and wastewater applications.

4. The float switch shall include an integral, flexible, water resistant 18-gauge conductor available in various lengths up to 50 Feet.

5. The float switch shall be UL listed, and manufactured by Anchor Scientific, SJE Rhombus or equal.

E. Sensor/Probe Protection: 1. Analytical sensors and or probes that are located in an area that contains

Biofilm Carrier Media will require a protective cover for the sensor/probe. 2. Guards shall allow free flow of fluids and allow for the escape of any air

bubbles. 3. The guards shall be removable by hand without the use of tools to facilitate

routine inspection, cleaning, and servicing of the instrument. 4. Guard material shall be non-corroding polymer housing provided with a hand-

operated, stainless steel clamping means to secure it to the instrument.

2.25 ACCESSORIES

A. Accessories: 1. Portable Gantry Crane for pumps, and for pulling out upper level.


2. Pallet jack for moving blowers.

PART 3 EXECUTION

3.01 SHIPMENT, HANDLING AND STORAGE

A. The CONTRACTOR shall be responsible for receipt, protection and storage in accordance with manufacturer’s recommendations of all items shipped to the site from the time of delivery until installation is completed and the units and equipment are ready for operation. The equipment shall be suitably covered and protected at all times. Sufficient blocking shall be provided to prevent noticeable sagging of stored materials between supports and to prevent permanent distortion of the equipment. No iron or steel tools shall be allowed to come into contact with stainless steel components during handling and storage of the equipment. The CONTRACTOR shall follow manufacturers’ instructions to exercise any stored rotating equipment.

3.02 INSTALLATION/STARTUP

A. The CONTRACTOR shall install the equipment specified herein in accordance with the manufacturers’ instructions and recommendations.

3.03 SYSTEM START-UP, TESTING, AND CERTIFICATION

A. The SYSTEM SUPPLIER shall provide ten (10) days of service in not less than two (2) trips by a fully qualified service engineer to inspect the installed equipment, assist the CONTRACTOR to start the equipment operation.

B. The SYSTEM SUPPLIER in conjunction with the installing contractor shall inspect equipment furnished by the SYSTEM SUPPLIER and provide certification on the installation. This certification shall be limited to the visual inspection and known quantitative aspects of the SYSTEM SUPPLIER’s equipment.

C. The SYSTEM SUPPLIER shall provide the services of a factory trained I&C engineer to check and verify the PLC program functionality (Dry testing).

D. Instruments and other devices that require calibration and checkout will be carried out after the contractor has the equipment installed and verified continuity, hooked up electrically where/if required. Instruments and devices shall be configured and demonstrated to function prior to start-up. A document indicating the set points and calibration shall be furnished for documentation records.

E. The contractor shall furnish all consumables, including oil and grease prior, to operation of equipment. All consumables after beneficial occupancy will be by the owner.

F. Operation, maintenance and installation manuals shall be provided for the supplied equipment. A total of five (5) copies shall be furnished.


3.04 TRAINING

A. The SYSTEM SUPPLIER shall provide a minimum of three (3) days of on-site training to the OWNER’s plant personnel. Training shall be repeated for each of the shifts of the OWNER’s personnel.

B. The training services shall comprise of a qualified representative to instruct and train plant personnel in the proper startup, operation, shutdown, maintenance, repair and troubleshooting of the system. The O&M Manual shall be the primary training tool with supplemental training provided from a presentation. Mechanical equipment suppliers will also provide training on their specific equipment.

C. A training outline shall be submitted to the ENGINEER for approval including the credentials of the training staff.

D. The training shall include the following topics: 1. Theory of Operation . 2. Actual Operation. 3. Mechanical Maintenance. 4. Electrical Maintenance . 5. Instrumentation. 6. Optimum Operation . 7. Troubleshooting. 8. Hands-on. 9. Question and Answer Session.

END OF SECTION


SECTION 14554

SCREW CONVEYORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Shaftless screw conveyors complete with auxiliary equipment, appurtenances, and controls to provide a complete, operational system to convey dewatered sludge (cake). The screw conveyor system including all components described in this Specification Section and related sections shall be provided as a system by Solids Storage System Supplier (Supplier).

B. Reference Location: 1. Pre-THP Cake Silo Distribution Conveyor. 2. Pre-THP Cake Silo Conveyor No. 1. 3. Pre-THP Cake Silo Conveyor No. 2. 4. Cake Screw Conveyor Train No. 1. 5. Cake Screw Conveyor Train No. 2. 6. Distribution Screw Conveyor. 7. Live Bottom Screw Conveyor.

1.02 REFERENCES

A. American Gear Manufacturer's Association (AGMA).

B. American Institute of Steel Construction (AISC).

C. American Iron and Steel Institute (AISI).

D. American National Standards Institute (ANSI).

E. American Welding Society (AWS).

F. National Electrical Manufacturer's Association (NEMA): 1. 250 – Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS

A. NEMA Type 4X enclosure in accordance with NEMA 250.


A. General: 1. One complete screw conveyor system for Pre-THP Cake Silo distribution

conveyor. 2. One complete screw conveyor system for Pre-THP Cake Silo No. 1 and Pre-

THP Cake Silo No. 2. Each system includes: a. Pre-THP Cake Silo No. 1: Three Slide Gates. b. Pre-THP Cake Silo No. 2: Three Slide Gates.


3. One Complete screw conveyor system for Post-THP Dewatering Centrifuge No.1 and Post-THP Dewatering Centrifuge No. 2. Each System includes: a. Post THP Dewatering Centrifuge No. 1.

1) Cake Screw Conveyor Train No. 1: Three Slide Gates. b. Post THP Dewatering Centrifuge No. 2.

1) Cake Screw Conveyor Train No. 2: Three Slide Gates. 4. One bypass screw conveyor. 5. One Silo Loading Conveyor for the conveyance of cake from the two Cake

Collection Belt Conveyors. System Includes: a. Two slide gates.

6. One Live Bottom Conveyor Systems for the conveyance of dewatered cake from the cake storage silos to the truck load outs. System includes the following: a. Three screw conveyors. b. Slide gates as specified:

1) Distribution Screw Conveyor: Three Slide Gates. 7. Provide all components, drivers, motors, intermediate bearings, and auxiliary

components, and controls necessary to provide a complete operational system in accordance with the Contract Documents. Auxiliary components shall include, but not be limited to, slide gates, covers, zero speed switches (motion sensors), pull cord safety switches, bifurcating chutes from each centrifuge, discharge chutes, access ramp along inclined conveyors, and all supports for all conveyors.

8. Controls and control strategy: As specified.

B. Design requirements: 1. Design of the conveyor system shall be based on the design parameters and

performance criteria specified herein and presented in the Conveyor Schedule and the operational experience of the manufacturer for the specified service. a. Conveying capacity of the conveyor shall be 1.5 times the design loading

without changing the design operating speed. 2. Design calculations showing dead, live, and dynamic loadings are required.

a. Calculations shall demonstrate that the design stress at 250 percent of the motor nameplate horsepower in the auger shall not exceed 30 percent of the Fy value in the extreme fiber of the flight material.

3. Structural Design Criteria: a. Project design criteria: As specified. b. Seismic design criteria: As specified. c. Wind design criteria: As specified. d. Access platforms and ramp live load: 100 psf.

4. The conveyor system shall consist of screw conveyors as indicated on the Drawings to collect cake discharged from the centrifuges and discharge in a continuous manner to the container. a. Sectional welded plate sections are not acceptable. b. The conveyor system shall be of the size and location as indicated on the

Drawings. c. Manufacturer shall provide support mountings, bifurcating centrifuge

discharge chutes, and conveyor discharge chutes as indicated on the Drawings.


5. Each conveyor shall be sized to convey dewatered sludge cake at a solids content of 20 to 35 percent by weight. a. Design shall accommodate the sludge thixotropic characteristics and its

tendencies to plug, ball, and bridge during transport. b. Typical bulk density for sludge cake is approximately 45 to 65 wet pounds

per cubic foot. c. Designed for intermittent or continuous operation of 24 hours a day,

7 days a week when conveying the specified dewatered sludge. 6. Each conveyor system shall be provided with a bifurcated cake-receiving silo

as indicated in the Drawings. a. The cake-receiving silo will convey the dewatered cake from the

centrifuge discharge chute to the inlet of either conveyor. b. Coordinate the design of the cake-receiving silo with the centrifuge

discharge chute. c. Manufacture to construct the silo to capture all cake leaving the centrifuge

discharge chute. 7. Approximate lengths of each conveyor are indicated in the Conveyor Schedule

below and shown on the Drawings. The exact final dimensions shall be confirmed by the Contractor to facilitate the installation of the conveyor and solids storage systems.

8. Conveyor systems shall be provided as outlined in the Conveyor Schedule given below.

9. The conveyors shall be furnished by a manufacturer with a minimum of 5 years experience in the design and manufacture of wastewater sludge conveying equipment including shaftless screws and who is fully experienced, reputable, and qualified in the manufacture of the system components to be furnished.

10. Basis of design: a. The Drawings have been prepared based upon the layout of the conveyor

manufacturer and dewatering equipment manufacturer listed in this specification section.

b. If alternate equipment is proposed which requires modifications to the basis of design, then include in the lump sum bid all modifications and accessories as required to provide a complete and operable system.

c. In addition, include in the lump sum bid all necessary structural, electrical, and mechanical modifications to the proposed system and to the access platform (if required), centrifuge support structure, shaftless screw conveyor, and other support facilities.

C. Supports: 1. Provide structural supports and access ramps.

a. The support structure and access ramps shall be designed and provided by the conveyor manufacturer.

2. Provide full structural steel ground supports. a. The design of the support structure shall be integrated with other

conveyors and the sludge silos. 3. All structural members shall be designed so that the unit stresses will not

exceed AISC allowable stresses by more than 1/3 when subject to loading of twice the static load.


1.05 ASSEMBLY REQUIREMENTS

A. General: Include all material and equipment necessary to provide complete working system, except such material and equipment specifically excluded. Provide all fasteners, whether shop installed or not for structural supports and mechanical equipment.

B. Clearances: Install equipment of the approximate dimensions shown or specified to fit the spaces shown with adequate clearances, and capable of being handled through openings provided in the structure for this purpose.

C. Fabricated Sections: Furnish all fabricated sections shop assembled into units as large as practicable and as shipping regulation will permit and matched marked for the field assembly, in order to keep the field assembly to a minimum. Furnish required lifting lugs.

D. Miscellaneous Components: Shop assemble all bearings onto the motor and speed reducers.

E. Identification: Clearly identify loose items by equipment number and erection mark numbers to facilitate assembly.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Screw conveyor: One of the following, no equal: 1. Spirac. 2. Jim, Myers, and Sons, Inc. (JMS). 3. KWS Manufacturing Co. Ltd. 4. Custom Conveyors Corporation. 5. Schwing Bioset.


2.02 SHAFTLESS SCREW CONVEYORS

A. Materials: The shaftless screw conveyor shall be new and of current manufacture, and shall be designed to transfer municipal dewatered sludge as specified and shall be constructed in accordance with CEMA 350 standards.

ITEM SHAFTLESS SCREW CONVEYORS Trough, Chutes 1/8 inch (3.2 mm) minimum; Type 304 Stainless Steel

Covers 1/8 inch (3.2 mm) plate; Type 304 Stainless Steel

Drive and End Plates 1/2 inch (12.7 mm) plate; Type 304L Stainless Steel

Spiral Flights 1-inch minimum (25.4 mm) thickness with spiral inset; cold-formed carbon, spring steel, Brinell 220 minimum

Wear Liner (UHMW) 1/2-inch (12.7 mm) minimum thickness; Plastimeric, 2 color

Cover Fasteners Type 304 stainless steel hinges and toggle clamps.

Drive Shaft AISI 4150

Saddles and Supports Type 304 Stainless Steel

Hardware Type 316 Stainless Steel

B. Spiral Flighting: 1. Design spiral flighting to convey material without a center shaft and designed

with the stability to prevent distortion and jumping in the trough. 2. Form spiral flighting in sections from 1 continuous flat hot-rolled spring steel

bar. a. The spiral flighting shall be made from cold formed flat hot-rolled bar of

60 millimeters by 25 millimeters (1 inch) minimum thickness with a minimum cross-sectional area of 1,500 millimeters2, 80,000-pounds per square inch minimum yield strength, and 220 minimum Brinell.

b. Material shall be corrosion-resistant micro-alloy steel bar and be concentric to within 1/16 inch.

c. Spirals formed from cut plate are not permitted. 3. The spiral shall be cold formed into the final diameter and pitched in

2 separate forming stages to reduce spiral neck-down and eliminate spiral cracking. a. Single-stage rolling and pitch formation is not acceptable.

4. The spiral shall be rolled in such a way as to limit "neck-down" of the outside edge of the cold-rolled spiral to 10 percent of the thickness of the inside edge of the spiral. a. The spiral edges shall be smooth in the as-rolled condition and not show

cracks or grinding marks when tested with a dye penetrant. 5. Connect spiral flighting to the drive shaft by welding the spirals to a 3/4-inch

minimum circular torque plate properly reinforced with a gusset 180 degrees of the coupling disk. a. A separate connection plate shall be bored with a hole equal to the shaft,

and the drive shaft shall be concentrically welded to the plate to effectively transmit torque and bolted to the torque plate.

6. Spiral connections shall be AWS requalified full penetration welds. a. Flights shall be welded in a jig to assure true alignment.


7. All spirals shall have a welded insert to increase strength and decrease fall back.

C. Trough and Liner: 1. Construction: Materials shall be 1/8-inch minimum thick, Type 304 stainless

steel, U-trough with neoprene gasketing at each trough flange and 1/8-inch gauge stainless steel cover.

2. Conveyor shall have standard removable trough end plates (both ends) with split-gland seal at the drive end. a. Provide zerk fitting for lubrication of seal.

3. All components, including saddle supports, shall be Type 304 stainless steel, except the drive unit, and Helix.

4. Equip trough with a filling chute at the loading area. 5. Provide a 3-inch diameter drain at the low end of conveyor. 6. Conveyor trough shall have removable bolted cross braces. 7. Conveyor covers shall be hinged.

a. Hinge shall be removable pin-style with a length at least 90 percent of the lid length.

b. Cover shall come equipped with lid stops to prevent over-opening the cover.

8. Each lid shall have 2 stainless steel pull-action toggle clamps to keep the lid secure during operation. a. Each clamp shall be double-locking with a U-bolt arm adjustable up to

1/2 inch. b. The latch plate shall be mounted on the lid with the toggle body mounted

below the lid on the trough. 9. The trough shall have a replaceable liner constructed of preformed 1/2-inch

minimum ultra-high molecular weight polyethylene with anti-wear agents and retainer strips welded to the trough along the top of the liner. a. Fasteners shall not be used below the spiral centerline to hold the liner.

10. The liner shall be a single piece, formed and bonded with 2 layers, each a different color, to provide a visible indication when the liner is nearing the end of its useful life and there is only 1/8 inch remaining.

11. Conveyor troughs to be complete with saddle-type supports shaped to be profile of the screw conveyor trough and extending to a common fixed distance below the centerline of the screw. Support spacing shall not be greater than 12 feet center-to-center. Include separate support points under the drive end assembly and end shaft assembly welded as an integral part of these assemblies using 3/8 inch plate.

12. Provide filling and discharge openings as indicated on the Drawings. Each filling and discharge opening shall be flanged, suitable for connection slide gates, chutes, and hoppers as indicated on the Drawings.

13. Discharge openings from conveyors shall have a width equal to the full width of the trough and length not less than 1.5 times the spiral pitch nor less than the dimension where indicated on the Drawings.

D. Trough: 1. Conveyor trough body shall be rolled to shape, with double flanges formed

with or welded to the trough.


2. Each trough Section body shall be fabricated in single welded constructions for lengths up to 12 feet. Troughs greater than 18 feet in length shall be constructed for two or more sections bolted together at the trough joining the flanges.

3. Neoprene gasket shall be glued over full face of flanges (on one face only for adjoining).

4. End plates shall be fabricated from single Type 304L stainless steel plates and bolted across end of the trough.

5. Fabricate drive motor/gear reducer/bearing and stuffing box assembly of all welded construction using minimum 3/8 inch plate, shape to support the bearings and drives in true alignment. These assemblies to be welded to the screw conveyor trough end plates, or may be bolted to the trough end plate using a matching minimum 3/8 inch thick mounting plate.

6. Provide 4-inch drain with a flanged connection at bottom of conveyor as shown on the Drawings.

7. Provide discharge openings as indicated on the Drawings. Each discharge opening shall be flanged, suitable for connection slide gates, as indicated on the Drawings.

E. Rotors, Drive Shaft and End Shaft: Screw conveyor rotors shall be constructed of Type 304L stainless steel, with wall thickness to give a maximum deflection not exceeding 5/32 inch between any two bearing support points, based upon formulas for a simply supported tube and flight material, but not less than Schedule 80 pipe. 1. Each rotor center tube shall be made from single-piece tubing (not fabricated

with butt-welding of two sections of tube). Each end of rotor center tube shall be fitted with a welded face plate not less than 1 inch thickness, drilled and tapped for bolted, flanged connections, with bolt holes parallel to the center axis of the rotor center tube and a 1/8 inch or greater register relief matching the adjoining flange face. Rotor center tube shall not be drilled or fitted with bolts that are perpendicular to its centerline axis. Shaft flanges shall have 3/32 inch or greater register relief matching the adjoining flange face. The design of the rotor face plates and their flange bolt holes shall be such as to permit removal bolts in the “as installed” position of the rotor center tube in the screw conveyor through without moving adjoining parts (i.e., bolts can be completely removed without disturbing other conveyor components).

2. Torque tube diameter shall be not less than the greater of 8 inches or the largest O.D. of the intermediate bearing/ flexible coupling assembly.

F. Flighting: 1. Screw conveyor flight shall be either full face (i.e., continuous from the outside

diameter of the rotor center tube to the outside diameter of the flight) or integral ribbon-face flights.

2. Flights to extend beyond the end of the screw conveyor rotor center tube to within 3/16 inch (4 mm) of the trough inlet end plate and intermediate bearing supports. Flights shall extend to not more than the midpoint of the farthest outlet. Flights to be sectional construction made from precut plate, of uniform thickness, formed with an average deviation of the pitch not exceeding plus or minus 1/16 inch (1.60 mm) over the length of the screw conveyor rotor between bearings. Radial welds of the sectional flight segments shall be bevel-welded both sides. All welds shall be full and continuous both sides of flight junction to center tube.


3. The pitch of flights, unless otherwise specified, to be constant value over the entire length of the conveyor (but not less than 0.5 nor more than 1.0 times the outside diameter of the screw).

4. Welding: Continuous, all sides, to pipe shaft.

G. Quality of Construction: The screw conveyor rotor, plus flight, shall have a true circular diameter about the centerline axis of the rotor center tube within plus 1.6 mm or minus 4.8 mm. Machine flange faces to true parallel faces perpendicular to centerline axis within plus or minus 0.025 mm. 1. Each Section of the screws shall be finished-machined so that the variance of

the outside diameter of the flights over the entire length of the screw conveyor between bearings is less than plus or minus 1.25 mm.

2. The pitch measured between flights, measured at the outside diameter of the screw flights, along four straight lines parallel to the axial centerline through the bearings at 0, 90, 180, 270 degrees, shall not vary more than plus or minus 2/100 times the outside diameter of the screw flights from the design pitch.

3. The total deflection of each Section of the horizontal screw shaft center shall not exceed 5/32 inch (4 mm) measured from the axial centerline through the bearings in the vertical plane.

H. Drive Assembly and End Shaft Assembly: 1. Drive shafts and end shafts shall be constructed of ASTM 4140, 42 Cr Mo4V,

or equivalent shaft steel. Shafts shall include complete flanged ends and mating bolt holes to match the conveyor rotor center tube flanged end plates and shall incorporate a registered fit with a 5/32 inch (4 mm) or greater register between mating of flanges. Shaft shall be integral with the shaft flange as single-piece forging or as welded shaft-to-flange construction. Maximum torsional stress and maximum combined stress at full motor horsepower shall be less than 9,600 psi and 12,000 psi, respectively.

2. Provide Replaceable wear sleeve on the drive and non-drive shafts, to extend over the complete length of the stuffing box housing length. Wear sleeve shall be secured to the shafts to prevent rotation.

3. Stuffing boxes shall be complete with 1/2 inch (13 mm) by 1/2 inch (13 mm) nominal Teflon-impregnated packing (number as specified, but not less than two packing rings per stuffing box), packing ring adjustment to tighten packing onto shaft, packing ring housing bolted to screw conveyor trough end plate. Lubricated packing rings where specified shall incorporate a grease fitting with lantern ring set in the middle of the packing rings with not less than two rings of packing on the sludge side of the lantern ring.

I. Bearings: Outside support bearings to be SKF spherical roller bearings mounted in SKF, Type SDN, SNI, or SNH, cast iron pillow block bearing houses (Type SSNAD modular iron castings when supporting shaft-mounted gear reducers or return gear assemblies). Mount bearings outboard of the stuffing box assembly, with sufficient clearance to permit removal of stuffing box bolts, cover, and repacking without having to remove the bearing housing or bearing from the housing. Each bearing housing shall be fitted with a grease nipple, with escape release provisions. 1. Thrust-carrying bearings shall be fixed location, with spherical roller bearing

mounted on drive shaft, complete with bearing recess shoulder.


2. Non-thrust bearings shall be non-locating, free-floating assembly and shall be mounted with a tapered bore, plus adaptor ring, on a plain diameter shaft, where no power shall be transmitted from the shaft to another shaft.

3. Mounting of pillow block bearings to the drive or end shaft assembly, and all components mounted to or upon which the bearing is mounted, shall conform to the requirements of the bearing manufacturer for the loading and design conditions of the service.

4. Each bearing shall have a minimum L-10 life of 100,000 hours.

J. Speed Target Ring: Speed target ring shall consist of a metal protrusion or its equivalent, providing sufficient impulse for a proximity-type sensor that can be mounted in a support arm mounted adjacent to the pillow block bearing support.

K. Intermediate Bearings: Intermediate bearings in the live bottom screw conveyors are not acceptable.

2.03 DRIVES

A. Drive: 1. Drive units shall be located as indicated on the Drawings. 2. Each screw conveyor shall be driven by a constant-speed integral gear

reducer/motor drive unit mounted to an adapter flange, which is in turn mounted to the end plate of the conveyor.

3. The adapter flange shall allow the leakage of any material from the conveyor trough to atmosphere rather than into the gear reducer/motor drive unit. Direct coupling of the gear reducer/motor drive unit to the end flange of the conveyor will not be accepted.

4. The drive unit shall be rigidly supported so there is no visible “wobble” movement under any operating condition.

5. The drive system shall be designed, at a minimum, to start the conveyor from a dead stop with the trough filled throughout its entire cross sectional area and length with partially dried and hardened dewatered material.

6. The drive unit shall be a hollow shaft mounted drive. 7. Manufacturers: one of the following, no "or equal":

a. Nord Gear Corporation. b. SEW Eurodrive.

8. Gear Reducers: a. Designed for the full thrust loads from the spiral flights. b. Flange mounted to the conveyor end plate and rigidly supported. c. All gears shall be AGMA Class II, single, double, or triple reduction, helical

gear units with high capacity roller bearings. d. Bearings shall be designed for the thrust loads from the fully loaded

startup condition and shall have an AFBMA B10 life of 100,000 hours minimum.

e. V-belt driven speed reducers or chain driven reducers will not be accepted.

f. The reducer shall be a standard air-cooled unit with no auxiliary cooling required.

g. The gear reducer shall be sized with a torque service factor of 1.5 times the absorbed power or 1.1 times the motor nameplate, at the driven shaft speed, whichever is greater.

h. Close coupled with drive motor.


9. Motor: a. Motor shall be as specified. b. Motor horsepower for each conveyor shall be as specified herein. c. Constant speed, 480 V, 60 Hz, 3 phase. d. Ambient temperature (degrees C): 50. e. Service factor: 1.15. f. Insulation: Class F. g. Temperature rise under full load: Not to exceed that for Class B insulation. h. Enclosure: TEFC. i. Design B speed/torque characteristics.

10. Finish: Drive finish shall be severe duty washdown surface protection finish with stainless steel paint.

11. Thermal protection: Provide automatic reset motor stator temperature detectors, one switch in each phase winding. If any detector is activated, the sensor shall activate an alarm and shut down the motor. The thermal detectors shall activate when the stator temperature exceeds 125 degrees Celsius.

2.04 SLIDE GATES

A. Provide slide gates where shown on the Drawings.

B. The slide gates shall be specifically designed to operate as an integral part of the conveyor system and shall be supplied by the conveyor manufacturer.

C. Maximum installed vertical dimension of 4-inch including the operator and its accessories.

D. Gate opening shall be at least the full width of the live bottom conveyor trough. The length of the gate shall be 1 1/2 times the width, unless otherwise specified or indicated on the Drawings.

E. Gates shall be provided with pneumatic cyclinder operators.

2.05 SUPPORTS AND ACCESS RAMPS

A. The Supplier shall design and supply all structural supports for all conveyors and the inclined conveyor access catwalks, unless otherwise specified herein. Conveyor supports shall be generally as shown on the Drawings and as specified herein.

B. All supports shall be designed in accordance with the specified design criteria including seismic and wind.

C. The Supplier is responsible for detailed design, including structural supports, of the inclined conveyor and access ramps. All structural supports shall be Type 304L stainless steel.

D. Configuration of access ramps shall be as shown on the Drawings, including ships ladder. Provide Type 304 stainless steel anti-slip grating on access ramp.

E. Unless specific support spacing is indicated, provide supports at each end of the conveyors troughs and at a maximum spacing of 12 feet along the length of the trough.


F. Support system shall be from floors below or above conveyors or from support steel, when such steel have been designed for such loads or as shown. Supports shall not obstruct access to conveyor covers or drives.

G. Supports shall allow conveyor thermal movement and shall allow building thermal movement across expansion joints.

H. All support locations shall be submitted for approval and revised if required to coordinate with allowable structural loading, site constraints, and access.

I. Provide auxiliary ASTM A-53 steel supports from the conveyor saddle supports to the structural support point. Supports shall be bolted to the auxiliary supports.

J. The inclined conveyor supports shall also provide support for all ventilation ducts and electrical conduit routed along the conveyor supports as indicated on the Drawings. Supports for piping, ventilation ducts and electrical conduits shall be designed and supplied by the Contractor and shall be coordinated with the conveyor supplier and design of the conveyor supports.

2.06 CONTROLS ACCESSORIES

A. Emergency stop cables: 1. Provide emergency stop cables on both sides of the conveyor with 2 switches

per 50 feet minimum length of cable. 2. Cable shall be orange plastic coated safety cable mounted through eyebolt

spaced no more than 10 feet. 3. The emergency stop cables (pull cords) shall have a NEMA 4X, 316 stainless

steel enclosure. Provide DPDT output for each pull cord switch.

B. Zero speed switches (motion sensors) shall be provided and installed so they stop the operation of the drive motor when conveyor motion is not detected. Provide an under speed detection motion probe and a motion failure alarm controller. The motion probe shall have a temperature rating of -40 to 60 degrees Celsius. The motion probe enclosure rating shall be type NEMA 4X. The motion monitor/controller shall accept 120 V AC. The enclosure rating for the motion controller shall be NEMA 4X stainless steel. Provide manufacturer's mounting accessories for the motion probe and motion controller. The motion controller shall provide a dry contact output for motion detection.

C. Conveyor manufacturer shall provide a cake drop chute designed to control the fall of cake from the live bottom to the truck loading conveyor. 1. Discharge chute materials shall be 18 ounces per square yard heavy-duty

nylon scrim reinforced vinyl. a. Material shall be water repellent, flame retardant, mildew resistant, and

acid resistant. 2. All hems shall be double reinforced and 2 inches thick with fabric folded over

to the outside to prevent sludge accumulation. 3. Each flexible chute shall be provided in 2 sections of 5-feet long each and

mounted to the bottom of the conveyor discharge. 4. Individual chutes shall attach to each other and the bottom of the cake gate

frame using stainless steel retaining strips attached through the hem. a. All retaining strips shall have the same bolthole pattern.


5. A 1/4-inch nylon rope shall be attached to the middle (through eyebolt) and bottom retaining strips so the discharge chute can be pulled up to the bottom of the conveyors.

6. Contractor shall feed the rope through a single pulley attached to the conveyor support structure and tie down to a rope cleat mounted on the outside wall of the dewatering building.

D. Bifurcated Chute: 1. 1 per centrifuge. 2. Purpose: Convey the dewatered cake from the centrifuge to the inlet of either

centrifuge discharge conveyor. 3. Fabricated and provided by the shaftless screw system manufacturer. 4. Fabricated of the same material as the conveyor trough. 5. Construct of 3/16-inch wall thickness with 1/4-inch flanges for connection to

conveyors. 6. Shall be flanged at top to connect to the centrifuge flexible coupling and

flanged at bottom to connect to conveyors. Coordinate flange dimensions with centrifuge and conveyor manufacturers.

7. Provide bifurcated chute with external body reinforcing stiffeners as required. 8. Provide 0.125 inch thick neoprene gaskets at flanged connections. 9. Provide bifurcated chute with two 3-inch diameter welded lifting rings

fabricated with 1/2 inch thick (min) stainless steel bars. 10. All materials used for fabrication shall conform to the structural and

miscellaneous standards of the AISC. 11. Provide bifurcated chute with both the interior and exterior surfaces smooth,

free from sharp edges, burrs, and projections, and with all welds ground smooth and all edges and corners rounded.

12. Overlap the discharge chute from the centrifuge above the sloped inlet section of the bifurcated chute. a. The minimum spacing between the bifurcated chute and the discharge

chute is 3 inches. 13. The minimum incline angle of the sloped section of bifurcated chute is

60 degrees from horizontal. 14. Bifurcated chute shall be designed with two access hatches as indicated on

the Drawings. 15. Bifurcated chute shall be designed with internal shelf to seal gates. 16. Extend the walls of the bifurcated chute vertically so that they overlap with the

Centrifuge discharge chute a minimum of 4 inches. 17. Bifurcated chute shall be designed to support the actuator weight without

affecting the operation of the gate. 18. The shaftless screw conveyor will be designed to support the bifurcated chute.

a. The bifurcated chute shall not be supported by any element of the centrifuge.

b. Additionally, no part of the bifurcated chute shall come in contact with the centrifuge or interfere with normal centrifuge operations.

19. Gate: a. Gate blade shall direct dewatered sludge from one branch of the

bifurcated chute to the other branch and be designed to withstand dewatered cake impact from centrifuge.

b. Blade shall be constructed of 3/16-inch AISI 316L stainless steel. Shaft shall be constructed of AISI 316L stainless steel.


c. Blade shall be sized for the full dimensions of the bifurcated chute. Internal shelf shall be designed to minimize leakage.

20. Electric Actuator: a. Provide electric actuator. Actuators shall be Rotork Model IQ3, Auma

Model SA/GK, or Limitorque Model Accutronix MX, no equal. Actuators shall operate on 480V, 3 Phase, 60 Hz power. Enclosures shall be NEMA 4X and watertight. Actuators shall be provided with local and remote controls and shall include de-clutchable handwheel override. They shall be provided with LED indication for each position type. Actuator shall have manual override handwheel. Actuator shall be supported by bifurcated chute.

E. Pneumatic Cylinder Operators for Silo Discharge Gates (furnished by Primary Solids System Supplier): 1. Materials:

a. In accordance with AWWA C541. b. Non-metallic materials shall be limited to seals only. c. Non-metallic cylinders are not acceptable.

2. Cylinder construction: a. Cylinders: Heavy duty, double acting type with cushions at both ends. b. Cylinder operators: Tie rod construction type with heavy-duty front flange

mounting. c. Pistons: Equip with lip type seals. d. Rod cartridge: Removable without the use of special tools. e. Support rods with bell crank, cross head, internal stops, or other device to

give support to extended piston rods and to reduce rod's effective unsupported length.

f. Provide tail rods when specified or indicated on the Drawings. 3. Mounting:

a. Mount cylinders to gates at the factory in accordance with the manufacturer's recommendations. Support cylinders at both ends.

4. Equipment with open/close indication: a. Provide limit switches to indicate open and close positions on cylinder-

actuated equipment. b. Limit switch enclosures:

1) Where explosion-proof construction is indicated on the Drawings, provide NEMA Type 7 enclosures.

2) Other locations: Provide NEMA Type 4X enclosures. c. Limit switches for gates: End-of-travel proximity switches mounted in the

head and cap of the cylinder. 5. Gates with continuous position indication:

a. Provided on gates as specified in the Gate Schedule. b. Transmitter enclosures:

1) Where explosion-proof construction is indicated on the Drawings, provide NEMA Type 7 enclosures.

2) Other locations: Provide NEMA Type 4X enclosures. c. Continuous position indicators:

1) Magnetically coupled position transducer mounted on cylinder head. 2) Incorporate transmitter to convert position sensor output to a

4-20 milliamps signal. 3) Powered from a 2-wire signal transmitter circuit.

6. Cylinder connections: Flexible connection with isolation ball valve.


7. Local control stations shall be furnished by the Contractor: a. Meet requirements of this Section, as indicated on the Drawings. b. Nonmodulating equipment: Incorporate:

1) "OPEN-CLOSE" or "RAISE-LOWER" local pushbutton controls as indicated on the Drawings.

2) "OPEN-CLOSE" or "RAISED-LOWERED" status lights as indicated on the Drawings.

3) "OPEN ALL GATES" local pushbutton to request VCP PLC to open gate.

c. Modulating equipment: Incorporate: 1) Continuous position indicating gauge.

d. Enclosures for local control stations: Rated NEMA Type 4X. 8. Fittings:

a. Pneumatic systems: Stainless steel. 9. Coatings: 10. Prime coat for exposed metal surfaces including operator, support, and

position indicating devices: As specified in Section 09960 High Performance Coatings.



CONVEYOR SCHEDULE

Name Designation Tag Number Type

Flight Dia. Min

(inches)

Approx. Length (feet)

Capacity (cf/hr)

Max. Fill

Rate (%)

Max. Speed (rpm)

Motor hp per

Conveyor Pre-THP Cake Silo Distribution Conveyor Horizontal Shaftless 14 30 505 8

Pre-THP Cake Pump Distribution Conveyor Horizontal Shaftless 14 25 505 8

Pre-THP Cake Pump Distribution Conveyor Horizontal Shaftless 14 25 505 8

Post-THP Shaftless Screw Conveyors Inclined 15 degrees 12 40 333 8

Post-THP Shaftless Screw Conveyors Inclined 15 degrees 12 40 333 8

Bypass Emergency Screw Conveyor Horizontal Shaftless 16 85 667 15

END OF SECTION


SECTION 14558

BELT CONVEYOR SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Completed troughed belt conveyors including conveyor supports, framework, discharge chutes, belts, idlers, drive station, take-up station, safety devices, access platform, and accessories.

1.02 REFERENCES

A. American Gear Manufacturers” Association (AGMA).

B. American Institute of Steel Construction (AISC): 1. Design Guide 11: Vibrations of Steel-Framed Structural Systems due to

Human Activity (Second Edition).

C. American Society of Mechanical Engineers (ASME): 1. B20.1 - Safety Standards for Conveyors and Related Equipment.

D. Conveyor Equipment Manufacturers Association (CEMA): 1. “Belt Conveyors for Bulk Materials.” second edition.

E. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

F. Occupational safety and Health Administration (OSHA).

1.03 DEFINITIONS

A. Type 4X enclosure in accordance with NEMA 250.



A. Belt conveyors shall include belts; head, tail, and bend pulleys; head and tail shafts; carrying, return, impact, training, and transition idlers; bearings and pillow block take-ups; belt cleaners; drive gear reduction units; skirts; zero speed switch, belt misalignment switch alarm, structural stainless steel supports and anchorage; hydraulically operated plows; and auxiliary equipment necessary for a complete installation; and provided as follows:

Designation Value

Material handled Dewatered cake solids Material unit weight, pounds per cubic foot 60-90 Material moisture content, percent Maximum 85 Conveyor type Belt Conveyor configuration S-shape Conveyor Angle; 1A, 2A, 1C, 2C Horizontal Conveyor Angle; 1B, 2B 33 Degrees Belt width 24 inches Sidewall height 3 inches Carrying idler style 20 degree Carrying idler spacing, inches 48 inches Return idler style Flat Return idler spacing, inches 48 inches maximum Belt speed, feet per minute 100 Peak loading rate, tons per hour 22.5 Head pulley minimum diameter Minimum 18 Head pulley minimum length Minimum 26 Tail pulley minimum diameter, inches Minimum 12 Tail pulley minimum length, inches Minimum 26 Minimum motor drive horsepower at 1,200 revolutions per minute

Minimum 5

B. Belt conveyor will be in a wet and humid environment, and subject to exposure to corrosive gases.

C. As part of Belt Bulk Material Conveyor equipment package, provide conveyor supports, and access platform and stairs as indicated on the Drawings.

1.05 SUBMITTALS

A. Product data.

B. Shop drawings: Include manufacturer's complete erection, installation, and adjustment instructions and recommendations, details of parts individually and severally, and detailed test procedures for field-testing.


C. Structural and mechanical calculations: 1. Calculations shall include but not be limited to the following: belt conveyors,

conveyor supports and anchorage, access platform, discharge chutes, and accessories.

2. Verify conformance with specified structural design criteria. 3. Provide calculations sealed by a Professional Engineer licensed in the State of

Missouri.

D. Operation and maintenance manuals.


A. Belt conveyors shall be supplied by 1 manufacturer with similar parts interchangeable.

B. Detailed design of the conveyor, conveyor supports, and appurtenances shall be reviewed by the conveyor manufacturer and portions of the design deemed unacceptable to the manufacturer shall be indicated in writing in the shop drawing.


A. Match mark sections and loose items prior to delivery.

1.08 WARRANTY

A. System shall be covered by a conventional 2-year limited warranty against defects in materials and workmanship.

B. Warranty period shall commence after on-site acceptance of equipment by Owner.

C. Warranty shall be provided with the following provisions: 1. Frame and coating:

a. Warrant for 5 years to be free of manufacturing defects without preventative maintenance.

b. Defects or corrosion occurring within the 5 years to the frame shall be repaired or replaced by manufacturer at no cost to the Owner.

2. Bearings: a. Warrant the bearings for 5 years from date of acceptance of the

equipment. b. Warranty shall include all parts and labor for repairing or replacing

bearings that fail during the warranty period providing the Owner has properly lubricated the bearing.

1.09 SPARE PARTS

A. Deliver the following spare parts to the Owner When and where directed by the Engineer: 1. Carrying idlers (flat): 2. 2. Return idlers: 2. 3. Training idler: 1. 4. Impact idler: 1. 5. Set of head pulley bearings: 1. 6. Set of tail pulley bearings: 1.


7. Drive motor: 1. 8. Set of drive belts: 1. 9. Speed reducer: 1. 10. Ten-foot section of conveyor belting: 1. 11. Bolted hinged stainless steel belt splice kits and splicing tools: 2. 12. Belt wiper blades: 2.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Belt conveyor: One of the following or equal: 1. KWS Manufacturing, Burleson, TX. 2. Custom Conveyor Corp., Rogers, MN. 3. JMS, Inc. Charlotte, NC.

2.02 COMPONENTS

A. Conveyor belting: 1. Conveyor belts: 24 inches wide:

a. Manufacturers: One of the following or equal: 1) Goodyear, Plylon 2100. 2) B.F. Goodrich, Hycar No. 210.

2. Belt shall have 2-ply nylon carcass with 1/8-inch cover on carrying side and 1/16-inch cover on pulley side.

3. Covers: Cover compound shall be resistant to deterioration from animal, vegetable fats and other oils. a. Manufacturers: One of the following or equal:

1) Goodyear, "MORS." 4. Each shall be spliced once with a vulcanized splice and shall have a minimum

tension rating of 220 pounds per inch of belt width. 5. Belt shall be designed to withstand maximum operating and starting tensions,

both empty and fully loaded, and to bend properly over pulleys without overstressing cover, carcass or splice.

6. For belt conveyors less than 40’ long, belts shall be vulcanized in the conveyor manufacturer’s facilities. For conveyors longer than 40’ in length, conveyor manufacturer shall provide personnel to field vulcanize the belt onsite.

7. The conveyor shall have 3” high sidewalls vulcanized to the belt to contain the materials and prevent spillage. The sidewalls shall be recessed to provide sidewall stability and allow deflection wheels to transition the conveyor from horizontal to incline and incline to horizontal direction. Sidewall shall be spliced with cold vulcanizing kit and a single stainless-steel fastener. Sidewall splice shall be offset six-inches from the conveyor belt splice.

8. The belt shall have cleats spacing and height designed to contain product at the specified incline to prevent fallback. Cleats shall be factory vulcanized to the belt.

B. Pulleys: 1. Pulleys shall be solid faced pulleys of welded steel construction with taper lock

bushings: a. Manufacturers: One of the following or equal:

1) FMC-Link Belt Company.


2) Rex Chainbelt, Inc. 3) Precision Pulley & Idler.

2. Lagging shall be provided for head and tail pulleys. a. Lagging shall consist of a solid herringbone rubber coating vulcanized to a

rust-resistant steel backing plate. b. Steel plates shall be pre-formed to the pulley diameter. c. Rust resistant metal retainers shall be permanently welded to the pulley

face. d. Backing plates shall be designed to slide on the pulley and to be held by

the metal retainers. e. Rubber lagging shall have a durometer hardness of 50 Shore A scale. f. Lagging shall be grooved in a herringbone shaped pattern. g. Grooves shall be 1/4-inch wide by 1/4-inch deep, with a 1/4-inch minimum

thickness of rubber under the bottom of the groove. h. Grooves shall be spaced on 1-1/2-inch centers.

3. Shafts shall be of cold finished steel of adequate size to prevent excessive deflection or torsional stresses.

4. Head shaft and bend shaft bearings: At least 1 bearing on each shaft shall be adjustable for belt training purposes: a. Manufacturers: One of the following or equal:

1) FMC-Link Belt Company, Series 400. 2) Rex Chainbelt, Inc., normal duty 2000 Series, fixed pillow block roller

bearings. 3) Dodge Bearings.

5. Tail shaft bearings: Take-up as indicated on the Drawings: a. Manufacturers: One of the following or equal:

1) FMC-Link Belt Company, Series DS 3-400A. 2) Rex Chainbelt, Inc., normal duty 2000 Series take-up roller bearings. 3) Dodge Bearings.

6. Tail pulley pillow block bearing assembly shall be provided with a protected, corrosion resistant screw take-up (stainless steel) to adjust belt tension and alignment. a. Stainless steel screw take-ups shall be compatible with other materials in

the take-up assembly.

C. Idlers: 1. Conveyor idlers shall be flat as indicated on the Drawings.

a. Idlers shall be at least 2 inches wider than the conveyor belt. b. Outer shells shall be chambered to protect the belt. c. Idlers shall be supplied by a single manufacturer. d. Idler spacing shall not exceed the spacing indicated on the Drawings. e. Idlers shall have factory sealed bearings requiring no field lubrication. f. Idlers shall be covered with corrosion and wear resistant urethane and

supported from type 304 stainless steel frame by type 304 stainless steel brackets.

2. Training idlers shall be similar to the troughing idlers with the carrying roll frame mounted on a central pivot approximately perpendicular to the conveyor belt. a. Placement of the training idlers shall be based on the manufacturer's

calculated belt tension and standard industry practice. b. Training idlers or side guide idlers shall be provided as indicated on the

Drawings, or as required to maintain proper belt alignment.


c. Idler frames shall be 1 piece, jig-welded having formed steel end and center brackets welded to an inverted angle, or equivalent construction. Idlers shall be for continuous operation, medium capacities.

3. Return idlers shall be 5-inch diameter rubber tread rolls. 4. Impact idlers shall be used at loading and transfer points as indicated on the

Drawings. a. Idlers shall have grooved, molded rubber rolls. b. A minimum of 3 impact idlers shall be provided at each loading and

transfer point or as indicated on the Drawings. 5. Side guide idlers:

a. Where indicated on the Drawings and where necessary. b. Side guide idlers shall be 4 inch in diameter with 5-inch face and shall

have roller bearings: c. Manufacturers: One of the following or equal:

1) FMC-Link Belt Company. 2) Rex Chainbelt, Inc. side guide idlers. 3) Precision Pulley & Idler.

6. Idlers shall be suitable for travel in either direction.

D. Weather Covers: 1. Where indicated on the Drawings and where the belt conveyor is located

outdoors. 2. Top and bottom covers for full enclosure with access doors for maintenance. 3. Provide hinged covers with latches, screw will not be accepted. 4. Covers shall be minimum 3/16 inch thick type 304 stainless steel with capped

edges.

E. Belt cleaner: 1. Drive station shall be provided with belt scrapers for scraping of the full belt

width. a. Scrapers shall be adjustable spring-loaded type with grease and

oil-resistant neoprene or rubber blades. 2. Scrapers:

a. Fabricated of type 6061-T6 aluminum. b. Scrapers shall be mounted to belt conveyor frame: c. Manufacturers: One of the following or equal:

1) Conveyor Components Company, Type FA.

F. Zero motion switch: 1. Zero-motion switch assembly shall be installed on the tail pulleys.

a. Assembly shall consist of a 6-inch diameter pulley connected to a plugging switch with flexible coupling.

2. Plugging switch shall be housed in a NEMA 4X enclosure suitable for a Class I, Division 2 hazardous location, and mounted off the side of the conveyor frame with a bolted aluminum bracket.

3. Contacts shall be normally closed. 4. Switch shall have a field adjustable time relay of 0 to 30-second and be rated

at 20 amps, double pole double throw, 120 volts alternating current. 5. Plugging switch:

a. Manufacturers: One of the following or equal: 1) Conveyor Components Co., Model MS.


G. Structural frames, supports, and exterior access platform: 1. Coordinate details of frames and supports with final layout, configuration and

details of conveyor. Check details for proper fit and assembly after fabrication. 2. Conveyor frame, support, and access platform sizes and configuration shall as

indicated on the Drawings and acceptable to the Engineer. a. Coordinate layout and details of conveyor supports with final configuration

of belt filter press units and other adjacent equipment. b. Provide access platform and stairs at discharge end of conveyor as

indicated on the Drawings. All components of platform including grating, guardrails, stairs, and equipment shields shall conform to applicable building code and OSHA requirements.

3. Design conveyor, conveyor supports, access platforms, and all required anchorage in accordance with the building code and for wind and seismic loadings specified in the specification submittals. a. Minimum live load on grating access areas and stairs: 100 psf. b. Provide supports required to carry the design load and to conform to

deflection criteria for all loading conditions, including conditions with conveyor fully loaded.

c. The last 10-feet of the belt conveyor is cantilevered over the biosolids pad as indicated on the Drawings. Design support structure to comply with the following criteria. 1) If required to satisfy these criteria and if acceptable to Engineer,

design may include vertical columns supported on the west wall of the Biosolids Storage Facility and diagonal tension ties with turnbuckles to support the cantilevered end currently shown on the Drawings.

2) General: Deflections as recommended by the conveyor manufacturer, subject to acceptance by Engineer.

3) Cantilevered end: Deflections not greater than the following: a) Total deflection: 1 inch, maximum, vertical and horizontal. b) Live/wind/seismic load deflection: not exceeding 1/2 inch

maximum, vertical and horizontal. c) Stiffness in resisting walking excitation (from operators) and

rhythmic excitation (from equipment): Conforming to criteria recommended in AISC Design Guide 11.

4. Materials: a. Structural steel: Type 304 stainless steel. b. Anchor bolts (to concrete): Type 316 stainless steel. c. Frame assembly bolts: Type 304 stainless steel bolts as required to match

steel of members being connected. d. Welding: In accordance with AWS requirements. e. Access platforms and stairs:

1) Guardrails: Aluminum. 2) Grating: Aluminum.

H. Adjustable screw take-up assemblies: 1. Protected screw type take-ups shall be provided for each conveyor.

a. Take-up to be located at the tail pulley and shall be equipped with double roller bearings.

b. Take-up adjustment of 30 inches minimum shall be provided. c. Take-up screw shall be type 316 stainless steel.


2. Take-up bearings shall be sized to accept a 2-15/16-inch diameter shaft and shall be Type E: a. Manufacturers: One of the following or equal:

1) Dodge, Inc. 3. Screw take-ups:

a. Manufacturers: One of the following or equal: 1) Link-Belt, Series DSH-B22500H, extra-strength welded steel frame. 2) Dodge, Frame No. TP40.

I. Drip Pans: 1. Drip Pan shall be type 304 stainless steel and shall be a minimum 12-gauge

thickness. Drip pan shall be provided beneath the return belt on all sections of the conveyor.

2. The edges of the drip pan shall extend beyond the belt edges at least 2 inches and shall turn up at least 2 inches.

3. The drip pans drains shall have a 3 inch threaded connection to accept hose.

J. Conveyor guards and skirt boards: 1. Guards for conveyor equipment:

a. Fabricate from type 304 stainless steel unless otherwise indicated on the Drawings.

b. Guards shall be free-draining to prevent accumulation of water. c. Include appropriate guards for chain drives, nip guards at nip points. d. Nip guards at the take-up pulleys shall be constructed such that the nip

point will still be guarded throughout the entire take-up range. 2. Belt conveyor shall be provided with skirt boards continuous along the width of

each belt filter press discharge indicated on the Drawings. a. Skirt boards shall be mounted from the conveyor framework and

positioned indicated on the Drawings. b. Loading skirts shall be fabricated of type 304 stainless steel as indicated

on the Drawings. c. Each skirt shall be provided with full-length 1/2-inch by 6-inch neoprene

edging bolted to the skirt boards with provisions for vertical adjustment. 3. Height and width of the skirt boards design shall be coordinated with the belt

filter press manufacturer to allow extension of the belt filter press discharge chute pan over the belt conveyor.

K. Emergency Pull Cords/Safety stop switch: 1. Belt conveyors, as a minimum, shall meet the applicable sections of

ASME B20.1 and OSHA Standards. 2. Cable-operated stop switch shall be mounted on both sides of each conveyor.

a. Stop switches shall be activated by tag lines that extend the full length of the conveyor.

b. Stop switch shall be designed for cable operation in both directions from 1 electrical connection.

c. Stop switch shall be double plug, double throw to handle multiple electrical signals.

d. Stop switch shall be equipped with a positive safety lock to prevent accidental reset of the switch.

e. Actuating force on the cable shall be field adjustable.


3. Safety switch housing and associated components shall be constructed as suitable for a Class I, Division 2 hazardous location. a. Cable shall be a 3/32-inch, 7-by-7 preformed, galvanized aircraft cable

coated with an orange colored vinyl to a 3/16-inch overall outside diameter.

4. Manufacturers: One of the following or equal: a. Conveyor Components Company, Croswell, MI, Model RS.

L. Conveyor drives: 1. Each belt conveyor shall be belt driven through a shaft-mounted speed

reducer. a. Reducer and belt drives shall be of proper ratios to provide the required

conveyor belt speed. 2. Each motor shall be severe duty with integral induction brake. 3. Each belt drive shall be of the multiple V-belt type with stationary drive

sheaves and companion sheaves and shall have a rigid belt guard. a. Slide base shall be provided for belt slack adjustment. b. Enclosed belt guard shall be suitably anchored and arranged to be

removed without removing belts. 4. Gear reducer shall be enclosed in a dust-tight cast-iron enclosure with ample

space provided for oil. a. Lubrication shall be by splash lubrication with gears operating in an oil

bath. b. Casing shall include provisions for filling and draining the oil and shall

have an oil level gauge in a convenient location. 5. Gear reducer shall be of the parallel shaft type with split case for easy

maintenance. a. Gear reducer shall be designed for conveyor easy service, and have a

minimum AGMA service factor of 1.5. b. Gear reducer shall have an AGMA nameplate. c. Drive shall have an integral backstop in the gear reducer to prevent the

conveyor from running backwards when not in operation. 6. Maximum noise level measured 5 feet from each drive shall not exceed

85 dBA. 7. Conveyor drive motor shall be of a standard frame size and have the following

characteristics in addition to those specified:

Horsepower Not less than 5 Volts 460 Phase 3 Hertz 60 Insulation Class F W/B rise or H, moisture resistant Service factor 1.15 Ambient temperature 40 Centigrade Enclosure TEFC Revolutions per minute 1,800


8. Gear reducer: Shaft mounted on the 2-15/16-inch shaft: a. Manufacturers: One of the following or equal:

1) Falk Corporation. 2) Dodge, a Division of Reliance Electric.

9. Motor shall contain motor winding heater.

M. Controls: 1. Provide associated controls, including alarms and alarm switches as indicated

on the Drawings. a. Operation and control shall be as shown on the electrical schematic

diagrams and process and instrument diagrams. 2. A belt misalignment roller microswitch housed in a NEMA 4X corrosion

resistant housing shall be installed on each side of the head and tail pulley so that a belt movement of more than 1 inch to either side will send a signal.

N. Discharge Chutes: 1. Discharge chutes shall be provided as indicated on the Drawings. The chutes

shall be of sufficient size whereby material can be transferred without spillage or clogging. Suitable deflector plates shall be attached to the inside of the chutes to limit falling velocities.

2. Shields shall be provided around the discharge end of the chutes to prevent splashing and spillage.

3. Discharge chutes shall be provided with bracing and supports as necessary. a. Chutes shall be a minimum 10-gage thickness type 304 stainless steel.

The interior of the chute shall be lined with 1/4-inch thick UHMW polyethylene and shall be bolted to the chute.

O. Bolts, nuts, fasteners, and hardware: Type 18-8 stainless steel throughout.


END OF SECTION


SECTION 14593

POST-THP SLUDGE STORAGE SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Complete Sludge Storage System including cake conveyance system, cake storage, and truck loading system, excluding the associated local control panels, and other appurtenances as required for a complete conveyance and storage system for centrifuge dewatered municipal sludge cake. All components of the Solids Storage System as specified herein and in associated Sections shall be the responsibility of a single supplier, hereinafter referred as the “Primary Supplier,” unless otherwise specified.

B. Equipment: 1. Cake Storage.

C. Dimensions: 1. Rectangular: 40-feet width, 20-feet length. 2. Volume of storage: 389-Cubic YardsA.

1.02 DESCRIPTION

A. General: 1. Where other listed Standards and Specifications differ in requirements and

interpretations, they shall take precedence over CEMA Standards.

B. All components of the Sludge Storage System shall be the responsibility of a single supplier, hereinafter referred as the “Primary Supplier.” In addition to the Sludge Storage System specified herein, the Primary Supplier shall also provide the complete conveyor system, and shall be responsible for coordinating the physical and operational requirements of the individual components of the systems to result in a complete and operational system. Primary Supplier shall coordinate the design of the system including foundations and structural supports for all components, access to components for operation and maintenance, equipment controls and the general physical relationship of the system components.

C. The Primary Supplier is not responsible to design and provide the concrete building that encloses the cake loading facility. That enclosure structure shall be supplied and constructed by the Contractor as shown on the Drawings. The Primary Supplier is not responsible to design and provide the truck scale. The truck scale shall be provided by the Contractor.

D. Cake Storage Silos: 1. One silo designed to receive, store, and discharge dewatered cake from the

cake conveyor system. 2. Each silo shall be covered with tread plate and provided with a foul air duct

connection for foul air removal as indicated on the Drawings.


3. The manufacturer shall be responsible for designing and providing the ships ladder, access platforms, and supports for the silos, conveyors, and all other appurtenances.

4. The silos shall be provided with OSHA approved railing and walkways, as indicated on the Drawings.

5. Each silo shall have the ability to install two Contractor furnished ultrasonic level instruments to determine levels in the silo.

E. Screw Conveyors: As specified in Section 14554 Screw Conveyors.

F. Enclosure ratings: 1. All instrumentation and control equipment shall be rated for a minimum of

NEMA 4X. 2. Provide NEMA 7 rating for classified areas.

1.03 REFERENCES

A. American Institute of Steel Construction, Inc. (AISC).

B. Anti-Friction Bearing Manufacturers Association (AFBMA).

C. American Gear Manufacturers Association (AGMA).

D. ASTM International (ASTM): 1. A 36 – Standard Specification for Carbon Structural Steel. 2. A 242 – Standard Specification for High-Strength Low-Alloy Structural Steel.

E. Standards of the American Welding Society (AWS).

F. Conveyor Equipment Manufacturers Association (CEMA).

G. National Electrical Manufacturers Association (NEMA): 1. 250 – Enclosures for Electrical Equipment (1000 V Maximum).

H. National Fire Protection Agency (NFPA): 1. 70 – National Electrical Code (NEC). 2. 820 – Fire Protection in Wastewater Treatment and Collection Facilities.

1.04 DEFINITIONS

A. NEMA Type 4X enclosure in accordance with NEMA 250.

B. NEMA Type 7 enclosure in accordance with NEMA 250.

1.05 ASSEMBLY REQUIREMENTS

A. General: Include all material and equipment necessary to provide complete working system, except such material and equipment specifically excluded. Provide all fasteners, whether shop installed or not, for structural supports and mechanical equipment.


B. Clearances: Install equipment of the approximate dimensions shown or specified to fit the spaces shown with adequate clearances, and capable of being handled through openings provided in the structure for this purpose.

C. Fabricated Sections: Furnish all fabricated sections shop assembled into units as large as practicable and as shipping regulation will permit and matched marked for the field assembly, in order to keep the field assembly to a minimum. Furnish required lifting lugs. Field welding, if required, shall be completed by the Contractor, in strict accordance with the manufacturer’s instructions.

D. Identification: Clearly identify loose items by equipment number and erection mark numbers to facilitate assembly.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Cake silo: One of the following, no equal: 1. Spirac. 2. Jim Myers & Sons, Inc. 3. KWS Manufacturing Co., Ltd. 4. Custom Conveyor Corporation. 5. Schwing Bioset.

2.02 DESIGN REQUIREMENTS

A. Design and manufacture components for dewatered undigested municipal sludge containing between 20 and 35 percent solids by dry weight, and bulk density between 45 and 65 pcf.

B. Silo shall have a material storage capacity of 450 cubic yards.

C. Project design criteria: As specified.

D. Seismic design criteria: As specified.

E. Wind design criteria: As specified.

F. Live Load: 1. Platforms and walkways live load of 100 psf. 2. Silo cover live load of 100 psf.

G. Design silo supports to support the weight of the storage silos and its related components, and the weight of dewatered sludge when full. An additional live load of 90 pounds per square foot based on the top dimensions of the storage silo shall be included in the design. The number and location of the supports shall designed as indicated on the Drawings. 1. The maximum weight for each sludge storage system, including the cake silo,

live bottom conveyor, structural supports, platforms, weight of Silo Loading Conveyors, Horizontal Transfer Conveyor, weight of solids at maximum level (460 tons) shall not exceed 590 tons.


H. Comply with all other applicable sections of the specifications.

I. The Primary Supplier is responsible for detailed design, including the structural supports of the silos, all conveyors and associated equipment as described in this Section and other associated Sections.

2.03 MATERIALS

A. Silo shall be fabricated from A167 Stainless Steel, Type 304L.

B. Silo and Conveyor Supports: Stainless Steel, Type 304L.

C. Structural Steel: Structural steel shall be fabricated in accordance with Specifications.

D. Metal Fabrications: In accordance with Specifications.

E. Grating: Type 304 stainless steel.

2.04 CAKE STORAGE SILOS

A. Cake Silos: 1. Each cake silo shall be of the general configuration indicated in the Drawings,

and shall be of welded steel construction conforming with the materials required in this specification. A bolted and gasketed silo is not acceptable.

2. The silo shall be structurally adequate to safely support their own weight, the full weight of material weighing 65 pcf, seismic loads, wind loads, snow loads, and the associated live/dead loads of the appurtenances.

3. The size, configuration, and accessory locations for each component shall be as indicated in the Drawings and described in this section.

4. Angle of sloped sides and ends shall be not less than 65 degrees from horizontal.

5. The silos shall be watertight. 6. The Primary Supplier shall provide a closure detail that is a watertight seal at

the roof between the silo units and the concrete roof. This closure detail must be designed in accordance with structural design criteria, contract documents. Submit design and drawings sealed by a registered engineer in the state of Texas for review.

7. Silos shall be shop fabricated with structural reinforcement as required. Silo discharge flanges and flange bolt holes shall be coordinated to match foundation locations and adjoining equipment locations.

8. Silo interior shall be smooth, with no protruding flanges or structural members which could impede the flow of material.

9. Each silo structure shall be supported by structural legs and located generally as indicated on the Drawings, maintaining minimum clearances shown. Provide all necessary stiffeners, bracings, frames, and supports for the silo fabrication and support.

B. Access Platforms and Stairs: 1. The Supplier shall design and supply all structural supports for the access

platforms and stairs, unless otherwise specified herein. Supports shall be generally as shown on the Drawings and as specified herein.


2. All supports shall be designed in accordance with the specified design criteria including seismic and wind.

3. The Supplier is responsible for detailed design, including structural supports, of the access platforms and stairs.

4. Configuration of access platforms and stairs shall be as shown on the Drawings. Provide non-skid surface on access platforms and stairs.

5. Supports shall allow building thermal movement across expansion joints. 6. All support locations shall be submitted for approval and revised if required to

coordinate with allowable structural loading, site constraints, and access. 7. The access platform supports shall also provide support for all piping,

ventilation ducts and electrical conduit as indicated on the Drawings. Supports for piping, ventilation ducts and electrical conduits shall be designed and supplied by the Contractor and shall be coordinated with the solids storage system supplier and design of the supports.

C. Silo Live Bottom Gates: 1. All silo live bottom gates shall be complete, including discharge chute,

horizontal gate blade, gate operator, and miscellaneous accessories in accordance with Specifications.

2. The horizontal slide gates shall be fabricated and contain components adequate to meet the following capacities and service conditions: a. Material: Dewatered municipal sludge. b. Bulk Density: 45 to 65 pounds per cubic foot. c. Solids Percent Weight: 20 to 35 percent. d. Angle of Repose: 0 to 45 degrees. e. Characteristic: Very abrasive.

3. The gates shall be equipped with pneumatic actuators (double cylinder) and be able to move and hold discrete open positions throughout the full range of gate blade travel to ensure accurate metering of sludge. a. Actuators shall be provided as specified in Specifications.

4. The gates shall be flanged, gasketed, and bolted to the live bottom conveyor discharge flanges. All gate operators shall be supported from the gate frame.

5. Each gate shall be designed to withstand the full capacity for the silo under unseating head. The gates shall be watertight.

6. All components of the gate shall be 316L stainless steel. 7. Gate opening shall be designed such that the width of the gate shall be at

least the full width of the live bottom conveyor trough. The length of the gate shall be as indicated on the Drawings.

8. The gate blade shall have a maximum deflection of 1/8 inch over the actual width of the blade or 1/1000 of the span of the gate, whichever is less, when under the design head. The blade thickness shall be a minimum 1-1/4 inches and shall be fabricated from a solid piece of 316L stainless steel. Liners will not be acceptable. The gate manufacturer must submit calculations showing the deflection under a load of 1,500 pounds per square foot or the load of a completely filled silo of the specified sludge cake, whichever is greater.

9. The silo discharge gates shall have a 316L stainless steel flanged connection. 10. Gaskets shall be furnished to match the flange which bolts to the live bottom

conveyor. Gaskets shall be 1/4 inch thick, neoprene rubber, conforming to the applicable parts of ANSI B16.21 and AWWA C207. Gasket material shall be free from corrosive alkali or acid ingredients and suitable for use in domestic sewage sludge. Gaskets shall be one-piece, full-face, with holes to pass the bolts.


11. Silo Discharge Chutes: a. Provide a discharge chute to be flange-mounted to under side of the

discharge end of the live bottom conveyors. Chute dimensions shall match the opening of the live bottom and extend a minimum of 3 feet below the discharge end of the live bottom conveyors or as indicated on the Drawings. Contractor to field cut bottom of chute to match truck height requirements. Discharge chute shall be one piece, heavy duty, nylon or polyester scrim reinforced vinyl material. Discharge chute shall be water repellent, mildew resistant and inherently flame retardant. Top hem shall be double reinforced.

D. For each silo, provide ten load cells and multi-channel weigh indicating transmitters to measure the weight of the contents of the entire silo. 1. Load cell:

a. Each load cell shall have a minimum capacity of 50,000 pounds. b. Load cells shall be certified by NTEP and meet the specifications set forth

by NIST H-44 for Class IIL devices. c. Load cell shall not require check rods of chain links for stabilization. d. Stainless steel construction and hermetically sealed with a minimum

NEMA 6P/IP68 (submersible) rating. e. Load cell shall have a positive-lock quick connector integral to its housing

for connecting and disconnecting the load cell interface cable at the load cell. The connector shall be of glass-to-metal, pin-type construction to maintain a hermetic seal. Alternatively, load cell cables shall be wired directly into load cells.

f. Load cells shall be connected via a CAN (Controller area network) bus system to the weight indicating transmitter.

g. Provide rough-in hardware, supports, connections, attachments, and other accessories required for complete installation.

2. Weight Indicating Transmitters: a. Weight indicating transmitters shall provide analog 4-20 mA outputs to the

Solids System Supplier Control Panel VCP. b. Weight indicating transmitters shall be powered using 120 VAC power

from the UPS power distribution line on Solids System Supplier Control Panel VCP.

c. Primary supplier is responsible for providing manufacturer’s cable between each load cell and the Weight indicating transmitters.

d. Provide a sunshield for all weight indicating transmitters located outdoors. 3. Electrical requirements:

a. Power supply: 1) Unless otherwise specified, the power supply to the equipment shall

be 120 volts, single phase, 60 hertz. 2) Where control voltages lower than the power supply voltage is

required, suitable control power transformers shall be furnished. b. Lightning protection: Lightning protection for each scale system shall be

provided to protect the load cells, instrumentation, and power supply. c. Grounding: Tinned 1/0 copper grounding conductors shall be furnished

and installed from the scales to the ground grid or to a ground rod furnished for the grounding electrode system as required by the equipment furnished.


E. Level Measurement: 1. For each silo, provide two 6 inch spool pieces with flanges to mount the

contractor-provided ultrasonic level measuring devices for each silo, located over the deepest part of each compartment. Contractor to provide ultrasonic level instruments as specified in Specifications.

2. The Solids System Supplier Control Panel shall accept the inputs from the Ultrasonic Level Indicating Transmitters.

F. Cake Loading Control Panel: 1. Contractor to coordinate with Primary supplier and provide the cake loading

control panel in accordance with Specifications. 2. At a minimum, provide the devices and functions specified in Specification and

as shown on the Drawings.


END OF SECTION


SECTION 14594

PRE-THP SLUDGE STORAGE SILOS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Complete Pre-THP Sludge Storage System including sliding frame, pre-THP cake storage, and truck loading system, excluding the associated local control panels, and other appurtenances as required for a complete conveyance and storage system for centrifuge dewatered municipal sludge cake. All components of the pre-THP Solids Storage System as specified herein and in associated Sections shall be the responsibility of a single supplier, hereinafter referred as the “Primary Supplier,” unless otherwise specified.

B. Two circular pre-THP cake silos to be provided with the following dimensions: 1. 22-feet diameter, 23-feet & 6-inch height.

C. Both pre-THP cake silos should be supported off the existing incinerator slabs in the dewatering facility.

D. Materials of Construction:

Silo, Bin, and Structure A167 Stainless Steel, Type 304L Conveyor/Livebottom Trough Construction A167 Stainless Steel, Type 304L

Spiral Flighting ASTM A242 steel. Minimum 3/16 in. thick. Wear Liner UHMW-PE with Wear Indicator Sliding Frame Assembly A167 Stainless Steel, Type 304L Handrails, Ladders, Platforms, Accessories As Specified

PART 2 PRODUCTS

2.01 MATERIALS

A. Methods of Construction: 1. Fabrication. All welds to be continuous unless otherwise specified. Facing

surfaces of field-welded components are beveled and match marked. 2. Welding: All shop welding conforms to the latest standards of the American

Welding Society (AWS). 3. Edge Grinding. Sharp corners of all cut and sheared edges are made smooth. 4. Fasteners. Bolts, nuts, washers, and other fasteners are stainless steel. 5. Surface Preparation:

a. Iron and mild steel surfaces to be coated, are dry abrasive blasted in accordance with SSPC-SP6. Surfaces are painted or hot dip galvanized within 24 hours to prevent rusting and surface discoloration.


b. Stainless steel is cleaned with mild abrasive wheels and/or nonferrous blast media to remove heavy scale and welding carbon and/or passivated with stainless steel cleaner, then rinsed.

6. Painting. a. Stainless Steel surfaces do not require painting, and spirals shall be

furnished with one coat of shop primer only. b. Painted Silos and Bins shall receive factory applied 2 part coating of

Tnemec epoxy, suitable for the application and approved by the reviewing authority.

c. Wetted Sliding Frame Components shall be coated with an abrasion resistant coating system to a total minimum 30 mils DFT. Acceptable coating types are SherGlass FF, PPG Sigmaguard 790, or approved equal.

d. Electric motors, gear reducers, electrical control panels, and other purchased sub-components shall be furnished with the manufacturer’s standard finish for the specified environment.

B. Round Silo with Sliding Frame: 1. Silo shall include a Sliding Frame Assembly with Hydraulic Power Unit and

integral controls. 2. The bin design shall be cylindrical with a flat operating surface, and include a

sliding frame system for enhanced outloading and reduced risk of bridging. All internal components shall be coated with the specified epoxy to reduce friction and protect the surface.

3. The entire structure shall be designed to prevent water from pooling at or seeping from, any joints. The cover shall be rated for foot traffic, and have an elastomeric weatherseal gasket, which shall form a continuous watertight seal along the cover's edge.

4. The Silo cover shall include flanged connections for odor control, vents, sensors, inspection and/or maintenance access (sizes as required) and other appurtenances indicated in the Contract Documents.

5. Silo shall be constructed of A167 Stainless Steel, Type 304L, minimum 1/4-inch thickness and shall be reinforced as required. Steel supports and framework, shall be provided to incorporate Load Cells, and support the hopper from the concrete floor as indicated.

6. Sliding Frame: a. The Sliding Frame shall be hydraulically operated, with frame components

fabricated of A167 Stainless Steel, Type 304L structural steel members. b. Each sliding assembly shall include floor guides to reduce lifting, with

bolted top plates for ease of installation and service. c. Sliding frame cylinders shall penetrate the sidewalls through a fully

serviceable stuffing box, mounted with fasteners to a mating plate fixed to the silo wall.

d. Each sliding frame shall be supplied with a Hydraulic Power Unit with integral local Control Panel, for a complete standalone system.

e. Cylinders shall have front end trunnion mount, and utilize fixed cushions with a threaded rod.

f. The cylinder piston rod shall be chrome-plated steel with clevis style rod end connection. Cylinders and the rod mounted proximity sensors, shall be protected by a corrosion resistant cover fixed to the cylinder mounting frame.



END OF SECTION


SECTION 14633

TOP RUNNING DOUBLE GIRDER BRIDGE CRANES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Top running double girder bridge crane.

1.02 REFERENCES

A. American Society of Civil Engineers (ASCE).

B. Crane Manufacturers' Association of America, Inc. (CMAA).

C. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS

A. NEMA Type 4 enclosure in accordance with NEMA 250.

B. Arrange working parts for convenient inspection, lubrication, adjustment, repair, and replacement.

1.04 SUBMITTALS

A. Submit as specified in Section OR-01300 - Submittal Procedures.

B. Product data: 1. Parts, devices, and accessories including special safety and control devices. 2. Manufacturer's installation instructions.

C. Calculations: 1. Structural and seismic calculations for runway beams, rails, bridge beams, and

anchor bolts.

D. Shop drawings: 1. Dimensional drawings and other construction details, including materials of

construction, equipment weights, electrical connection diagrams, and schematics showing electrical control or power requirements.

2. Include CMAA Specification No. 79- Crane Operators Manual and CMAA Overhead Crane Inspection and Maintenance Checklist.

E. Commissioning submittals: 1. Manufacturer’s Certificate of Source Testing as specified in Section OR-01756

- Commissioning. 2. Manufacturer's Certificate of Compliance with Federal Regulations. 3. Provide Manufacturer’s Certificate of Installation and Functionality Compliance

as specified in Section OR-01756 - Commissioning.


F. Design data: Structural and seismic calculations for rails and bridge beams.

G. Certificates: 1. Certificate of tests conducted by the crane manufacturer in accordance with

industry standards and federal regulations: a. Prior to shipment.

2. Load test certificate.

H. Project closeout documents: 1. Provide vendor operation and maintenance manual as specified in

Section OR-01770 - Closeout Procedures: a. Include CMAA Specification No. 79- Crane Operators Manual and CMAA

Overhead Crane Inspection and Maintenance Checklist.

1.05 WARRANTY

A. Provide warranty as specified in Section OR-01770 - Closeout Procedures.

PART 2 PRODUCTS

2.01 GENERAL

2.02 MANUFACTURERS

A. Top running double girder bridge crane: 1. One of the following or equal with Owner approval:

a. Heco Pacific Manufacturing. b. CraneWorks, Inc.


A. Design requirements: 1. Design in accordance with CMAA Specification No. 70. 2. Top running, double girder, traveling bridge crane system with electric motor-

driven bridge and electric motor-driven trolley, hoist, bridge crane girders, girders cross bracing, end trucks, runways, rails, end stops, complete electrification and reels, and accessories based on the following values:

Item Requirement Equipment Name Centrifuge Bridge Crane Capacity 15 Tons Span (center to center crane runway) See Drawings Approximate hoisting speed, (minimum/maximum for range of speed)

16/4 feet per minute

Approximate travel speed of trolley (minimum/maximum for range of speed)


Approximate travel speed of bridge (minimum/maximum for range of speed)



Item Requirement Hoist motor, minimum 20 horsepower Trolley motor, minimum 1 horsepower Bridge end truck motors, minimum 1 horsepower

3. The bridge crane will be used to lift and move large centrifuge components within the centrifuge room and outside the dewatering building.

B. Cranes shall conform to CMAA Service Class A2 for infrequent use.

C. Assemble, paint, test, and adjust crane system in manufacturer’s shop before shipment as far as practical.

D. Arrange working parts for convenient inspection, lubrication, adjustment, repair, and replacement.

2.04 MANUFACTURED UNITS

A. Bridge: 1. Top running, double girder type, supported by end trucks on crane rail.

a. End trucks: Structural steel members capable of distributing loading equally to each wheel.

b. Wheels: Minimum 2-inch diameter; double flanged with rotating axles and safety lugs; forged steel, hardened to 425 Brinell fitted with anti-friction bearings with seals and grease fittings.

c. Stops and bumpers: Capable of absorbing energy and stopping moving bridge at end of travel.

B. Bridge drive unit: 1. Type: Single-speed, adjustable torque cushioned start, motor-driven CMAA

units at ends of bridge. a. Tractor type drives are not acceptable.

2. End trucks: 2-inch minimum diameter wheels with safety lugs. 3. Speed reducers: Oil-lubricated with oil tight cases. 4. Shaft bearings: Anti-friction. 5. Holding brakes: Cushioned stop. 6. Motors: Specially designed and constructed for crane service; 460 volt,

3 phase, 3 wire, TENV squirrel-cage induction type, operating at 1,800 revolutions per minute maximum, with Class B or Class F insulation.

C. Trolley and hoist: 1. Trolley drive: Provided with adjustable torque cushioned start feature and

single or dual-speed motor, and direct current cushioned stop holding brakes. Tractor drive units are not acceptable. a. Double-flanged wheels with rotating axles: Forged steel, hardened to

425 Brinell, and fitted with anti-friction bearings with seals and grease fittings.

b. Drive units: Separate for each runway or one that drives wheels on runway through a common shaft.

c. Trolley head wheels: Minimum 5-inch diameter wheels with safety lugs.


2. Hoist: HMI Duty Service Classification H2 (Standard); single or dual-speed, electric motor-driven, with load break, lower limit switch, and an overload device. a. Load break:

1) Mechanical Weston multiple disc type running in an oil bath and automatically holding loads indefinitely and permitting lowering without acceleration under full control.

2) Direct current operated motor brake acting directly on the motor pinion shaft the instant power is shut off.

3) Capable of sustaining a load equal to 125 percent of hoist capacity. 4) Capable of at least 15 operations per minute, and controlled smooth

inching for both directions in vertical plane. 5) Hoisting drum: 6) Steel or cast iron with machined grooves to depth equal to 1/2-rope

diameter. 7) Capable of retaining at least 2 complete wraps of rope with hook in

lowest position and accommodating full rope length without overlapping when hook is in highest position.

b. Hoisting rope: Specifically designed for specified service loads; preformed, improved plow steel with fiber core; double-reeved.

c. Hoisting block: Steel with hook supported on ball or roller bearings. d. Hoisting block hook: Forged or rolled steel freely rotating on bearing

support and with heavy-duty type safety latches. 3. Drive speed reducers: Oil-lubricated heat-treated steel helical gears with oil

tight cases, and shafts running in anti-friction bearings. 4. Drive motors:

a. A specially designed and constructed for crane service. b. 460 volt, 3 phase, 3 wire, TENV squirrel-cage induction type, operating at

1,800 revolutions per minute maximum, with Class B or Class F insulation.

D. Crane rails: 1. ASCE crane rail: 40 pound.

a. Splice using light splice joints by bolting. 2. Rail:

a. Rail shall be arranged so that joints on opposite sides of the runway will be staggered with respect to each other and with respect to the wheelbase of the crane.

b. Rail joints shall not occur at crane girder splices.

E. Rail clamps: 1. Rail clamping shall use steel plates with eccentric fillers for adjustment of rail

location. 2. Clamps shall be double-hole fixed clamps at 2 feet apart on each side of rail in

staggered position.

F. Electrification: 1. Runway: Insulated bar electrification 3 power, 1 ground. 2. Bridge: Industrial rigid track festoon system. 3. Control voltage: 120 volts alternating current, supplied from a transformer on

the crane.


G. Control: 1. Capable of controlling hoist speed, trolley travel, and bridge travel. 2. Unit Type: Pendant, momentary-contact, maintain-pressure type, automatically

de-energizing, 2-speed pushbutton stations hanging from hoist and attached to bridge, supported by a steel cable parallel to the control cable.

3. Pushbuttons: a. Start-stop. b. 2 Pushbuttons for hoisting: 1 for each direction. c. 2 Pushbuttons for trolley travel: 1 for each direction. d. 2 Pushbuttons for crane travel: 1 for each direction.

4. Push button labels: Directions of horizontal motions clearly marked on bridge or trolley and on control pendant.

5. Pendant control station and other electrical control enclosures: NEMA Type 4 6. Limit switches: Set to limit the up and down travel of hook to stop hoist at

highest safe point. 7. Electric power: 480 volt, 3 phase, 60 hertz electric service with junction boxes

for connection of field services and ground pad.


END OF SECTION

January 2020 - DRAFT 15936-1 11168A60 pw://Carollo/Documents/Client/MO/Kansas City/11168A60/Specifications/Specs-Custom/15936 (PDS)

SECTION 15936

BUILDING AUTOMATION SYSTEM

PART 1 - GENERAL

1.01 SUMMARY

A. This Section includes control equipment and installation for HVAC systems and components, including control components for terminal heating and cooling units not supplied with factory-furnished controls.

B. See "Sequences of Operation" on plans for requirements that relate to this Section.

1.02 DEFINITIONS

A. BACnet: An industry standard data communication protocol for Building Automation and Control Networks. Refer to the latest version of AHSRAE standard 135.

B. Scope Terminology: 1. Provide = Furnish equipment, engineer, program and install. 2. Furnish = Furnish equipment, engineer and program. 3. Mount = securely fasten or pipe. 4. Install = mount and wire. 5. Wire = wire only.

1.03 WORK INCLUDED

A. The BAS Contractor shall provide a complete and operational system that will perform the sequences of operation as included in Contract Documents.

B. Furnish a complete distributed direct digital control system in accordance with this specification section. This includes all system controllers, logic controllers, and all input/output devices. Items of work included are as follows: 1. Provide a submittal that meets the requirements below for approval. 2. Coordinate installation schedule with the mechanical contractor and general

contractor. 3. Provide installation of all panels and devices unless otherwise stated. 4. Provide power for panels and control devices unless otherwise stated. 5. Provide all low voltage control wiring for the DDC system. 6. Provide miscellaneous control wiring for HVAC and related systems regardless

of voltage. 7. Provide engineering and technician labor to program and commission software

for each system and operator interface. Submit commissioning reports for approval.

8. Provide testing, demonstration and training as specified below.

C. The installation of the control system shall be performed under the direct supervision of the controls manufacturer with the shop drawings, flow diagrams, bill of materials, component designation, or identification number and sequence of operation all bearing the name of the manufacturer.


1.04 SUBMITTALS

A. Provide submittals for fast track items that need to be approved and released to meet the schedule of the project. Provide submittals for the following items separately upon request: 1. Valve schedule and product data. 2. Damper schedule and product data. 3. Mounting and wiring diagrams for factory-installed control components. 4. Thermostat locations.

B. Provide a complete submittal with all controls system information for approval before construction starts. Include the following: 1. Schematic flow diagrams showing fans, pumps, coils, dampers, valves, and

control devices. 2. Wiring Diagrams: Power, signal, and control wiring. Detail the wiring of the

control devices and the panels. Show point-to-point wiring from field devices to the control panel. Show point-to-point wiring of hardwired interlocks. Show a ladder diagram or schematic of wiring internal to the panels, including numbered terminals. Clearly designate wiring that is done at a factory, at a panel shop or in the field.

3. Details of control panel faces, including sizes, controls, instruments, and labeling.

4. Schedule of dampers and actuators including size, leakage, and flow characteristics. If dampers are furnished by other, submit a damper actuator schedule coordinating actuator sizes with the damper schedule.

5. Schedule of valves including leakage and flow characteristics. 6. Written description of the Sequence of Operations. 7. Network riser diagram showing wiring types, network protocols, locations of

floor penetrations and number of control panels. Label control panels with network addresses and BACnet device instance numbers. Show all routers, switches, hubs and repeaters.

8. Point list for each system controller including both inputs and outputs (I/O), point numbers, controlled device associated with each I/O point, and location of I/O device.

9. Starter and variable frequency drive wiring details of all automatically controlled motors.

10. Reduced size floor plan drawings showing locations of control panels, thermostats and any devices mounted in occupied space.

11. Product Data: Include manufacturer's technical literature for each control device indicated, labeled with setting or adjustable range of control. Indicate dimensions, capacities, performance characteristics, electrical characteristics, finishes for materials, and installation and startup instructions for each type of product indicated. Submit a write-up of the application software that will be used on the operator workstation including revision level, functionality and software applications required to meet the specifications.

12. Submit BACnet Protocol Implementation Conformance Statements (PICS) for all direct digital controllers, software and other system components that will communicate on the BAS utilizing BACnet.

C. Submit blank field check-out and commissioning test reports, customized for each panel or system, which will be filled out by the technician during start-up.


D. Variance letter: Submit a letter detailing each item in the submission that varies from the contract specification or sequence of operation in any way.

E. Operation and Maintenance Data: In addition to items specified in Section OR-01770 - Closeout Procedures, include the following: 1. Product data with installation details, maintenance instructions and lists of

spare parts for each type of control device. 2. Keyboard illustrations and step-by-step procedures indexed for each operator

function. 3. Inspection period, cleaning methods, cleaning materials recommended and

calibration tolerances. 4. Calibration records and list of set points.

1.05 PROJECT RECORD DOCUMENTS

A. Project Record Documents: Submit three (3) copies of record (as-built) documents upon completion of installation. Submittal shall consist of: 1. Project Record Drawings. As-built versions of the submittal shop drawings

provided as AutoCAD compatible files in electronic format and as 11 x 17 inch prints.

2. Testing and Commissioning Reports and Checklists. Completed versions of reports, checklists, and trend logs used to meet requirements in the Control System Demonstration and Acceptance section of this specification.

3. Operation and Maintenance (O & M) Manual: a. As-built versions of the submittal product data. b. Names, addresses, and 24-hour telephone numbers of installing

contractors and service representatives for equipment and control systems.

c. Operator’s Manual with procedures for operating control systems, logging on and off, handling alarms, producing point reports, trending data, overriding computer control, and changing set points and variables.

d. Programming manual or set of manuals with description of programming language and of statements for algorithms and calculations used, of point database creation and modification, of program creation and modification, and of editor use.

e. Engineering, installation, and maintenance manual or set of manuals that explains how to design and install new points, panels, and other hardware; how to perform preventive maintenance and calibration; how to debug hardware problems; and how to repair or replace hardware.

f. Documentation of all programs created using custom programming language, including setpoints, tuning parameters, and object database.

g. Graphic files, programs, and database on electronic media. h. List of recommended spare parts with part numbers and suppliers. i. Complete original-issue documentation, installation, and maintenance

information for furnished third-party hardware, including computer equipment and sensors.

j. Complete original original-issue copies of furnished software, including operating systems, custom programming language, operator workstation software, and graphics software.

k. Licenses, guarantees, and warranty documents for equipment and systems.


B. Operating manual to serve as training and reference manual for all aspects of day-to-day operation of the system. As a minimum include the following: 1. Sequence of operation for automatic and manual operating modes for all

building systems. The sequences shall cross-reference the system point names.

2. Description of manual override operation of all control points in system. 3. BMS system manufacturers complete operating manuals.

C. Provide maintenance manual to serve as training and reference manual for all aspects of day-to-day maintenance and major system repairs. As a minimum include the following: 1. Complete as-built installation drawings for each building system. 2. Overall system electrical power supply schematic indicating source of

electrical power for each system component. Indicate all battery backup provisions.

3. Photographs and/or drawings showing installation details and locations of equipment.

4. Routine preventive maintenance procedures, corrective diagnostics troubleshooting procedures, and calibration procedures.

5. Parts list with manufacturer's catalog numbers and ordering information. 6. Lists of ordinary and special tools, operating materials supplies and test

equipment recommended for operation and servicing. 7. Manufacturer's operation, set-up, maintenance and catalog literature for each

piece of equipment. 8. Maintenance and repair instructions. 9. Recommended spare parts.

D. Provide Programming Manual to serve as training and reference manual for all aspects of system programming. As a minimum include the following: 1. Complete programming manuals, and reference guides. 2. Information and access required for independent programming of system.


A. Codes: 1. Perform all wiring in accordance with Division 16, NEC, local codes and

Owner’s requirements. 2. Electrical Components, Devices, and Accessories: Listed and labeled as

defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

3. Comply with NFPA 90A, "Installation of Air Conditioning and Ventilation Systems."

4. Comply with ASHRAE 135-2010 BACnet: A Data Communication Protocol for Building Automation and Control Networks.

5. All equipment shall be UL listed and approved and shall meet with all applicable NFPA standards, including UL 916 - PAZX Energy Management Systems.

6. All electronic equipment shall conform to the requirements of FCC Regulation, Part 15, and Governing Radio Frequency Electromagnetic Interference and be so labeled.


7. The manufacturer of the building automation system shall provide documentation supporting compliance with ISO-9002 (Model for Quality Assurance in Production, Installation, and Servicing) and ISO-140001 (The application of well-accepted business management principles to the environment).

B. The BAS contractor shall maintain a service organization consisting of factory trained service personnel and provide a list of ten (10) projects, similar in size and scope to this project, completed within the last five years.

C. For any BAS system and equipment submitted for approval, the BAS contractor shall state what, if any, specific points of system operation differ from these specifications.

D. All portions of the system must be designed, furnished, installed, commissioned and serviced by manufacturer approved, factory trained employees.

E. The system shall have a documented history of compatibility by design for a minimum of 15 years. Future compatibility shall be supported for no less than 10 years.

1.07 COORDINATION

A. Coordinate IP drops, network connections, user interfaces, firewall, etc. with Owner’s IT representative.

B. Coordinate location of thermostats, humidistats, panels, and other exposed control components with plans and room details before installation.

C. Coordinate power for control units and operator workstation with electrical contractor.

D. Coordinate equipment with provider of starters and drives to achieve compatibility with motor starter control coils and VFD control wiring (if required).

E. Coordinate scheduling with the mechanical contractor and general contractor. Submit a schedule for approval based upon the installation schedule of the mechanical equipment.

F. Coordinate installation of taps, valves, airflow stations, etc. with the mechanical contractor.

G. Products furnished but not installed under this section: 1. Hydronic and Refrigerant Piping accessories:

a. Temperature Sensor Wells and Sockets. b. Pressure Sensor Wells and Sockets. c. Flow Switches. d. Differential Pressure Transmitters.

1.08 WARRANTY

A. Warranty shall cover all costs for parts, labor, associated travel, and expenses for a period of 12 months from completion of system demonstration.


B. Hardware and software personnel supporting this warranty agreement shall provide on-site or off-site service in a timely manner after failure notification to the vendor. The maximum acceptable response time to provide this service at the site shall be 24 hours.

C. During normal building occupied hours, failure of items that are critical for system operation shall be provided within 4 hours of notification from the Owner’s Representative.

D. This warranty shall apply equally to both hardware and software.

PART 2 PRODUCTS


A. The Building Automation System (BAS) contractor shall furnish and install a networked system of HVAC controls. The contractor shall incorporate direct digital control (DDC) for makeup air units, and exhaust fans.

B. Provide standalone controls where called for on the drawings or sequences.

2.02 BUILDING AUTOMATION SYSTEM NETWORK

A. All networked control products provided for this project shall be comprised of an industry standard open protocol internetwork. Communication involving control components (i.e. all types of controllers and operator interfaces) shall conform to ASHRAE 135-2010 BACnet standard.

B. The Building Level Controllers shall be able to support subnetwork protocols that may be needed depending on the type of equipment or application. Subnetworks shall be limited to: 1. BACnet MS/TP. 2. Apogee FLN. 3. Modbus.

C. Controllers and software shall be BTL listed at the time of installation.

D. Systems that use variations of BACnet using Point-to-Point (PTP) between controllers, gateways, bridges or networks that are not peer-to-peer are not allowed.

E. The system shall be installed with a 10 percent spare capacity on each subnetwork for the addition of future controllers.

2.03 CONTROL PANELS

A. Controllers in mechanical rooms shall be mounted in NEMA 4X enclosures.

B. Controllers in areas where moisture is a concern shall be mounted in NEMA 4X enclosures.


C. Panels shall be constructed of 16 gauge, furniture-quality steel, or extruded-aluminum alloy, totally enclosed, with hinged doors and keyed lock and with ANSI 61 gray polyester-powder painted finish, UL listed. Provide common keying for all panels.

D. Provide power supplies for control voltage power. Provide transformer to take the 120/1/60 power down to 24V control voltage.

E. Dedicate 1 power supply to the DDC controller. Other devices shall be on a separate power supply, unless the power for the control device is derived from the controller terminations.

F. Power supplies for controllers shall be a transformer with a fuse or circuit breaker. Power supplies for other devices can be plain transformers.

G. All power supplies for 24V low voltage wiring shall be class 2 rated and less than 100VA. If low voltage devices require more amps, then provide multiple power supplies. If a single device requires more amps, then provide a dedicated power supply in a separate enclosure and run a separate, non-class 2 conduit to the device.

H. Surge transient protection shall be incorporated in design of system to protect electrical components in all DDC Controllers and operator’s workstations.

2.04 UNINTERRUPTIBLE POWER SUPPLY

A. Provide an UPS for each of the following: 1. Main Control Panel.

B. Each UPS shall power the device for a minimum of 30 minutes, in the case of power interruption.

C. The UPS shall be DIN rail mounted within the associated control panel and consist of a battery power source, charger, AC output inverter system and automatic load transfer circuits for a full automatic operation.

D. The batteries shall be of the totally enclosed nickel-cadmium type or equal.

E. Provide UPS system compatible with KCMO Water Service Department Standards.

2.05 SENSORS

A. General: 1. Provide mounting hardware for all devices, including actuator linkages, wells,

installation kits for insertion devices, wall boxes and fudge plates, brackets, etc.

2. All temperature sensors shall meet the following specifications: a. Accuracy: Plus or minus 0.2 percent at calibration point. b. Wire: Twisted, shielded-pair cable. c. Vibration and corrosion resistant.


B. Equipment operation sensors as follows: 1. Status Inputs for Fans: Differential-pressure switch with adjustable range of

0 to 5 inches wg. 2. Status Inputs for Pumps: Differential-pressure switch piped across pump with

adjustable pressure-differential range of 8 to 60 psig. 3. Status Inputs for direct drive electric motors: Current-sensing relay with current

transformers, adjustable and sized for 175 percent of rated motor current. 4. Status inputs for belt drive electric motors: Current sensing transmitter with

linear 4-20mA output.

C. Air Differential Pressure Switches: Diaphragm type air differential pressure switches with die cast aluminum housing, adjustable setpoint, minimum 5 amp switch rating at 120VAC, SPDT switches, and the switch pressure range shall be suited for the application. Provide Dwyer or equal. These switches shall be utilized for filter status.

2.06 ELECTRO-MECHANICAL THERMOSTATS

A. Fire-Protection Thermostats: UL listed with fixed or adjustable settings to operate at not less than 75 degrees Fahrenheit above normal maximum operating temperature, with the following: 1. Reset: Automatic with control circuit arranged to require manual reset at

central control panel, with pilot light and reset switch on panel labeled to indicate operation.

B. Electric Low-Limit Duct Thermostat (Freezestat): Snap-acting, single-pole, single-throw, manual- or automatic-reset switch that trips if temperature sensed across any 12 inches of bulb length is equal to or below set point. Setpoint shall be adjustable. 1. Bulb Length: Minimum 20 feet. 2. Quantity: One thermostat for every 20 sq. ft. of coil surface.

PART 3 EXECUTION

3.01 INSTALLATION

A. Provide all relays, switches, sources of emergency and UPS battery back-up electricity and all other auxiliaries, accessories and connections necessary to make a complete operable system in accordance with the sequences specified. All field wiring shall be by this contractor.

3.02 ELECTRICAL WIRING SCOPE

A. This contractor shall be responsible for power that is not shown on the electrical drawings, to controls furnished by this contractor. If power circuits are shown on the electrical drawings, this contractor shall continue the power run to the control device. If power circuits are not shown, this contractor shall coordinate with the electrical contractor to provide breakers at distribution panels for power to controls. This contractor is then responsible for power from the distribution panel. 1. Coordinate panel locations. If enclosures for panels are shown on the

electrical drawings, furnish the enclosures according to the electrician’s installation schedule.


B. This contractor shall not be responsible for power to control panels and control devices that are furnished by others, unless it is part of the control interlock wiring.

C. Refer to Coordination section for what devices this contractor is responsible to mount and which are turned over to others to mount.

D. This contractor shall be responsible for wiring of any control device that is furnished as part of this section of specification.

E. Interlock wiring shall be run in separate conduits from BAS associated wiring.

F. Provide network wiring for equipment that is called to be integrated to the BAS.

3.03 ELECTRICAL WIRING AND CONNECTION INSTALLATION

A. All low voltage control wiring shall be class 2. Control wiring that is not class 2 shall be run in separate conduits from class 2 wiring.

B. Install raceways, boxes, and cabinets according to the Project Technical Requirements.

C. Install building wire and cable according to Division 16 Sections on wires cable and fiber optic cables.

D. Installation shall meet the following requirements: 1. Conceal cable and conduit, except in mechanical rooms and areas where

other conduit and piping are exposed. 2. Install exposed cable in raceway or conduit. 3. Install concealed cable using plenum rated cable.

E. Rigid conduit shall be steel, hot dip galvanized, threaded with couplings, ¾ inch minimum size, manufactured in accordance with ANSI C-80-1.

F. Concealed control conduit and wiring shall be provided in all spaces except in the Mechanical Equipment Rooms and in unfinished spaces. Install in parallel banks with all changes in directions made at 90 degree angles.

G. Ground equipment.

3.04 COMMUNICATION WIRING

A. Do not install communication wiring in raceway and enclosures containing Class 1 wiring.

B. RS485 Cabling: 1. RS485 cabling shall be used for BACnet MS/TP networks. 2. RS485 shall use low capacitance, 20-24 gauge, twisted shielded pair. 3. The shields shall be tied together at each device. 4. The shield shall be grounded at one end only and capped at the other end. 5. Provide end of line (EOL) termination devices at each end of the RS485

network or subnetwork run, to match the impedance of the cable, 100 to 120 ohm.


C. Ethernet Cabling: 1. Ethernet shall not be run with any Class 1 or low voltage Class 2 wiring. 2. CAT6, unshielded twisted pair (UTP) cable shall be used for BAS Ethernet. 3. Solid wire shall be used for long runs, between mechanical rooms and

between floors. Stranded cable can be used for patch cables and between panels in the same mechanical room up to 50 feet away.

4. When the BAS Ethernet connects to an Owner’s network switch, document the port number on the BAS As-builts.

D. All runs of communication wiring shall be unspliced length when that length is commercially available.

E. Grounding of coaxial cable shall be in accordance with NEC regulations article on “Communications Circuits, Cable, and Protector Grounding.”

3.05 SYSTEM CHECKOUT AND STARTUP

A. After the controls devices and panels are installed and power is available to the controls, perform a static checkout of all the points, including the following: 1. Inspect the setup and reading on each temperature sensor against a

thermometer to verify its accuracy. 2. Inspect the setup and reading on each humidity sensor against a hygrometer

to verify its accuracy. 3. Inspect the reading of each status switch to verify the DDC reads the open and

close correctly. 4. Command each relay to open and close to verify its operation. 5. Command each 2-position damper actuator to open and close to verify

operation. 6. Command each 2-position valve to open and close to verify operation. 7. Ramp each modulating actuator to 0 percent, 25 percent, 50 percent,

75 percent and 100 percent to verify its operation. 8. Ramp each modulating output signal, such as a VFD speed, to verify its

operation. 9. Test each safety device with a real life simulation, for instance check

freezestats with ice water, water detectors with water, etc.

B. After all of the points are verified, and power is available to the mechanical system, coordinate a startup of each system with the mechanical contractor.

C. Perform all program changes and debugging of the system for a fully operational system.

3.06 SYSTEM COMMISSIONING, DEMONSTRATION AND TURNOVER

A. The BAS Contractor shall prepare and submit for approval a complete acceptance test procedure including submittal data relevant to point index, functions, sequence, inter-locks, and associated parameters, and other pertinent information for the operating system. Prior to acceptance of the BAS by the Owner and Engineer, the BAS contractor shall completely test the BAS using the approved test procedure.

B. The BAS contractor shall fix punch list items within 30 days of acceptance.


3.07 TRAINING

A. During System commissioning and at such time as acceptable performance of the Building Automation System hardware and software has been established, the BAS contractor shall provide on-site operator instruction to the owner's operating personnel.

END OF SECTION


SECTION 15954

TESTING, ADJUSTING, AND BALANCING FOR HVAC

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Heating, ventilation, and air conditioning systems testing, adjusting, and

balancing.

1.02 REFERENCES

A. Associated Air Balance Council (AABC).

B. National Environmental Balancing Bureau (NEBB).

C. Sheet Metal and Air Conditioning Contractors' National Association (SMACNA).

D. Testing, Adjusting, and Balancing Bureau (TABB).

1.03 TESTING, ADJUSTING, AND BALANCING WORK REQUIREMENTS

A. Procure the services of an independent air balance and testing agency belonging to and in good standing with the AABC, NEBB, or the TABB to perform air and hydronic balancing, testing, and adjustment of building and process air conditioning, heating, and ventilating air systems.

B. The Work includes: Balancing new air and hydronic systems installed as part of this contract and existing air and hydronic systems affected by the installation of new equipment.

C. Perform testing of heating, ventilating, and air conditioning equipment, balancing of distribution systems, and adjusting of air terminal units and ductwork accessories to ensure compliance with Specifications and Drawings. Perform tests for following: 1. Air conditioning units. 2. Fan coil units. 3. Make up air heating units. 4. Fans. 5. Ductwork accessories. 6. Ducting. 7. HVAC controls. 8. Other specified HVAC equipment.

D. Test each mode of operation of thermostats, electronic controllers, and pneumatic, electric or electronic heating, ventilating, and air conditioning instruments to ensure operation as specified.

E. Provide instruments required for testing, adjusting, and balancing operations; retain possession of instruments; remove instruments from site at completion of services.


F. Provide test holes for pressure and pitot flow measurements; provide plugs for all test holes after testing.


A. Test, balance, and adjust environmental systems in accordance with either: 1. AABC: National Standards for Field Measurements and Instrumentation, Total

Systems Balance, Air Distribution-Hydronic System. 2. NEBB: Procedural Standards for Testing, Adjusting, and Balancing of

Environmental Systems. 3. TABB: International Standards for Environmental Systems Balance.

B. Perform services under direction of AABC, NEBB, or TABB certified supervisor.

C. Calibrate and maintain instruments in accordance with requirements of standards.

D. Testing, adjusting, and balancing performance requirements: 1. Comply with procedural standards of certifying association. 2. Accurately record required data. 3. Make measurements in accordance with recognized procedures and practices

of certifying association. 4. Measure air volume discharged at each outlet and adjust air outlets to design

air volumes within 5 percent over.

1.05 SUBMITTALS

A. Final report: At least 15 days prior to Contractor's request for final inspection, submit 3 copies of final reports, on applicable reporting forms. Include: 1. Procedures followed to perform testing, adjusting, and balancing. 2. Identification and succinct description of systems included in report. 3. Initial balance test results made with all dampers and air control devices in full

open positions. 4. Description of final locations and sizes, including opening area and

dimensioned configuration of orifices and other restrictions used to achieve final balanced flows.

5. Description of final location and opening positions of dampers, registers, louvers, and valves.

6. Schematics of systems included in report; use schematics as part of testing, adjusting, and balancing report to summarize design and final balanced flows.

7. Testing, adjusting, and balancing report forms. 8. Final field results established for system balancing including airflow, fan

speeds, and fan static pressures at the fan inlet and outlet. 9. Appendices. 10. Include appendices for:

a. Raw field data taken during testing. b. Sample calculation sheet for each type of calculation made to convert raw

field data to final results. c. Initial air balance results with dampers and registers in full open position;

include airflow at all inlets and outlet, initial fan speed and fan suction and discharge pressures.


1.06 SITE CONDITIONS

A. Prior to start of testing, adjusting, and balancing, verify that: 1. Systems installation is complete and in full operation. 2. Outside conditions are within reasonable range relative to design conditions. 3. Lighting fixtures are energized. 4. Special equipment such as computers, laboratory equipment, and electronic

equipment are in full operation. 5. Requirements for preparation for testing and balancing have been met for

elements of each system which require testing.

PART 2 PRODUCTS Not Used.

PART 3 EXECUTION

3.01 TESTING, ADJUSTING, AND BALANCING

A. Initial testing, adjusting, and balancing: Perform first test on each system with dampers, grilles, orifices, and other variable airflow devices in their full open position; measure and report initial airflows, fan speed, and fan static pressures at fan inlet and outlet. 1. Adjust total system flow downward or upward by adjusting fan speed until

1 inlet or outlet is at indicated flow and all other flows exceed indicated flows. 2. Adjust fan speed by changing fan drives or sheaves as necessary.

B. Subsequent testing, adjusting, and balancing: Perform adjustments in subsequent testing, adjusting, and balancing by adjusting dampers, louvers, or size of orifices or plates. 1. Measure and record air volume discharged at each inlet and outlet and adjust

air inlets and outlets to design air volumes within 0 to 5 percent over design rates.

2. Adjust fan speeds and motor drives within drive limitations, for required air volume.

3. Measure cubic feet per minute and static pressures and adjust air supply and exhaust fan units to deliver at least 100 to 105 percent of the design air volume.

4. Measure and record static air pressure conditions on fans, including filter and coil pressure drops, and total pressure across the fan.

5. Evaluate building and room pressure conditions to determine adequate supply and return air conditions.

6. Evaluate space and zone temperature of conditions to determine adequate performance of the systems to maintain temperatures without draft.

7. Permanently mark final balance positions of balancing dampers.

C. Develop heating, ventilating, and air conditioning system schematics similar to Figure 6-1 in SMACNA Testing, Adjusting, and Balancing.

D. Accurately record the required data on AABC, NEBB, or TABB test and balance report forms.


E. Measure amperage draw of fan and pump motors for final balance.

F. Test primary source equipment in accordance with AABC, NEBB, or TABB procedures. 1. Primary source equipment includes items listed in this Section not previously

tested as part of this testing, adjusting, and balancing work. 2. Complete appropriate AABC, NEBB, or TABB equipment test forms for each

piece of equipment. 3. Calculate cooling and heating capacities to show conformance with specified

capacities. 4. Adjust equipment as needed to deliver specified cooling and heating loads. 5. Record final equipment performing characteristics and adjustment settings in

the final design report.

END OF SECTION


SECTION 16222

LOW VOLTAGE MOTORS UP TO 500 HORSEPOWER

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Low voltage motors up to 500 horsepower (hp).

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. American Petroleum Institute (API): 1. 670 - Vibration, Axial Position, and Bearing Temperature Monitoring Systems.

C. ASTM International (ASTM). 1. B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus.

D. Institute of Electrical and Electronic Engineers (IEEE): 1. 43 - IEEE Recommended Practice for Testing Insulation Resistance of

Rotating Machinery. 2. 112 - IEEE Standard Test Procedure for Polyphase Induction Motors and

Generators. 3. 841 - IEEE Standard for Petroleum and Chemical Industry-Premium-

Efficiency, Severe Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors - Up to and Including 370 kW (500 hp).

E. National Electrical Manufacturers' Association (NEMA): 1. MG-1 - Motors and Generators. 2. MG-2 - Safety Standard for Construction and Guide for Selection, Installation,

and Use of Electric Motors and Generators.

F. Underwriters Laboratories Inc. (UL): 1. 674 - Electric Motors and Generators for Use in Division 1 Hazardous

(Classified) Locations.


A. Furnish and install electric motors and accessories as specified in this Section and the Sections specifying driven equipment to provide a complete and operable installation.

1.04 SUBMITTALS

A. Submit completed motor data sheets for each motor supplied: 1. Conform to data sheet in the appendix of this Section.


2. Manufacturer’s or other data sheets are not acceptable.

B. Product data: 1. Descriptive bulletins. 2. Machine tag and loop number as indicated on the Drawings and in the

specification section number of the driven machine. 3. Complete electrical data. 4. Torque, current, and power factor versus speed curves:

a. At 100 percent rated voltage for all full voltage started and VFD-driven motors.

b. For motors on reduced voltage start at 70, 80, 90, and 100 percent rated voltage.

5. Accessories data: a. Power factor correction capacitors:

1) Size in KVAR, for all motors not connected to variable frequency drives.

b. Motor winding heaters: 1) Voltage. 2) Watts.

c. Winding temperature detectors: 1) Type. 2) Rating.

d. Moisture detectors. 6. Mechanical data:

a. Bearing design and bearing life calculations. b. Resonant frequencies for all VFD-driven motors 50 hp or greater.

C. Shop drawings: 1. Motor weight. 2. Frame size. 3. Conduit box(es), size(s), and location(s). 4. Outline drawings with dimensions. 5. Installation details for the project seismic criteria.

D. Test reports: 1. Factory test reports with test reference standard identified.

E. Certification: 1. When motors are driven by variable speed drive systems, submit certification

that selected motor: a. Is capable of satisfactory performance under the intended load. b. Meets the requirements of the latest edition of NEMA MG-1 Part 31.

F. Calculations: 1. Where site conditions specified in the Project Technical Requirements exceed

manufacturer’s ratings, provide derating calculations for each motor.


A. Motors 200 hp and larger: 1. Rotate shaft 90 degrees once per month.


1.06 WARRANTY

A. 3-year parts and labor.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or approved equal: 1. US Motors. 2. General Electric. 3. Reliance. 4. Toshiba. 5. Baldor.

2.02 EQUIPMENT

A. 3-phase induction motors - general: 1. Voltage:

a. All motors 1/2 hp and larger shall be rated 460 V, 3-phase unless otherwise indicated on the Drawings.

b. Dual voltage motors rated 230/460 V, 3-phase are acceptable provided all leads are brought to the conduit box.

2. Motors driving identical machines shall be identical. 3. All motors greater than 1 hp and up to 500 hp shall meet the "NEMA Premium

Efficiency" percent listed in NEMA MG-1. 4. Horsepower as indicated on the Drawings:

a. Horsepower ratings indicated on the Drawings are based on vendor’s estimates. Provide motors sized for the load of the actual equipment furnished without operating in the service factor.

5. Service factor: a. 1.15 service factor on sine wave power. b. 1.0 when driven by VFD.

6. Torque: a. Provide motors that develop sufficient torque for acceleration to full speed

at voltage 10 percent less than motor nameplate rating. b. When started using reduced voltage starters:

1) Provide motors that develop sufficient torque for acceleration to full speed.

c. NEMA Design B except where driven load characteristics require other than normal starting torque: 1) In no case shall starting torque or breakdown torque be less than the

values specified in NEMA MG-1. 7. Enclosures:

a. As specified in the individual equipment Specifications or in this Section. b. Totally enclosed fan cooled:

1) Cast iron conduit box. 2) Tapped drain holes with Type 316 stainless steel plugs for frames

286 and smaller, and automatic breather and drain devices for frames 324 and larger.


c. Explosion-proof: 1) Tapped drain holes with corrosion resistant plugs for frames 286 and

smaller and automatic breather and drain devices for frames 324 and larger.

d. Lifting devices: All motors weighing 265 pounds (120 kilograms) or more shall have suitable lifting devices for installation and removal.

8. Manufactured with cast iron frames in accordance with NEMA MG-1 or manufacturer’s standard material for the specified rating.

9. Nameplates: a. Provide all motors with a permanent, stainless steel nameplate indelibly

stamped or engraved with: 1) NEMA standard motor data.

a) Indicate compliance with NEMA MG-1 Part 31 for inverter duty motors.

2) AFBMA bearing numbers and lubrication instructions. 10. Hardware:

a. Type 316 stainless steel. 11. Conduit boxes:

a. Cast iron or stamped steel. b. Split from top to bottom. c. Provide gaskets at the following interfaces:

1) Frames and conduit boxes. 2) Conduit boxes and box covers.

d. Rotatable through 360 degrees in 90-degree increments. 1) Where available based on the size of the conduit box.

e. Exceeding the dimensions defined in NEMA MG-1. f. Provide grounding lugs inside conduit boxes for motor frame grounding.

12. Motor bearings: a. Antifriction. b. Regreasable and initially filled with grease for horizontal motors and

vertical motors per manufacturer’s standard design. c. Bearings and lubrication suitable for ambient temperature and

temperature rise. d. Suitable for intended application and have ABMA L-10 rating life of

60,000 hours or more. e. Fit bearings with easily accessible grease supply, flush, drain, and relief

fittings using extension tubes where necessary. f. Where specified in the equipment Specifications, provide split-sleeve type

hydrodynamic radial bearings. Provide a bearing isolator to protect bearings from contaminants.

13. Insulation systems: a. Motors installed in ambient temperatures 40 degrees Celsius or less:

1) Provide Class F insulation. 2) Design temperature rise consistent with Class B insulation. 3) Rated to operate at an ambient temperature of 40 degrees Celsius at

the altitude where the motor will be installed. b. Motors installed in ambient temperatures between 40 degrees Celsius

and 50 degrees Celsius: 1) Provide Class F insulation. 2) Design temperature rise consistent with Class B insulation. 3) Rated to operate at an ambient temperature of 50 degrees Celsius at

the altitude where the motor will be installed.


c. Motors installed in ambient temperatures between 50 degrees Celsius and 65 degrees Celsius: 1) Provide Class H insulation. 2) Design temperature rise consistent with Class F insulation. 3) Rated to operate at an ambient temperature of 65 degrees Celsius at

the altitude where the motors will be installed. 14. Motor leads:

a. Insulated leads with non-wicking, non-hydroscopic material. Class F insulation.

15. Noise: a. Maximum operating noise level in accordance with NEMA MG-1.

B. Submersible motors: 1. Enclosures:

a. Totally enclosed non-ventilated (TENV) watertight casing. b. Inner and outer shaft seals separated by an oil chamber.

2. Cooling: a. Suitable for continuous operation in totally, partially, or nonsubmerged

condition without overheating. b. Convection cooling by the surrounding environment or pump cooling by

circulating a portion of the pumped media through a cooling water jacket as recommended by the manufacturer based on hp and application.

3. Electrical cables: a. Wire unit without splices. Coordinate with Contractor to ensure cables of

adequate length. b. Epoxy encapsulated cable entry into terminal box.

4. Insulation: a. Sealed moisture resistant windings. b. Class H.

5. Motor protection: a. Provide temperature detection in motor windings. b. Provide moisture detection in motor housing. c. Other detection and protection functions specified in the in the driven

equipment Section.

C. Vertical motors: 1. Enclosures:

a. Totally enclosed fan cooled (TEFC) for motors 200 hp and less installed outdoors.

b. Weather protected Type II (WPII) for motors greater than 200 hp installed outdoors.

c. Weather protected Type I (WPI) where installed indoors. 2. Thrust bearings:

a. Selected for combined rotor and driven equipment loads. b. Coordinate with driven equipment supplier for maximum vertical thrust of

driven equipment. 3. Anti-reverse ratchet.

D. Motors driven by variable frequency drives: 1. Compatible with the variable frequency drives specified. 2. Inverter duty rated and labeled. 3. Meet the requirements of NEMA MG-1 Part 31.


4. Winding insulation meets the requirements of NEMA MG-1 Part 31.4.4.2. 5. Capable of running continuously at 1/10th of full speed, with no harmful effects

or overheating. 6. All motors except explosion proof motors:

a. Shaft grounding ring: 1) Provide a shaft grounding ring for each VFD-driven motor. 2) Aluminum frame and internal components. 3) Conductive microfiber brushes. 4) Maintenance free design. 5) Aegis Bearing Protection ring as manufactured by Electro Static

Technology or equal. 7. Explosion proof motors:

a. On motors less than or equal to 100 hp, provide insulated bearings on one end of the motor.

b. On motors over 100 hp, provide insulated bearings on both ends of the motor.

8. On motors over 100 HP, provide insulated bearings on both ends of the motor or on the end opposite of the shaft ground ring as recommended by the motor manufacturer.

E. Motors installed in hazardous locations: 1. Class I, Division 1 or Class II, Division 1 areas:

a. Enclosures: 1) Explosion proof for 3-phase motors. 2) UL listed in conformance with UL-674. 3) UL approval with nameplate and serial number.

2. Other hazardous areas: a. Enclosures:

1) TEFC for motors in Class I, Division 2 areas. 2) Vertical motors as specified in this Section. 3) Hazardous area and temperature code approval stamped on

nameplate. 3. Single-phase motors: Explosion proof motor enclosure.

F. Motors installed in corrosive environments: 1. Stator double dipped in varnish and baked. 2. Stator and rotor coated with corrosion resistant epoxy. 3. Frame, brackets, fan guard and conduit box coated with minimum of 2 coats of

epoxy paint. 4. Withstand salt spray tests in accordance with ASTM B117.

G. Single-phase motors: 1. Capacitor start type rated for operation at 115 volts, 60 hertz, unless otherwise

specified or as indicated on the Drawings. 2. Totally enclosed fan cooled (TEFC) motors manufactured in accordance with

NEMA MG 1. 3. Ball bearings: Sealed. 4. 1/2 hp or less fan motors:

a. Split-phase or shaded pole type when standard for the equipment. b. Open type when suitably protected from moisture, dripping water, and lint

accumulation.


5. Wound rotor or commutator type single-phase motors only when their specific characteristics are necessary for application and their use is acceptable to the Engineer.

6. Integral overload protection.

H. Immersible motors: 1. Meet all general requirements for 3-phase induction motors except as modified

in this Section. 2. Inverter duty as indicated on the Drawings or in the driven equipment

Specifications. 3. Enclosure:

a. Cast iron. b. Designed and constructed to meet or exceed IP67. c. Epoxy paint finish:

1) Withstands salt spray and corrosion tests in accordance with ASTM B117.

d. Furnished with lifting plates or lugs. e. Vertical or horizontal mounting as required by the application.

4. Conduit box: a. Cast iron. b. Bolted and sealed cover. c. Rotatable in 90-degree increments. d. Watertight gland or potable hub for power cable entry.

5. Power cable: a. Type SOOW or W cable, non-shielded. b. Length as required for the installation.

6. Cooling blower: a. As required by the motor manufacturer. b. Washdown duty rated. c. Constant speed.

7. Humidity moisture detector.

2.03 ACCESSORIES

A. Motor winding heaters: 1. Provide all 3-phase motors with belted or cartridge space heaters mounted

within the motor enclosure. 2. Space heater rating shall be 120 volts, single-phase, unless otherwise

indicated on the Drawings. 3. Power leads for heaters wired into conduit box. 4. Installed within motor enclosure adjacent to core iron.

B. Winding temperature detectors: 1. Provide factory installed winding temperature detector with leads terminating in

the conduit box: a. Where required by the driven equipment Specification or as indicated on

the Drawings. b. RTD type, 2 per phase, 100-ohm platinum.

2. Temperature switches with normally closed contacts as indicated on the Drawings.


C. Vibration detectors: 1. Where required by the driven equipment Specification. 2. As specified in the driven equipment Specification.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install motors in accordance with manufacturer's instructions.

B. Install shaft grounding ring on VFD-driven motors in accordance with the manufacturer’s instructions.

3.02 COMMISSIONING AND PROCESS START-UP


B. Factory testing: 1. Motors less than 250 hp:

a. Perform manufacturer’s standard production tests including but not limited to: 1) No load current. 2) High potential test. 3) Winding resistance.

b. Furnish copies of standard test reports on prototype or identical units. 2. Motors 250 hp and larger:

a. Perform tests in accordance with IEEE 112 or IEEE 43. b. Tests shall include the following:

1) Winding resistance (cold). 2) Locked rotor test. 3) Temperature rise test. 4) Load test. 5) Breakdown torque test. 6) No-load test. 7) High-potential test. 8) Insulation resistance test. 9) Vibration test in accordance with NEMA MG-1. 10) Polarization index. 11) Speed-torque curve. 12) Shaft voltage. 13) Bearing insulation resistance. 14) Efficiency and power factor versus load test performed at rated

speed and 50 percent, 75 percent, 90 percent, and 100 percent of rated load. The curves from the motor tests shall be submitted for information.

15) The maximum allowable residual unbalance in each correction plane (journal) shall be calculated using the following equation: U = 4 W/N where: U = residual correction plane unbalance, in ounces-inches W = static correction plane journal loading, in pounds N = maximum specified operating speed, in revolutions per minute.


c. Furnish copies of test reports.


A. Before start-up, perform insulation resistance test on each motor furnished or installed on this project: 1. Windings energized to 1,000 volts DC for 1 minute. 2. Resistance measured at the end of the test, recorded, and submitted to the

Engineer for review. 3. Inform the Engineer of any unusual or unacceptable test results.

END OF SECTION


MOTOR DATA SHEET

MOTOR/ EQUIPMENT TAG MOTOR NUMBER

SPECIFICATION NUMBER OF DRIVEN MACHINE

MOTOR NAMEPLATE DATA

MANUFACTURER MODEL/SERIES MODEL NO.

FRAME ENCLOSURE NEMA DESIGN

HP SERVICE FACTOR RPM

INSULATION CLASS VOLTS FULL LOAD AMPS

AMBIENT TEMP PHASE NO LOAD AMPS

DESIGN TEMP

HERTZ LOCK ROTOR AMPS

INRUSH CODE LETTER

100% LOAD 75% LOAD 50% LOAD

GUARANTEED MINIMUM EFFICIENCIES:

GUARANTEED MINIMUM POWER FACTOR:

MAXIMUM SIZE OF POWER FACTOR CORRECTION CAPACITOR: KVAR

ACCESSORIES

MOTOR WINDING HEATER VOLTS WATTS

WINDING THERMAL PROTECTION

WINDING TEMP SWITCHES (YES/NO)

RTD:

TYPE QUANTITY PER PHASE # OF WIRES

NOMINAL RESISTANCE NOMINAL TEMP COEFFICIENT

RECOMMENDED ALARM

DEGREES CELSIUS

RECOMMENDED TRIP

DEGREES CELSIUS

SPECIAL APPLICATIONS

INVERTER DUTY* (YES/NO) PART WINDING (YES/NO) WYE - DELTA (YES/NO)

2 SPEED, 1 WINDING (YES/NO) 2 SPEED, 2 WINDING (YES/NO)

AREA CLASSIFICATION:

CLASS DIVISION GROUP TEMP CODE * Conforms to NEMA MG-1 Part 31.


SECTION 16224

MEDIUM VOLTAGE MOTORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. 3-phase, form-wound, squirrel cage induction motors 4,160 volts, 500

horsepower and larger.

1.02 REFERENCES

A. American Petroleum Institute (API): 1. 541 - Form-Wound Squirrel Cage Induction Motors - 500 Horsepower and

Larger. 2. 547 - General Purpose Form-Wound Squirrel Cage Induction Motors -

250 Horsepower and Larger.

B. National Electrical Manufacturers Association (NEMA): 1. MG-1 - Motors and Generators.

C. Institute of Electrical and Electronics Engineers (IEEE): 1. 85 - IEEE Test Procedure for Airborne Sound Measurements on Rotating

Electric Machinery. 2. 112 - IEEE Test Procedures for Polyphase Induction Motors and Generators.


A. Motors shall be furnished by the equipment manufacturer as specified in the Project Technical Requirements.

B. Coordinate characteristics and requirements of driven equipment, reduced voltage solid state starters, variable frequency drives, and accessories, to ensure a complete, fully functional, coordinated installation.

C. Equipment and motor suppliers shall coordinate starting requirements for constant speed equipment with starter supplier: 1. Provide minimum starting voltage and ramp time criteria. 2. Coordinate equipment acceleration requirements under all operating

conditions with motor and starter thermal capabilities and available starter settings.

D. Coordinate motor characteristics the short-circuit and coordination study as specified in Section 16305 - Electrical System Studies: 1. Provide design data as specified for the preliminary studies. 2. Provide test data for the final studies. 3. Coordinate recommended motor protection settings for motor protection

relays.


1.04 SUBMITTALS

A. Furnish submittals as specified in Section OR-01300 - Submittal Procedures.

B. Product data: 1. Descriptive bulletins for motor and accessories. 2. Complete bill of material identifying all accessories. 3. Machine tag and loop number as identified in the Contract Documents. 4. Weight of complete motor and of rotating parts. 5. Electrical data:

a. Voltage and phase. b. Nameplate horsepower. c. Nameplate service factor. d. At rated horsepower and voltage:

1) Full load amps. 2) Revolutions per minute.

e. Efficiency at 1/2 and 3/4 and full load. f. Power factor at 1/2 and 3/4 and full load. g. Locked rotor withstand time, with the motor at ambient temperature and at

its maximum rated operating temperature, at 70 percent, 80 percent, 90 percent, and 100 percent of rated voltage.

h. NEMA design. i. Description of insulation system. j. Winding insulation class and rated ambient temperature. k. Motor data for short-circuit and coordination study, including:

1) Submit design values for machine characteristics, including the following: a) Subtransient reactance (X"d). b) Transient reactance (X'd). c) Negative sequence reactance (X2). d) Zero sequence reactance (Xo).

6. Performance curves: a. Torque, current, and power factor vs. speed curves at 100 percent rated

voltage. b. Torque and current curves at 80 percent rated voltage. c. Rotor and stator thermal damage curves. d. Motor damage, safe stall time and acceleration curves at 80 percent,

90 percent and 100 percent of rated voltage. 7. Accessories data:

a. Space heaters: 1) Voltage. 2) Watts.

b. Winding and bearing temperature detectors: 1) Quantity and location. 2) Type. 3) Rating. 4) Recommended alarm and trip settings in degrees Celsius for the

stator winding and bearing temperature detectors. 8. Mechanical data:

a. Bearing design and bearing life calculations. 9. Recommended spare parts list. 10. Itemized list of special tools required.


C. Shop drawings: 1. Dimensional outline, detail, and cross sectional drawings.

a. Show location of all terminal boxes, identifying connections to be made in each.

2. Wiring diagrams for all accessory devices, including RTDs, current transformers, space heaters, and vibration switches.

3. Dimensions and arrangements of terminal boxes showing terminal identification and locations, and number and size of conduit entries.

D. Certification that the selected motor meets the compatibility requirement specified in this Section.

E. Test reports: 1. Submit certified factory test reports for all tests specified. 2. Provide final machine characteristic data determined from the tests.

F. Calculations.

G. Operations and maintenance data: 1. Spare parts list with supplier names and part numbers. 2. Start-up and commissioning instructions and data. 3. Maintenance manual:

a. Instructions covering all details pertaining to care and maintenance of all equipment as well as identifying all parts.

b. Include, at a minimum, the following: 1) As-built version of all submittal drawings. 2) Safety procedures, equipment, and precautions. 3) Initial test, adjustment, alignment, and start-up procedures, including

applicable values and tolerances. 4) Procedures for normal starting, running, and shutdown. 5) Procedures for emergency shutdown. 6) Periodic inspections and adjustments. 7) Lubrication requirements. 8) Routine maintenance and repairs. 9) Special tools and recommended spare parts. 10) Test reports.


A. Furnish motors meeting the requirements of API 541: 1. Including optional requirements identified in these specifications and where

required for compatibility with the driven equipment.

B. Certify that the motor, when installed and driven by the actual variable frequency drive furnished: 1. Is capable of satisfactory performance under all specified conditions with the

actual pumps furnished. 2. Meets the requirements of the latest edition of NEMA MG-1 Part 31. 3. Is matched to the actual variable frequency drive being furnished. 4. Will not experience premature bearing failure due to induced voltages or

currents caused by the high frequency output of the drive.



A. Energize space heaters upon receipt of the motor at the jobsite using construction power source, and keep heaters energized from this source until motors are ready for service, and heater power is available from the starter or drive.

1.07 PROJECT/SITE CONDITIONS

A. Environmental requirements: 1. The equipment shall be de-rated in accordance with the manufacturer’s

guidelines for the project altitude and ambient temperature.

1.08 WARRANTY

A. Extended warranty: 1. Provide an additional 3 years manufacturer’s warranty for all equipment

provided under this Section.

1.09 MAINTENANCE

A. Furnish the following spare parts: 1. 1 complete set of air filters for each motor.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. National Oilwell Varco. 2. General Electric. 3. Teco Westinghouse. 4. Toshiba.

2.02 EQUIPMENT

A. General: 1. 3 phase induction motors. 2. Voltage: 4,000 volts, designed to operate on system with nominal 4,160 volts. 3. Motors driving identical machines shall be identical. 4. All motors shall be inverter duty rated:

a. Compatible with the variable frequency drives furnished. b. Inverter duty rated and labeled. c. In conformance with NEMA MG-1 Part 31. d. Winding insulation in conformance with NEMA MG-1 Part 31.40.4.2. e. Capable of running continuously at minimum pump speed, with no harmful

effects or overheating. f. Provide shaft grounding brushes to prevent bearing damage from induced

shaft voltage. g. Provide additional features as required to prevent premature failure of any

motor component due to operation with the variable frequency drives being furnished.


5. Efficiency and power factor: a. The guaranteed motor efficiency at rated voltage and frequency shall not

be less than 95.2 percent at full load, 95.0 percent at 3/4 load, and 94.8 percent at 1/2 load.

b. The guaranteed power factor at rated voltage and frequency shall not be less than 84 percent at full load, 80 percent at 3/4 load, and 72 percent at 1/2 load.

c. Coordinate power factor correction capacitors requirement with starter supplier. Minimum corrected full-load power factor is 95 percent.

d. Determine efficiencies in accordance with IEEE 112, Method F. 6. Horsepower as indicated on the Drawings and equipment schedules:

a. Horsepower ratings indicated on the Drawings are based on vendor’s estimates. Provide motors sized for the load of the actual equipment furnished without operating in the service factor. 1) If the size of the motor required to drive the actual equipment

furnished is larger than the size indicated on the Drawings, make structural, mechanical, and electrical changes that are necessitated by the increase, including but not limited to: a) Motor starter or VFD rating. b) Electrical distribution equipment size and ratings. c) Electrical service and transformer sizes. d) Conductor and conduit sizes for service, feeder, and motor

branch circuit. 7. Service factor:

a. 1.15 service factor when operating on a constant speed starter. b. 1.0 service factor when operating on a variable frequency drive.

8. Torque: a. Provide motors that develop sufficient torque to accelerate the actual load

to full speed at voltage 10 percent less than motor nameplate rating. b. When started using reduced voltage starters:

1) Provide motors that develop sufficient torque to accelerate the actual load to full speed at the starting ramp and current limit of the starter.

9. Enclosures: a. As specified in the individual equipment specifications. b. Provide with filters for inlet air passages:

1) Filters must remove 90 percent of particulates 10 microns and larger. 2) Easily replaceable while motor is operating.

10. Hardware: a. Type 316 stainless steel.

11. Conduit boxes: a. Cast iron or stamped steel. b. Provide gaskets at the following interfaces:

1) Frames and conduit boxes. 2) Conduit boxes and box covers. 3) Size as required to accommodate conductor and conduit quantities

and sizes indicated on the Drawings and specified in the conduit schedule.

c. Main power conduit box: 1) Provide NEMA 2-hole pads mounted on standoff insulators for

terminating medium-voltage power cables.


2) Provide space for medium-voltage terminations including stress cones, and adequate space to allow connections without bending incoming cables beyond cable manufacturer's minimum bending radius recommendations.

3) Suitable for bottom conduit entry as indicated on the Drawings. 4) Provide a grounding bus inside the conduit box for motor frame

grounding. d. Accessory terminal boxes:

1) Provide a separate box for motor winding heater connections. 2) Provide a separate conduit box for RTD connections. 3) Provide a separate conduit box with short-circuiting terminal blocks

for current transformer connections: a) Current transformer terminals may be located in the main power

conduit box provided that suitable barriers are installed to isolate the terminals from medium-voltage connections, the conduit entry for CT leads into the isolated terminal section, and that the terminals are accessible without removing the main power conduit box cover.

12. Motor bearings: a. Antifriction. b. Bearings and lubrication suitable for ambient temperature and

temperature rise. c. Suitable for intended application and have ABMA L-10 rating life of

60,000 hours or more. d. Provide water cooling if required to meet the L-10 life rating:

1) Using pump discharge water. 2) Coordinate pressure and flow rate requirements with the pump

manufacturer. 3) Coordinate inlet and outlet connection details and requirements with

the pump manufacturer. 4) Use stainless steel for all water pipes and coding coils.

e. Fit bearings with easily accessible lubrication fittings. f. Provide sight glasses for all oil reservoirs. g. Thrust bearings suitable for the weight of the rotor and pump plus

maximum down thrust delivered by the pump, and for any up thrust that can be delivered by the pump.

h. Insulate all bearings.

B. Stator: 1. Stator core:

a. Built up from high grade, non-aging laminated silicon steel. b. Insulate each lamination to minimize eddy current losses.

2. Stator windings: a. Form-wound copper coils. b. All coils of the same size and shape. c. Strand insulation: Polyester glass fiber or equal high temperature

insulating film. d. Turn-to-turn insulation:

1) Designed to prevent insulation damage from voltage surges. 2) For variable frequency drive applications, design for surges as

identified in NEMA MG1 part 31, paragraph 31.40.4.2.


e. Coil insulation: Suitable for voltage class of the motor, tightly applied to prevent all voids.

f. Insulation class: F. g. Design temperature rise consistent with Class B insulation when

delivering full motor service factor at an ambient temperature of 40 degrees Celsius.

h. Crimp and silver solder all coil and lead connections. i. Fully insulate and brace end turns, including all coil and lead connections.

Provide surge ring and bracing suitable for maximum fault current as determined by the short-circuit and coordination study.

3. Entire stator vacuum pressure impregnated with nonhygroscopic polyester or epoxy resin, and heat cured.

4. Motor leads: a. Insulated leads with non-wicking, non-hydroscopic material. Class F

insulation. 5. Noise:

a. Maximum operating noise level of 85 dB measured as per IEEE 85.

C. Rotor: 1. Shaft:

a. Constructed of forged or rolled steel, machined and finished. b. Sufficient strength to withstand all stresses resulting from normal

operation at any speed up to 125 percent of synchronous speed. c. Connections to match driven equipment.

2. Rotor core: a. Built up from high grade, non-aging laminated silicon steel. b. Insulate each lamination to minimize eddy current losses.

3. Rotor bars: a. Copper or copper alloy. b. Size and shape as required to provide starting and running characteristics

compatible with the driven load and starting method. c. Secured to the rotor slots to minimize movement or vibration. d. Attach bars to end rings by induction or torch brazing.

4. Statically and dynamically balance rotor before assembly into the motor. 5. Provide anti-reverse ratchet.

2.03 ACCESSORIES

A. Surge arresters: 1. Furnish metal oxide surge arresters in the main power conduit box. 2. Install low-impedance ground connection between stator core and ground bus

in main power conduit box. a. No. 4/0 AWG minimum.

B. Nameplates: 1. Provide all motors with a permanent, stainless steel nameplate indelibly

stamped or engraved with: a. NEMA standard motor data. b. Bearing description and lubrication instructions.


C. Space heaters: 1. Provide belted or cartridge space heaters mounted within the motor enclosure

sized to heat the motor winding to approximately 5 degrees Celsius above ambient temperature.

2. Space heater rating shall be 120 volts, single-phase, unless otherwise specified.

3. Power leads for heaters wired into a separate conduit box. 4. Installed within motor enclosure adjacent to core iron.

D. Winding temperature detectors: 1. Provide factory installed winding temperature detector with leads terminating in

a separate conduit box: a. RTD type, 2 per phase. b. Platinum, 100 ohms nominal at 0 degrees Celsius. c. Temperature coefficient of resistance compatible with monitoring

equipment.

E. Vibration detectors: 1. Where specified in the driven equipment specification. 2. Vibration switches:

a. Furnish 2 switches, 1 installed to respond to vibration along the X axis, the other to vibration along the Y axis.

b. Transducers: 1) Remote-mounted accelerometer in outdoor weather-protected

housing. 2) Same manufacturer as vibration switch. 3) Securely threaded directly into motor frame near the top of the motor. 4) Connect each transmitter to its switch with moisture-resistant cable

with stainless steel armor and jacket, as recommended by the transducer manufacturer. Length as required to connect transducer to remote-mounted switch.

c. Switch: 1) Convert accelerometer input to vibration velocity. 2) Power supply: 120 VAC. 3) 20-second time delay on motor start, as determined from motor

running input. 4) 2 form C output relays:

a) Each rated for 120 VAC, 5 amperes. b) Manual reset. c) 1 shutdown contact adjustable from 0.1 to 1.5 inches per

second. d) 1 alarm contact adjustable from 10 to 90 percent of the

shutdown setting. e) Time delay for each output, independently adjustable from 2 to

15 seconds. d. Metrix 440 series with SA6200A accelerometer in 7295 housing and

9334-111 armored cable or approved equal.

F. Air filter differential pressure switch: 1. Furnish differential pressure switch for all motors to indicate when filters

require cleaning or replacement: a. Form C contact rated for 5 amperes at 120 VAC or 24 VDC.


G. Current transformers: 1. Furnish current transformers. 2. Connect to short-circuiting terminal blocks in the current transformer accessory

conduit box. 3. 3 current transformers, 1 per each phase. 4. Core balance or full differential as required for compatibility with motor

protection relay furnished. 5. Ratio and accuracy class as determined by the short-circuit and coordination

study, and for the actual connections (core balance or full differential).

PART 3 EXECUTION

3.01 EXAMINATION

A. Per manufacturer requirements.

3.02 INSTALLATION


3.03 COMMISSIONING


B. Factory tests: 1. Submit test procedure a minimum of 6 weeks before factory tests. 2. Perform tests on all motors in accordance with API 541 and IEEE 112.

Perform tests required by these standards for all motors, and the following tests as described in API 541: a. Surge comparison test. b. Component balance. c. Bearing dimensional and alignment checks. d. DC high-potential test to establish reference values for field tests. e. Air filter differential pressure test.

3. Perform API 541 complete tests on 1 motor for each application to determine the following: a. Efficiency and power factor at 50 percent, 75 percent, and 100 percent of

full load and at full service factor load: 1) In accordance with Method F as defined in IEEE 112.

b. Locked rotor power factor. c. Full load current and slip. d. Locked rotor and breakdown torque. e. Temperature rise at service factor load:

1) If the test facility is not capable of operating the motor at service factor load, describe the test procedure and extrapolation method in the test procedure. Reduced-load tests will only be allowed where the test load and extrapolation method are approved by the Construction Administrator.

f. Speed-torque curve. g. Noise levels.


C. Test 1 or more motors with complete equipment system as required by the driven equipment specification section.

END OF SECTION


SECTION 16235

SINGLE SPARK-IGNITED GENERATOR SET

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Packaged automatic "standby" spark-ignited engine generator systems.

1.02 REFERENCES

A. ASTM International (ASTM): 1. A106 - Standard Specification for Seamless Carbon Steel Pipe for High-

Temperature Service.

B. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1,000 Volts Maximum). 2. MG-1 - Motor and Generators.

C. National Fire Protection Association (NFPA): 1. 110 - Standard for Emergency and Standby Power Systems.

D. Underwriters Laboratories (UL): 1. 508 - Standard for Industrial Control Equipment. 2. 2200 - Standard for Stationary Engine Generator Assemblies.

1.03 DEFINITIONS

A. NEMA: Type 12 enclosure in accordance with NEMA 250.

B. Specific definitions: 1. Equipment supplier: The manufacturer of at least one of the following items:

a. Engine. b. Alternator (generator). c. Control system.

2. Standby rated duty: Continuous operation for the duration of any power outage.


A. Provide a complete automatic standby spark-ignited combination natural gas/LP vapor fueled engine driven generator system, with all necessary components to make a complete and operating engine-driven power supply.

B. Include the supply of such minor details of electrical, plumbing, or mechanical Work not specified or indicated on the Drawings, which are necessary for the successful operation of the combination natural gas/LP vapor fueled engine-driven generator required by these Specifications.


1.05 SUBMITTALS

A. Furnish submittals as specified in Sections OR-01300 - Submittal Procedures.

B. Product data: 1. Weight of engine generator skid. 2. Dimensions of engine generator skid, including length, width, and height. 3. Type and grade of fuel recommended. 4. Fuel and lubricating oil consumption at:

a. 50 percent load. b. 75 percent load. c. 100 percent load.

5. Type and grade lubricating oil recommended. 6. Amount of lubricating oil required per oil change. 7. Normal lubricating oil consumption. 8. Recommended lubricating oil change periods:

a. By hours run. b. By time.

9. Combustion air required. 10. Cooling air required. 11. Gauges to be furnished with engine and the normal operating range of each:

a. Oil pressure. b. Coolant temperature. c. Fuel pressure.

12. Time interval from start-up contact closure until full load capabilities are available.

13. List of at least 4 installations using major components of the same type furnished for this application: a. Include name and telephone number of the persons most familiar with this

equipment who can be contacted during the submittal review. 14. Number of cylinders, bore, stroke, and piston speed. 15. Displacement in cubic inches. 16. Compression ratio. 17. RPM at 60 hertz. 18. Size of exhaust outlet. 19. The following gaseous exhaust emissions in grams/BHP-HR and Lbs/BHP-

HR: a. NOX. b. HC. c. CO. d. PM. e. Other exhaust emissions as required by the local air quality management

district issuing the permit for the engine generator system. f. These levels shall be reported at rated speed and load as measured by

SAE J177 and J215 recommended practices. 20. Voltage and frequency variation and duration with the step application and

removal of 25 percent, 50 percent, 75 percent, and 100 percent of resistive load maximum.

21. Time-overcurrent characteristic curves and thermal damage curve for the alternator, demonstrating the effectiveness of the protection provided by the output circuit breaker.


22. Battery discharge ampere ratings at the 8-hour rate and the 1-minute rate to 1.75 volts per cell.

23. Certified published engine horsepower curves showing manufacturer's engine rating for generator set standby and prime power application.

24. Free field mechanical noise level at 23 feet. Provide overall decibels (A) rating. 25. Exhaust noise level at 5 feet from discharge end of silencer. 26. Start battery catalog number and descriptive bulletin. 27. Recommended spare parts. 28. Space and ambient temperature requirements for the engine control panel. 29. Manufacturer of:

a. Engine. b. Generator. c. Generator control panel. d. Radiator. e. Enclosure.

30. Estimated number of days to ship complete unit. 31. Jacket water heater. 32. Strip heaters. 33. Crank case heaters.

C. Shop drawings: 1. Layout drawings:

a. Provide detailed dimensional and to-scale layout drawings including: 1) A single drawing incorporating all equipment furnished:

a) Submittals that consist solely of individual drawings for each component and require that these sheets be compiled by the Engineer, in order to view the entire piece of equipment, are not acceptable.

2. Detailed electrical wiring diagrams of the engine and generator including: a. Engine interconnection terminal box. b. Generator interconnection terminal box. c. Fuel system drawings. d. All interface drawings between the engine driven generator skid and the

transfer equipment. e. All wiring diagrams to show wire numbers and terminal block

identifications: 1) Wire numbers are to correspond to the wire number on the

equipment. 2) All wires are to be numbered.

f. Complete interior and exterior control panel layout: 1) Scaled. 2) With device descriptions. 3) With nameplates.

3. Installation drawings: a. Detailed installation drawings prepared and sealed by a registered

Professional Engineer licensed in the state where Project is located: 1) Detailing mounting requirements for the project site seismic

requirements as specified in Basis of Design Report.


D. Operation and maintenance manuals: 1. Operating instructions:

a. Printed and framed instruction chart shall be permanently mounted in the generator enclosure. The chart must detail the operational functions of all normally used controls that have been placed on the front of the control equipment.

2. Maintenance manual: a. Printed and bound instructions covering all details pertaining to care and

maintenance of all equipment as well as data identifying all parts. b. These manuals must include but are not limited to the following:

1) Electrical controls: a) Adjustment and test instructions covering the steps involved in

the initial test, adjustment, and start-up procedures. b) Detailed control instructions, which outline the purpose and

operation of every control device used in normal operation. c) Description of the sequence of operation that outlines the steps,

which the controls follow during normal power failure and normal power return conditions.

d) All schematic, wiring, and external diagrams. Also, internal device wiring and schematic diagrams for all sub-assemblies used in the equipment: (1) Drawing to be furnished in a reduced 11-inch by 17-inch

format and shall be fully legible at that drawing size. 2) Engine and generator:

a) Standard operational manuals normally furnished by the manufacturer.

b) Repair parts manuals normally furnished by the manufacturer: (1) Detailing all parts and sub-assemblies, which are available

as repair parts. 3) Shop maintenance manuals:

a) Provide 1 shop manual on-site that is equivalent to the manual used by factory-authorized shop repair personnel.

b) Manuals for the following equipment: (1) Engine. (2) Radiator. (3) Generator. (4) Engine generator control panel.

c. Material Safety Data Sheets (MSDS): 1) Complete MSDS forms for all substances. 2) Located in O&M manual. 3) Include separate manual labeled MSDS with additional copies of all

MSDS forms. d. Furnish a minimum of 6 manuals of each type identified, except for the

shop maintenance manual. Provide 1 additional copy on compact disc (CD) as specified in Section OR-01770 - Closeout Procedures.

E. Test reports: 1. Furnish complete test reports in accordance with the Source Quality Control

and Field Quality Control articles of this Section.

F. Manufacturer’s Certificate of Installation and Functionality Compliance.


G. Calculations: 1. Complete loading calculations to support the recommended size of the engine-

generator based upon actual facility loads. 2. Supply documentation identifying the maximum static pressure acceptable for

the radiator fan. It is the manufacturer’s responsibility to then provide calculations as part of the layout drawings, to ensure that the transition ductwork at the discharge of the radiator does not exceed the maximum static pressure acceptable for the radiator fan.

3. Submit certification that a torsional analysis has been completed. 4. Submit exhaust system silencer noise attenuation curves. 5. Structural, mounting, and seismic calculations to be signed and stamped by a

licensed Professional Engineer, registered in the state where the Project is located: a. Submit vibration isolator calculations. b. Submit exhaust silencer structural support calculations.

6. Submit factory certification of the radiator ambient capability. 7. Submit exhaust system pressure loss calculations: Include piping, fittings,

silencer, and rain cap in loss calculations.


A. Coordinate the generator control design with the switchgear or transfer switches specified in the Electrical Specifications and as indicated on the Drawings.

B. Manufacturer qualifications: 1. The manufacturer of the engine, generator, and all major items of auxiliary

equipment must be in current production of such equipment. 2. Factory authorized parts and service facility located within 100 miles of the

Project Site.

C. Regulatory requirements: 1. Meet NFPA-110 Type 10 (ten second) transfer requirements. 2. Regulations of the Fire Prevention Bureau of the Fire Department Having

Jurisdiction. 3. 2009 International Fire Code. 4. Other applicable state and local codes. 5. EPA approved. 6. Requirements of local Air Quality Management District or Air Pollution Control

District.

D. The generator set shall be manufactured to the applicable specifications on file with Underwriters Laboratories and labeled with the UL 2200 mark.


A. Ship the engine-driven generator skid and all associated equipment to the jobsite on equipment that will allow the Contractor to use the equipment he has on site to efficiently unload the engine-driven generator skid. 1. The engine-driven generator skid must be equipped with removable lifting and

jacking angles, eye bolts, etc., to facilitate unloading and move-in operations.

B. The engine-driven generator skid is to be shipped from the factory complete with lifting eyes, jacking angles, etc., attached to the structural base.


C. Provide the services of a manufacturer’s authorized representative to: 1. Be present at the jobsite when the engine-driven generator arrives:

a. Act as an advisor in assisting the Contractor regarding the unloading and move-in operations.

2. Coordinate the delivery of the shipment with the Contractor. 3. Before start-up, furnish written certification that the entire installation and all

connections, both mechanical and electrical, have been inspected and are proper and consistent with all Drawings and Specifications.

1.08 SEQUENCING

A. Complete factory prototype and factory acceptance tests in accordance with NFPA 110 and submit certified test results for Engineer’s review.

B. Conduct factory acceptance test and submit certified test results for Engineer’s review.

C. Ship equipment to Project Site after successful completion of factory acceptance test.

D. Assemble equipment in the field.

E. Conduct field acceptance test and submit results for Engineer’s review.

F. Submit Manufacturers of Installation and Functionality Compliance.

G. Conduct Owner’s training sessions.

H. Commissioning and start-up as specified in Section OR-01757 - Commissioning.

1.09 WARRANTY

A. Extended warranty: 1. The generator set and associated equipment shall be warranted for a period of

not less than 5 years from the date of commissioning against defects in materials and workmanship.

1.10 SYSTEM START-UP

A. Provide manufacturer services including, but not limited to: 1. Furnish the services of manufacturer-certified technicians during the start-up

and adjustment period to ensure that all items furnished are in proper operating condition: a. Engine technician must be completely knowledgeable in the operation,

maintenance, and start-up of the mechanical system. b. Electrical technician must be completely knowledgeable in the operation,

maintenance, and start-up of the electrical system. c. Provide training in conformance with the Demonstration and Training

article of this Section. d. Engine technician and electrical technician may be the same individual if

certified by the respective equipment manufacturers in both engine and electrical fields.


2. Furnish a written report after the start-up: a. Report must state that the installation is complete and satisfactory:

1) List the items requiring additional attention. 3. Minimum required time on site by technician for start-up:

a. 1 day to inspect entire installation, start-up, test operation, and conduct acceptance tests.

1.11 MAINTENANCE

A. Furnish the following spare parts: 1. Sufficient coolant so that entire system may be flushed and replaced after

initial burn-in period. 2. Sufficient lubrication products so that the entire system may be flushed and

replaced after initial burn-in period. 3. 3 sets of lube oil filters, fuel filters, and gaskets. 4. 2 sets of air filters. 5. 2 sets of belts. 6. 12 spare lamps of each different lamp type. 7. 2 fuses (for each control circuit). 8. Provide a 2-pronged battery test voltmeter. 9. 1 set of crankcase breather filters.

B. Special tools: Furnish a set of specialty tools necessary for routine maintenance of the equipment.

C. Maintenance service: Provide manufacturer’s standard service and maintenance contract for Owner’s review and /or acceptance.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Engine generators: 1. One of the following or equal:

a. Caterpillar. b. Onan-Cummins. c. MTU Onsite Energy.

B. Governor: 1. One of the following or equal:

a. Woodward, digital type, Model 723, with EGP type actuator sized for the engine.

b. Isochronous electronic by engine manufacturer.

C. Battery: 1. The following or equal:

a. Hawker.

D. Exhaust system: 1. One of the following or equal:

a. Silencer: 1) Harco Manufacturing.


2) Silex Innovations. b. Expansion joint:

1) DME. c. Exhaust pipe insulation:

1) Per manufacturers requirements. d. Expansion joint insulation:

1) Pittsburgh-Corning, Temp-Mat.

2.02 EQUIPMENT

A. Generator system performance requirements: 1. Power output rating: Minimum kilowatts and voltage as indicated on the

Drawings, delivered at 0.8 power factor, 3-phase, 4-wire, 60 hertz, without exceeding NEMA MG-1 temperature rise limits.

2. It is the manufacturer's responsibility to properly size the engine generator based upon site conditions and actual loads. The Drawings and Specifications indicate a minimum size that the Engineer has determined based upon non-certified information. a. Size the engine generator for a maximum voltage drop at any load step of

no more than 10 percent. b. No increase in Contract amount will be considered if the equipment size

needs to be increased to meet the load requirements after bids have been submitted.

c. Increases in size as a result of manufacturer sizing shall include any and all conduit and wire size changes.

B. Characteristics of assembled unit: 1. The engine-driven generator consists of a spark-ignited, combination natural

gas/LP vapor-fueled engine directly coupled to an electric generator providing continuous electric power for the duration of any power failure of the normal utility power supply.

2. The engine must start, attain full speed, voltage, and assume full load within a maximum of 10 seconds, with jacket water at 85 degrees Fahrenheit.

3. Furnish the engine-driven generator on a steel sub-base to support engine, generator, and accessories as a unit: a. Base: Welded construction. b. Engine direct connected through a flexible coupling to a single bearing

generator. c. System free of injurious torsional and bending vibrations within a speed

range from 10 percent below to 10 percent above synchronous speed. d. Engine-driven generator balanced such that the peak-to-peak amplitude

of vibration velocity in any direction does not exceed the engine or generator manufacturer's published limits.

e. If shims are required under the feet of the generator for alignment purposes, use 1-piece laminated shim stock that covers at least 90 percent of the foot.

f. Provide a complete assembled engine-driven generator skid requiring only the following field mechanical connections: 1) Power leads from generator to the automatic transfer equipment. 2) Control connections to:

a) Plant control system. b) Generator control system.


c) Automatic transfer equipment. 3) Exhaust system. 4) Fuel lines.

g. Connections to engine-driven generator skid: 1) Flexible connections are required on all connections to the engine

generator and are to be supplied by the manufacturer. 2) These connections include but are not limited to:

a) Exhaust. 3) The length of all flexible connections to exceed the flexible connector

manufacturer's minimum length recommendations for the diameter used and for the misalignment as measured after installation.

2.03 COMPONENTS

A. Engine generator base: 1. Support system:

a. Bolt the engine-driven generator to steel pads that are an integral part of structural support base.

b. Vibration isolators shall be provided between the engine generator and welded steel base or between the base and the floor: 1) As recommended by the manufacturer.

c. Support system design must meet the seismic requirements of the project site: 1) Support system design must be stamped by a licensed Professional

Engineer licensed in the State where the Project is located. d. Vibration isolators to properly support the engine driven generator skid on

its concrete base: 1) The isolators located for equal load distribution and deflection per

isolator. 2) Spring type designed for the load and seismic conditions as identified

for the Site.

B. Engine: 1. Spark-ignited, 4-cycle low emission unit, turbocharged, and aftercooled. 2. The rated net horsepower of the engine with all accessories, including radiator

fan, must not be less than that required to produce the minimum specified generator capacity at Site altitude.

3. For dual fuel systems, changeover from primary to secondary fuel shall be automatic.

4. Engine is to be equipped and designed as follows: a. Dual spin-on type replaceable lube oil filter cartridges. b. Replaceable fuel filters. c. Heat treated forged steel crankshaft:

1) Dynamically balanced. d. Forged steel connecting rods. e. Crankshaft driven gear type lubricating pump. f. Electric fuel shut-off valve. g. Engine air cleaner: Dry type replaceable filter.


h. 12 or 24 volt direct current positive engagement solenoid shift-starting motor: 1) The starting equipment must include the necessary devices to

prevent an overcrank and lockout if the starter pinion fails to engage the flywheel ring gear on the initial crank attempt.

2) This starter disconnect is to electronically sense the speed of the flywheel and when the flywheel setpoint speed has been reached, the electronic control signals the starter disconnect to disengage.

i. Oil level dip stick and oil drain pipe with valve and pipe plug: 1) Oil drainpipe and valve are to extend 3 inches beyond edge of

engine base. j. Dry electrical contacts to report:

1) Low oil pressure. 2) Over speed. 3) High water temperature.

k. Engines requiring glow plugs are not acceptable. l. Crankcase breather filter:

1) Provide crankcase ventilation system with coalescing filter/trap for blowby: a) Coalescing filter to be replaceable.

2) If engine manufacturer recommends an open crankcase breather system, route outlet of breather filter to outside at 3 inches above grade and away from engine components: a) Provide on breather outlet Nelson "EcoVent" or equal, sized to

match engine breather flow. 3) If engine manufacturer recommends a closed crankcase breather

system, provide integral crankcase pressure regulator with an automatic internal filter bypass and bypass indicator: a) Unit to be Racor Model CCV 4500 or equal.

m. Governor: 1) Isochronous type to maintain engine speed:

a) Within 0.5 percent for steady state conditions. b) Within 5 percent for a no load to full load step with recovery to

within 2 seconds of step load application. c) Suitable for use on combination natural gas/LP vapor-fueled

engines. d) Electronic governor control of fuel. e) Suitable for automatic, unattended starts. f) Speed sensing failure circuit to signal actuator to close if speed

pick-up signal is lost. g) With speed pick-up sensor. h) With capabilities of local or remote speed settings. i) Adjustable acceleration rate control from 0 to 8 seconds. j) Personnel guards over all exposed moving parts.

n. Equipped with a continuous duty shutdown system for normal remote stopping.

o. Equipped with gauges to indicate: 1) Lube oil pressure. 2) Fuel pressure. 3) Gauges are to be mounted such that vibration will not cause

premature failure.


p. Monitor engine coolant temperature by a thermometer with thermometer well or a temperature gauge.

5. Regulatory requirements: a. Specifically designed to meet the discharge of gaseous pollutants to the

atmosphere as required by the EPA and local agency issuing the permit for the engine generator system.

C. Exhaust system: 1. Provide a complete exhaust system following the general scheme as indicated

on the Drawings and as specified. 2. Back pressure:

a. Provide components such that the maximum back-pressure in the exhaust system including piping and silencer is as required by engine manufacturer, measured at the exhaust manifold header: 1) Reduce allowable back-pressure when recommended by the engine

manufacturer. b. Provide each exhaust manifold header with a lugged, tapped connection

for the attachment of a test manometer. 3. Exhaust piping:

a. Type: Schedule 40 high temperature black steel pipe conforming to ASTM A106.

b. Drainage: Slope piping to a drain point and provide drain plug. c. Finishes: Sand blast and coat outside of exhaust piping with not less than

6 mils of inorganic zinc primer. 1) Finish coat in the field as specified in Section 09960 - High-

Performance Coatings. d. Insulation: As specified in the Project Technical Requirements for engine

exhaust piping. 4. Exhaust expansion joints:

a. Type: 1) Metal with convoluted portion of 0.038 inch thick Type 321 stainless

steel. 2) Non-convoluted portions of expansion joint to be Type 304 stainless

steel, Schedule 10S pipe. 3) Provide flanged ends with ASME B16.5, Class 150 bolt hole drilling.

b. Length: Minimum of 18 inches in length. c. Movement:

1) Rated for a minimum of 1 inch lateral movement, and 1/2 inch axial movement.

2) Rated movement defined as plus or minus travel from neutral or free position.

d. Design life: Infinite cycle life with 1,200 degrees Fahrenheit exhaust, no insulation over the expansion joint, and continuous duty service.

e. Insulation: 1) Insulate expansion joints with custom fitted, removable with reusable

fastening system, ceramic fiber insulation blankets enclosed between inner and outer high temperature fabric cover rated for 1,200 degrees Fahrenheit continuous duty.

5. Exhaust silencer: a. Type: Heavy-duty industrial type fabricated of welded steel with ported

tubes and snubbing chambers, and a rating meeting the specified sound attenuation.


b. Mounting: As indicated on the Drawings. c. End connections: Steel flanges with Class 150-pound drilling pattern. d. Shell:

1) Sufficiently heavy and reinforced to eliminate excessive vibration, stress, or deflection and to support all operating loads with the silencer at elevated temperatures and insulated as specified.

2) Loads include insulation weight and connecting piping. e. Drain: Provide threaded, plugged condensate drain. f. Sound attenuation: Attain the following minimum sound attenuation at the

listed octave band center frequencies with the engine at full load:

Frequency (Hz) 63 125 250 500 1,000 2,000 4,000 8,000 Attenuation (dB) 39 42 42 40 38 38 38 38

g. Supports: Provide shell lug supports suitable for supporting and mounting the silencer as indicated on the Drawings; support design to account for elevated temperatures under insulated shell.

h. Insulation: Insulate as specified for engine exhaust piping as required. i. Pressure drop not to exceed 7-inch water column at maximum engine

rating.

D. Weatherproof acoustical housing: 1. Provide engine enclosure to protect engine, generator, starting system,

batteries, and other specified accessories from weather exposure. 2. Meet wind requirements at the project site. 3. Meet seismic requirements at the project site. 4. Construction:

a. Not less than 14-gauge steel panel thickness. b. All panels and members hot dip galvanized after fabrication. c. Enclosure removable to allow for maintenance. d. Fitted with lockable latches. e. Stainless steel latches and hinges.

5. Finishing: Factory or shop finished in epoxy and urethane coating system as required.

6. Noise reduction: a. Provide acoustical insulation and acoustical enclosure ventilation louvers

and fan discharge silencers as necessary to achieve a measured sound pressure level of 70 dBA when measured at 23 feet from the enclosure.

b. Protect acoustical insulation with perforated metal covers and plastic bagging to prevent damage from abrasion or weather elements.

E. Engine jacket water heater: 1. Provide an in-line thermostat that disconnects power when coolant

temperature exceeds an adjustable setpoint. 2. Contacts from the oil pressure switch to disconnect the heater power when the

engine is running. 3. Equip the water heater with shutoff valves and unions to allow heater

replacement without draining the cooling system. 4. Make all water heater connections with Aeroquip type hoses and fittings. 5. Size heater such that the engine block temperature is maintained at 85 to

100 degrees Fahrenheit in a 40 degree Fahrenheit ambient temperature.


6. Connect water heater and thermostat are to be connected to the engine in such a manner as to minimize heated water circulation through the radiator circuit.

7. Water heater power is to be supplied from a normal (utility) power source: a. Heaters larger than 3,000 watts shall be 460 volts, 3-phase.

F. Alternator (generator): 1. Brushless synchronous alternator. 2. Re-connectable 12 lead if available. 3. Self-ventilated. 4. Full amortisseur windings. 5. Skewed for smooth voltage waveform. 6. With permanent magnet generator pilot exciter. 7. Drip-proof enclosure. 8. Protected against corrosion. 9. Single bearing design. 10. Insulation:

a. Insulated for continuous operation at 50 degrees Celsius ambient temperature.

b. Temperature rise not to exceed 70 degrees Celsius by thermometer and 80 degrees Celsius by resistance, consistent with a Class B rise.

c. Class F (105 degrees Celsius rise by resistance) for medium voltage or Class H (125 degrees Celsius rise by resistance) for low voltage generators.

d. Vacuum impregnated with epoxy varnish to be fungus resistant per MIL I-24092.

e. Multiple dipped and baked with a non-hygroscopic varnish with a final dip of epoxy.

11. Terminate alternator power leads using compression lugs on an insulator and bus bar system within the alternator junction box: a. These terminations must not require any taping to complete the

connection. b. Utilize copper locomotive type cables to connect from the alternator to the

load bank manual transfer equipment: 1) Sized for 125 percent of the alternator full load current. 2) Neutral conductors shall be sized at 100 percent of the alternator full

load rating. c. Provide a ground terminal inside the junction box to terminate the ground

cables between the alternator to the automatic transfer equipment ground bus: 1) Minimum size of the equipment-grounding conductor: 12 1/2 percent

of the size of the phase conductors. 12. 120 VAC integral motor winding heaters wired to and powered from the engine

control panel. 13. Maximum balanced telephone interference factor not to exceed 50.

G. Alternator voltage regulator: 1. Located in the engine control panel. 2. Performance requirements:

a. Maintain the steady state voltage within 0.5 percent: 1) From 40 degrees Fahrenheit to 120 degrees Fahrenheit. 2) From no load to full load conditions.


3. Constant volts per hertz characteristics. 4. Static type. 5. Sized to match the power requirements at the permanent magnet generator

pilot exciter. 6. Include manual control to adjust voltage drop, voltage level, and voltage gain. 7. With 3-phase sensing. 8. Sealed from the environment and isolated from the load to prevent tracking

when connected to SCR loads. 9. Include loss of sensing shutdown to protect the generator against uncontrolled

voltage output when the sensing circuit to the regulator is opened. 10. Shut down regulator when the sensing circuit to the regulator does not have

continuity. 11. Include over-excitation shutdown to protect the generator against damage

caused by prolonged field forcing.

H. Radiator and cooling system: 1. Unit mounted:

a. Furnish a skid mounted closed type radiator system for the engine driven generator: 1) Sized and selected by engine manufacturer.

b. Provide all necessary coolant specifically suitable for the location and conditions of service throughout the year: 1) Ship both the engine and the radiator with the coolant installed.

I. Wiring: 1. All external wiring connection to and from the engine and alternator shall be

made via 2 engine mounted junction boxes: a. Boxes shall be NEMA Type 12. b. One box shall be used for all control, and direct current power

connections. c. The other box shall be used for the alternator output connections:

1) The alternator output breaker may be used for these connections. 2. Enclose wiring in an NEC approved and recognized conduit system selected

and sized by the engine generator manufacturer: a. Suitable for the temperatures, vibrations, and conditions on the engine-

driven generator skid. 3. Control wiring shall terminate on terminal blocks in the control junction box:

a. All connections shall be made to terminal blocks: 1) 600 volt rated. 2) Wires terminated on box with compression type ring type lugs,

installed with proper tooling. 3) Terminal blocks shall be numbered. 4) All wiring in terminal box both internal and field connections shall be

routed in plastic wire duct. 4. Terminate wires using solderless compression type lugs:

a. Lug manufacturer’s termination methods and tools must be used. 5. Splices are not allowed:

a. All connections are to be made at the terminal blocks in the control junction boxes.

J. Battery system: 1. Installed on the engine-driven generator skid.


2. Provide extra flexible minimum 4/0 welding cable to make the connection between the battery and the engine: a. Proper compression lugs and tooling must be used to terminate these

cables. 3. Provide a 24-volt lead acid recombination no maintenance engine start battery

system: a. The battery rated such that the 90 second cranking current to 1.0 volts per

cell exceeds the starter rolling current at 40 degrees Fahrenheit: 1) For the above ratings to be valid, the starter breakaway current must

not exceed the rolling current by a factor of more than 2.5. 2) Increase the battery size in order to supply power to the room

ventilation louvers, automatic transfer equipment relaying and controls, and any direct current lighting.

4. Charger: a. Sized to provide sufficient power to fully charge a drained battery and

power the automatic transfer equipment relaying and controls. b. Charger located on the engine skid. c. With direct current ammeter and direct current voltmeter. d. With On-Off switch. e. Solid-state device with adjustable float voltage control. f. Constant voltage design with current limit. g. With an equalize switch which will allow the battery to be overcharged for

maintenance purposes. h. Designed to meet the charge, float, and equalize requirement of the

battery furnished. i. Overload and short circuit protection.

K. Generator control panel: 1. Enclosure:

a. Skid mounted. b. NEMA Type 12.

2. Power supply to panel: 480 volt, 3 phase. 3. Provide an integral flange-mounted disconnect to disconnect the 480 VAC

power from all controls within the panel. 4. The panel to distribute power to all devices required for the complete engine

generator system. 5. Provide as a minimum all needed transformers, relays, power supplies,

overload, and short circuit protection needed in order to provide a complete and operating system: a. Engine generator controls. b. Interior light. c. Water heater. d. Battery charger. e. Motor winding heater.

L. Miscellaneous engine generator skid items: 1. Provide the following items:

a. Sectionalized drip pans. b. Rain shields for exhaust lines. c. Roof jacks.


M. Automatic generator control equipment: 1. Provide a microprocessor-based control system for automatic starting,

monitoring, and control functions for the engine generator system. a. UL 508 listed and labeled.

2. Control system features and functions: a. Control switches:

1) Mode selector switch: The mode select switch initiates the following control modes: a) Provide a rotary switch or control panel keypads with status

indicators. b) RUN or Manual position:

(1) Generator set starts, and accelerates to rated speed and voltage.

c) OFF or STOP position: (1) Generator set immediately stops, bypassing all time delays.

d) AUTO position: (1) Generator set accepts a signal from a remote device to

start and accelerate to rated speed and voltage. 2) EMERGENCY STOP switch:

a) Red “mushroom-head” pushbutton. b) Activating the emergency stop switch causes the engine to

immediately stop, and be locked out from automatic restarting. 3) RESET switch:

a) Clears all faults and allow restarting the engine generator after it has shut down for any fault condition.

4) PANEL LAMP switch or automatic display panel illumination. b. Alternating current output metering: Provide the control system with

metering including the following features and functions: 1) Voltmeter:

a) RMS voltage. b) Line-to-line. c) Line-to-neutral.

2) Ammeter: a) RMS current.

3) Frequency. 4) Power factor. 5) Kilowatts (kW):

a) kW-hours. b) Output kW.

6) Kilovars (kVars): a) kVar-hours. b) Output kVar.

7) Provide digital metering: a) 1.0 percent accuracy.

c. Generator alarm and status display: 1) Provide high-intensity LED alarm and status indication lamps.

Functions indicated include: a) Red alarm-indicating lamps. b) Red common shutdown lamp.


c) 2 green lamps: (1) One to indicate the engine generator is running at rated

frequency and voltage based on actual sensed voltage and frequency on the output terminals of the generator set.

(2) The second to indicate a remote start signal has been received.

d) Flashing red lamp to indicate that the control is not in automatic state.

e) Amber common warning indication lamp. 2) Display the following alarm and shutdown conditions on an

alphanumeric digital display panel: a) Low oil pressure (alarm). b) Low oil pressure (shutdown). c) Oil pressure sender failure (alarm or indication). d) Low coolant temperature (alarm). e) High coolant temperature (alarm). f) High coolant temperature (shutdown). g) High oil temperature (warning). h) Engine temperature sender failure (alarm or indication). i) Low coolant level (alarm or shutdown - selectable). j) Fail to crank (shutdown). k) Fail to start/overcrank (shutdown). l) Overspeed (shutdown). m) Low direct current voltage (alarm). n) High direct current voltage (alarm). o) High alternating current voltage (shutdown). p) Low alternating current voltage (shutdown). q) Under frequency (programmable for alarm or shutdown). r) Overcurrent (programmed for warning or shutdown). s) Short circuit - circuit breaker function (trip). t) Emergency stop (shutdown).

3) The control shutdown fault conditions shall be configurable for fault bypass.

d. Engine status monitoring: 1) Display the following status conditions on an alphanumeric digital

display panel: a) Engine oil pressure (pounds per square inch or kilopascal). b) Engine coolant temperature (degrees Fahrenheit or Celsius). c) Engine oil temperature (degrees Fahrenheit or Celsius). d) Engine speed (revolutions per minute). e) Number of start attempts. f) Battery voltage (direct current volts).

e. Data logging and display provision: 1) Log the last 10 warning or shutdown indications on the engine

generator. 2) Monitor the total load on the generator:

a) Maintain data logs of total operating hours at specific load levels ranging from 0 to 110 percent of rated load, in 10 percent increments.

b) Display total hours of operation at less than 30 percent load and total hours of operation at more than 90 percent of rated load.


3) The control system to log: a) Total number of operating hours. b) Total kW hours. c) Total control on hours. d) Total values since reset.

f. Engine control functions: 1) Provide a cycle cranking system, which allows for user selected

crank time, rest time, and number of cycles: a) Initial settings shall be for 3 cranking periods of 15 seconds

each, with 15-second rest period between cranking periods. 2) Provide an engine governor control, which functions to provide

steady state frequency regulation as noted elsewhere in this Specification, including adjustments for gain, damping, and a ramping function to control engine speed and limit exhaust smoke while the unit is starting.

3) Provide time delay start (adjustable 0 to 300 seconds) and time delay stop (adjustable 0 to 600 seconds) functions.

g. Battery monitoring system: 1) Initiate alarms when the direct current control and starting voltage is

less than 25 VDC or more than 32 VDC. 2) Disable the low voltage limit during engine cranking (starter

engaged). 3) Monitor direct current voltage as load is applied to the battery, to

detect impending battery failure or deteriorated battery condition. h. Remote control interfaces:

1) Provide a minimum of 4 programmable output relays: a) Configurable for any alarm, shutdown, or status condition.

2) Provide a minimum of 4 programmable inputs.

N. Generator output circuit breaker: 1. Engine generator skid mounted and line side connected to alternator. 2. Manually resettable. 3. Line current sensing. 4. Inverse time versus current response. 5. Sized and coordinated to protect the generator from damage from overload

and/or short circuit: a. Coordinated with down-stream devices:

1) As specified in Section 16305 - Electrical System Studies. 6. Breakers shall be furnished as specified in Section 16412 - Low Voltage

Molded Case Circuit Breakers.

O. Tank: 1. Furnish liquid propane storage tank.

PART 3 EXECUTION

3.01 INSTALLATION

A. Supply manufacture’s services for testing, installation supervising, testing, and guaranteeing the system.


B. General: 1. Install the equipment as indicated on the Drawings. 2. Perform all Work in accordance with manufacturer’s instructions and shop

drawings.

C. Installation shall be by personnel experienced and regularly engaged in field installation of power generation systems: 1. Make all field mechanical and electrical connections.

D. Mount fuel tank at the elevation relative to the engine recommended by the manufacturer to achieve proper engine fuel flow.

3.02 COMMISSIONING


B. Design prototype tests as follows: 1. Use design prototypes similar to the equipment specified in this Section for

testing, and not the actual equipment for the project. 2. Minimum testing requirements:

a. As required by NFPA. b. Maximum power in kW. c. Maximum starting kilovolt-ampere at 35 percent instantaneous voltage

dip. d. Alternator temperature rise:

1) By embedded thermocouple. 2) By resistance method. 3) In accordance with NEMA MG1-22.40 and 16.40.

e. Governor speed regulation under steady state and transient conditions. f. Fuel consumption at 25 percent, 50 percent, 75 percent, and 100 percent

load. g. Harmonic analysis, voltage wave form deviation, and telephone influence

factor. h. Cooling airflow. i. Torsional analysis testing to verify that the generator set is free of harmful

torsional stresses. j. Endurance testing. k. A certified copy of the test results will be furnished to the Owner.

C. Test each engine generator under varying loads with all machine safety guards and exhaust system in place. The complete engine generator system is to be tested at full load in the manufacturer’s establishment: 1. Owner’s representative to observe the tests. TEST shall include:

a. Radiator. b. Engine control panel. c. Single-step load pickup. d. Transient and steady-state governing. e. Safety shutdown device testing. f. Rated power. g. Maximum power.


2. During the full load tests, re-circulate the radiator cooling air through the radiator as necessary to test the system under the maximum ambient conditions specified in this Section.

3. Run the unit for 8 hours at 100 percent load with the following recordings made hourly: a. Frequency. b. Voltage. c. Amperage. d. Kilowatts. e. Room temperature as measured at the generator end of the unit. f. Radiator air inlet temperature. g. Coolant temperature. h. Oil pressure. i. Time engine takes to start in seconds.

4. Record the following items: a. Maximum block load capabilities of the unit. b. Maximum fuel pump vacuum in inches of mercury as measured with the

fuel suction line closed. c. Point at which over temperature shutdown occurs:

1) By actual test of over temperature switch remote from engine. d. Point at which over speed shutdown occurs:

1) By actual test of speed switch remote from engine. e. Point at which low oil pressure shutdown occurs:

1) By actual test of low oil pressure switch remote from engine. f. Point at which overcrank shutdown occurs. g. Point at which overspeed shutdown occurs. h. Low water temperature alarm. i. Low fuel level alarm. j. Fuel leak alarm. k. Overvoltage alarm and shutdown. l. Undervoltage alarm and shutdown. m. Under frequency alarm and shutdown. n. Low battery voltage alarm.

5. Furnish a certified copy of the test results to the Owner: a. These test results must record any minor adjustments made during the

test. b. If major changes, as determined by the Engineer, are made, the 8-hour

test must be repeated.

D. Owner training: 1. As specified in Sections OR-01757 - Commissioning.


A. Test actual backpressure during acceptance testing of the system.

B. Manufacturer to perform installation check, start-up, and load test.

C. Certify that fuel, lubricating oil, and antifreeze conform with the manufacturer's recommendations under the environmental conditions present.


D. Check accessories that normally function while the equipment is in standby mode for proper operation, before cranking the engine: 1. These accessories include but are not limited to:

a. Engine heaters. b. Battery charger. c. Generator strip heaters.

E. Start-up under manual mode: 1. Check for the following items:

a. Exhaust leaks. b. External path for exhaust gases. c. Cooling airflow. d. Movement during starting and stopping. e. Vibration during running. f. Normal and emergency line-to-line voltage and phase rotation.

F. Automatic start-up: 1. By means of simulated power outage test the following:

a. Set all timers for proper system coordination. b. Remote automatic starting. c. Transfer of load. d. Automatic shutdown.

2. Continuously monitor the following parameters during this test: a. Engine temperature. b. Oil pressure. c. Battery charge level. d. Generator voltage. e. Generator amperes. f. Frequency.

3.04 ADJUSTING

A. Make adjustments as necessary and recommended by the manufacturer, Engineer, or testing firm.

END OF SECTION


SECTION 16240

BATTERY SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Battery systems.

1.02 REFERENCES

A. Institute of Electrical and Electronics Engineers (IEEE): 1. 485 - IEEE. 2. 693 - IEEE. 3. 1115 - IEEE.

B. Occupational Health and Safety Administration (OSHA): 1. 1926.441 - Batteries and Battery Charging.

C. Underwriter’s Laboratories (UL): 1. 94 - Standard for Tests for Flammability of Plastic Materials for Parts in

Devices and Appliances.


A. Design requirements: 1. Battery systems to provide DC power to electrical equipment under normal

and emergency conditions as required.

B. Performance requirements: 1. Size battery system to meet the functional requirements of the equipment in

accordance with IEEE.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Batteries: 1. One of the following or equal:

a. C&D Technologies. b. EnerSys. c. HBL Power Systems. d. Alcad.

2.02 COMPONENTS

A. Provide batteries per application requirements and industry standards.


2.03 ACCESSORIES

A. Battery racks: 1. Designed and certified to conform to IEEE 693. 2. Welded steel support frames and rails. 3. Provisions for attachment of a grounding lug. 4. Flame-retardant spacers between each unit. 5. Seismic anchoring hardware.

B. Spill containment: 1. Sealed acid-resistant PVC or epoxy-coated steel floor pan and vertical barrier:

a. Designed to contain the entire electrolyte volume of the largest battery unit contained in the rack.

b. Containing electrolyte-neutralizing chemical packets covering the entire floor of the containment area plus 10 percent spare, designed to control and neutralize a spill from the largest battery unit contained in the rack to a pH of between 7.0 and 9.0.

C. Battery charger: 1. Designed to float and equalize the batteries per manufacturer’s requirements

and recommendations. 2. Sized to recharge the batteries from a fully discharged state to a fully charged

state in a period of 8 hours, while operating all continuous DC loads. 3. Input voltage as required. 4. AC input circuit breaker. 5. DC output circuit breaker. 6. DC output ammeter and voltmeter. 7. Battery temperature compensation sensor, configured to automatically adjust

recharge current based on battery temperature. 8. Voltage surge suppressors. 9. Contacts rated 5 A at 120 VAC for remote monitoring of the following signals:

a. Low battery voltage. b. Battery charger fail.

10. Enclosure rating as specified in the Project Technical Requirements for the area of installation.

D. Signage: 1. Provide warning signs meeting the requirements of OSHA 1926.441 at all

entrances to spaces containing batteries or battery chargers.

PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16262

VARIABLE FREQUENCY DRIVES 0.50 - 50 HORSEPOWER

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Variable frequency drives (VFD) 0.5 to 50 horsepower for control of NEMA

Design B squirrel cage induction motors.

1.02 REFERENCES

A. International Organization for Standardization (ISO): 1. 9001 - Quality Management Systems - Requirements.

B. National Electrical Manufacturers Association (NEMA): 1. MGI, Part 31 – Motors with higher peak voltage capability.

C. Underwriters’ Laboratories (UL): 1. 508A - Standard for Safety for Industrial Control Panels. 2. 508C - Standard for Power Conversion Equipment.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Eaton. 2. Allen-Bradley. 3. Siemens-Robicon. 4. Schneider Electric. 5. General Electric. 6. ABB.

2.02 EQUIPMENT

A. General: 1. 18-pulse VFD with Autotransformer.

a. 18-pulse diode bridge. b. Microprocessor based controls. c. Line and load reactors.

B. Ratings: 1. Voltage:

a. Input voltage as required.


C. Operational features: 1. Protective features:

a. Provide the following minimum protective features: 1) Motor overload protection. 2) Instantaneous overcurrent. 3) Instantaneous overvoltage. 4) Undervoltage. 5) Power unit overtemperature. 6) Phase loss. 7) VFD output short circuit.

2. Control mode: a. Operation in either a constant volts/hertz or sensorless vector mode:

1) The control mode selectable using the programming keypad. 3. Frequency control:

a. Minimum of 3 selectable skip frequencies with adjustable bandwidths. b. Programmable minimum frequency. c. Programmable maximum frequency.

4. Acceleration/deceleration: a. Separately adjustable acceleration and deceleration rates:

1) Each rate adjustable from 0.01 to 1,800 seconds. 5. Spinning load:

a. The VFD shall be capable of determining the speed and direction of a spinning load, “catch” the load and accelerate or decelerate it without damage to the load.

6. Programmable loss of signal: a. Upon loss of speed reference the VFD shall be programmable to either:

1) Stop. 2) Maintain current speed. 3) Default to pre-selected speed.

7. Power interrupt ride-through: a. The VFD shall be capable of continuous operation in the event of a power

loss of 5 cycles or less. 8. Inputs/Outputs:

a. Manufacturer’s standard number the following: 1) Analog inputs:

a) Configurable as either 0 to 10 volts or 4 to 20 milliamperes. 2) Analog outputs:

a) Programmable 4 to 20 milliamperes isolated. 3) Discrete inputs:

a) Programmable. 4) Discrete outputs:

a) Programmable. b) Form C relay contacts.

5) Potentiometer 3-wire input. b. Provide additional inputs/outputs as required to meet the control functions

as required. 9. Communications:

a. Provide each VFD with a DeviceNet Profibus DP EtherNet i/P Modbus TCP communications interface module.

10. Diagnostics: a. Store a minimum of 4 fault conditions in non-volatile memory on a first in-

first out basis.


b. Operational parameters stored at the time of the fault: 1) Operating frequency. 2) Drive status. 3) Power mode.

c. Fault memory accessible via RS-232, RS-422, or RS-485. 11. Automatic restart:

a. User selectable automatic restart feature allowing the VFD to restart following a momentary power failure or other VFD fault: 1) Programmable for up to 9 restart attempts. 2) Adjustable time delay between restart attempts.

2.03 COMPONENTS

A. Enclosure: 1. NEMA Type 12 or motor control center as required. 2. Provide cooling devices required to maintain the VFD within the

manufacturer’s specified temperature limits for the Project conditions: a. Provide cooling device failure alarm.

3. Provide 2 infra-red windows in each VFD section. Iris, Fluke, or Flir.

B. Power disconnect: 1. Flange-mounted motor circuit protector (MCP) thermal magnetic circuit

breaker. 2. Lockable in the OFF position.

C. Input Reactor: 1. 3 percent input line reactor.

D. Output Device: 1. 3 percent output load reactor.

E. Keypad: 1. Provide each VFD with a keypad for programming and control. 2. Keypad requirements:

a. Password security to protect drive parameters. b. Mounted on the door of the VFD. c. Back-lit LCD:

1) Minimum of 2 lines with a minimum of 16 characters per line. d. Programming and display features language: English. e. Capable of displaying the following parameters:

1) Speed (percent). 2) Output current (amperes). 3) Output frequency (hertz). 4) Input voltage. 5) Output voltage. 6) Total 3-phase kilowatt. 7) Kilowatt-hour meter. 8) Elapsed run time meter. 9) Revolutions per minute. 10) Direct current bus voltage.


3. In addition to all keys required for programming, provide the following controls on the keypad: a. Auto/manual selector. b. Start pushbutton. c. Stop pushbutton. d. Jog pushbutton. e. Speed increment. f. Speed decrement. g. Forward/reverse selector. h. Run LED indicator. i. Program LED indicator. j. Fault LED indicator.

4. Provide the VFD with the hardwired controls as required.

F. Control power transformer: 1. Furnish a control power transformer mounted and wired inside the VFD

enclosure. 2. With primary and secondary fusing. 3. Sized to power all VFD controls and options as well as any external devices as

required including the motor winding heater.

G. Bypass and Bypass starter: 1. Provide VFD with an integral bypass and reduced voltage solid state bypass

starter: a. Motor overload protection for bypass operation shall be provided.

2. Provide mechanically/electrically interlocked input and output contactors for bypass operation.

3. Provide a VFD/Off/Bypass selector switch on the VFD front panel.

2.04 ACCESSORIES

A. Metal oxide varistors: 1. Provide protection for the VFD against:

a. Line transients: 5,000 volt peak minimum. b. Line to ground transients: 7,000 peak minimum.

B. Conformal coating: 1. Provide conformal coating material applied to electronic circuitry and printed

circuit boards to act as a protection against moisture, dust, temperature extremes, and chemicals such as H2S and chlorine.

C. Control conductors shall be tin plated copper.

2.05 FINISHES A. Enclosure finish shall be manufacturer’s standard gray.


PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16264

VARIABLE FREQUENCY DRIVES 60 - 500 HORSEPOWER

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Clean power 18 pulse variable frequency drives (VFD), 60 to 500 horsepower

for control of standard NEMA Design B squirrel cage induction motors.

1.02 REFERENCES

A. National Electrical Manufacturers Association (NEMA).

B. Institute of Electrical and Electronics Engineers (IEEE): 1. 519 - IEEE Recommended Practices and Requirements for Harmonic Control

in Electrical Power Systems.

C. Underwriters’ Laboratories (UL): 1. 50 - Standards for Enclosures for Electrical Equipment. 2. 508A - Standard for Safety for Industrial Control Panels.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Eaton. 2. Allen-Bradley. 3. Schneider-Electric. 4. General Electric. 5. ABB.

2.02 EQUIPMENT

A. General: 1. Sinusoidal pulse width modulated, (PWM), voltage source type drive shall

consist of the following: a. Integral phase shifting auto-transformer:

1) Converts 3-phase utility power to 3 sets of 3 power circuits with each set phase shifted and powering its own 3-phase bridge rectifier.

b. Direct current link with capacitors. c. Minimum 18-pulse diode rectifier section consisting of 3 three-phase

bridge rectifiers. 1) Specifically designed as a system to share currents between the

bridges to within 1 percent. d. Insulated gate bipolar transistor (IGBT), inverter section. e. Microprocessor based controls.


f. Output filter. 2. VFDs that have an active input section for either harmonic or voltage control

are not acceptable.

B. Ratings: 1. Voltage:

a. Input voltage: 480 Volts plus or minus 10 percent, 3-phase 60 hertz. 2. Short-circuit rating:

a. As required.

C. Operational features: 1. Protective features:

a. Include the following protective features: 1) Motor overload protection. 2) Instantaneous overcurrent. 3) Instantaneous overvoltage. 4) Undervoltage. 5) Power unit overtemperature. 6) Phase loss. 7) VFD output short circuit. 8) VFD output ground fault. 9) Blown fuse. 10) Motor overtemperature protection:

a) Winding and bearing temperature: (1) From 100 ohm, platinum RTDS. (2) Quantity as specified in Section 16222 - Low Voltage

Motors up to 500 Horsepower and the driven equipment specification or as required.

2. Control mode: a. The VFD shall operate in a either a constant volts/hertz or sensorless

vector mode. Selectable using the programming keypad. 3. Frequency control:

a. Minimum of 3 selectable skip frequencies with adjustable bandwidths. b. Programmable minimum frequency. c. Programmable maximum frequency.

4. Acceleration/Deceleration: a. Separately adjustable acceleration and deceleration rates. b. Each rate shall be adjustable from 0.01 to 1,800 seconds.

5. Spinning load: a. Capable of determining the speed and direction of a spinning load, “catch”

the load and accelerate or decelerate it without damage to the load. 6. Programmable loss of signal:

a. Upon loss of reference speed signal the VFD shall be programmable to either stop, maintain current speed, or default to preselected speed.

7. Power interrupt ride through: a. Capable of continuous operation in the event of a power loss of 5 cycles

or less. 8. Hardwired inputs and outputs:

a. Manufacturer’s standard number the following: 1) Analog inputs:

a) Configurable as either 0 to 10 volts or 4 to 20 milliamperes.


2) Analog outputs: a) Programmable 4 to 20 milliamperes isolated.

3) Discrete inputs: a) Programmable.

4) Discrete outputs: a) Programmable. b) Form C relay contacts.

5) Potentiometer 3-wire input. b. Provide additional inputs and outputs as required to meet the control

functions as required. 9. Communications:

a. Provide each VFD with a DeviceNet, Profibus DP, EtherNet i/P Modbus TCP communications interface module.

b. Control and monitoring of the bypass starter shall be available over the communications network.

10. Automatic control: a. PID capability utilizing an internal or external setpoint.

1) Selectable setpoint source. 11. Diagnostics:

a. Minimum of 4 fault conditions in memory on a first in - first out basis. b. Operating frequency, drive status and power mode shall also be stored at

the time of the fault. c. Fault memory shall be maintained in the event of a power outage. d. The fault memory shall be accessible via RS-232, RS-422 or RS-485.

12. Automatic restart: a. User selectable, automatic restart feature allowing the VFD to restart

following a momentary power failure or other VFD fault: 1) Programmable for up to 9 automatic restart attempts with an

adjustable time delay between restart attempts.

2.03 COMPONENTS

A. Enclosure: 1. NEMA Type 12. 2. Provide cooling devices required to maintain the VFD within the

manufacturer’s specified temperature limits for the Project conditions: a. Provide cooling device alarm.

3. Provide 2 infra-red windows in each section. Iris, Fluke or Flir.

B. Power disconnect: 1. Flange mounted thermal magnetic circuit breaker:

a. Lockable in the OFF position.

C. Phase shifting transformer: 1. Auto-transformer. 2. Integral part of the VFD assembly and factory mounted and wired within the

VFD enclosure. 3. Rated for rectifier duty. 4. Copper or aluminum windings with 180-degree Celsius insulation.

D. Output filter: 1. 3 percent load reactor.


E. Keypad: 1. Furnished with a keypad for programming and control. 2. Password security to protect drive parameters. 3. Mounted on the door of the VFD. 4. Back-lit LCD with a minimum of 2 lines of a minimum of 16 characters each. 5. Programming and display features language: English. 6. Capable of displaying the following parameters:

a. Speed (percent). b. Input current (amperes). c. Output current (amperes). d. Output frequency (hertz). e. Input voltage. f. Output voltage. g. Total 3-phase kilowatt. h. Kilowatt hour meter. i. Elapsed run time meter. j. Revolutions per minute. k. Direct current bus voltage.

7. In addition to all keys required for programming, the keypad shall have the following: a. Automatic/Manual selector. b. Start pushbutton. c. Stop pushbutton. d. Jog pushbutton. e. Speed increment. f. Speed decrement. g. Forward/Reverse selector. h. RUN indicator. i. PROGRAM indicator. j. FAULT indicator. k. DRIVE READY indicator. l. Diagnostics.

8. Provide the VFD with the hardwired controls as required.

F. Control power transformer: 1. Furnish a control power transformer mounted and wired inside the drive

enclosure: a. Primary and secondary fusing.

2. Size the transformer to supply power to all VFD controls and options as well as any external devices as required including the motor winding heater.

G. Bypass and bypass starter: 1. The VFD shall be furnished with a bypass and integral reduced voltage solid

state bypass starter. 2. Provide motor overload protection for bypass operation. 3. Provide mechanically/electrically interlocked contactors for bypass operation. 4. Provide a VFD/Off/Bypass selector switch on the VFD front panel.


2.04 ACCESSORIES

A. Surge protection: 1. Metal oxide varistors:

a. Provide protection for the VFD against: 1) Line transients: 5,000 volt peak minimum. 2) Line to ground transients: 7,000 peak minimum.

B. Conformal coating: 1. Provide conformal coating material applied to electronic circuitry and printed

circuit boards to act as protection against moisture, dust, temperature extremes, and chemicals such as H2S and chlorine.

C. Air filters: 1. Mounted on the outside of the VFD enclosure:

a. Replaceable without requiring that the VFD be turned off or the door opened.

2. Located on the front or top of the VFD enclosure. a. Side or rear mounted air filters are not acceptable.

D. Control conductors shall be tin plated copper.

2.05 FINISHES

A. Enclosure finish shall be manufacturer’s standard gray.

PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16268

UNINTERRUPTIBLE POWER SUPPLIES 10 - 30 KVA

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. 3-phase double conversion uninterruptible power supplies rated 10 to

30 kilovolt-amperes.

1.02 REFERENCES

A. Code of Federal Regulations (CFR) Title 47: 1. Part 15, Subpart A - General. 2. Part 15, Subpart B - Unintentional Radiators.

B. Underwriters Laboratories, Inc. (UL): 1. UL 1778 - Uninterruptible Power Systems.

C. National Electrical Manufacturers Association (NEMA): 1. NEMA PE 1 - Uninterruptible Power Systems (UPS) - Specification and

Performance Verification.

D. Institute of Electrical and Electronic Engineers (IEEE): 1. IEEE 519 - IEEE Recommended Practices and Requirements for Harmonic

Control in Electrical Power Systems. 2. IEEE 1184 - IEEE Guide for the Selection and Sizing of Batteries for

Uninterruptible Power Systems.

E. American National Standards Institute (ANSI): 1. ANSI C62.41 - IEEE Recommended Practice for Surge Voltages in Low-

Voltage AC Power Circuits.

F. International Organization for Standardization (ISO).

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Liebert. 2. Powerware. 3. Mitsubishi.



A. System characteristics: 1. Safety factor:

a. The minimum kW and kVA ratings of the UPS shall be 1.5 times the connected load for both kW and kVA ratings.

2. For UPS units which are possibly powered from backup generators: a. Suitably rated for operation while on generator power.

3. Battery run time at full load and site ambient temperature as indicated in the UPS schedule.

4. Efficiency: a. Greater than 89 percent AC-AC, no input transformer. b. Greater than 83 percent when input transformer implemented.

5. Acoustical noise: a. Less than 58 dBA at 1 meter after installation.

6. Input connections: a. As indicated on the UPS Schedule.

7. Output connections: a. As required.

8. UPS power quality abnormalities: a. Undervoltage:

1) Operate on battery power if incoming source voltage drops below UPS system limits.

b. Overvoltage: 1) Operate on battery power if incoming source voltage rises above

UPS system limits. c. Overcurrent:

1) Input and output current-limiting protection to ensure adequate overcurrent protection for UPS.

2) 125 percent of full load current for 30 seconds. 3) Sub-cycle fault clearing for currents in excess of 300 percent of full

load current. d. Surge protection:

1) MOV-based.

B. Electrical characteristics: 1. AC input:

a. Voltage: 1) As required:

a) Fully functional within +10 percent, -15 percent of nominal voltage.

b. Current: 1) Reflected total harmonic distortion (THD) less than 4 percent at rated

load. 2) Maximum inrush current 800 percent of full load. 3) Rectifier walk-in:

a) 20 seconds to full rated input current maximum. b) Field selectable 5 to 20 seconds.

c. Frequency range of operation: 1) 60 hertz within 5 percent.

d. Power factor: 1) Not less than 0.96 at nominal voltage and full rated load.


e. Rectifier current limiting to 125 percent of the rated input. 2. Output:

a. Voltage: 1) As indicated in the UPS Schedule. 2) Voltage regulation:

a) Within 2 percent 3-phase RMS average for a 100 percent unbalanced load for the combined effects of input voltage, connected load, battery voltage, ambient temperature, and load power factor.

3) Total harmonic distortion (THD): a) 1 percent THD for linear loads. b) Less than 4 percent for 100 percent non-linear loads without

derating at a crest factor of 3:1. 4) Transient recovery time:

a) To within 1 percent of nominal voltage within 1 cycle. 5) Voltage unbalance:

b. Within 1 percent for 100 percent unbalanced load. c. Load power factor:

1) 0.7 lagging to 0.95 leading. d. Frequency regulation:

1) Within 0.1 hertz when synchronized to source. e. Frequency slew rate:

1) Maximum 1.0 Hz/s. 2) User selectable 0.1 to 1.0 Hz/s.

f. Phase displacement: 1) Within 0.5 degree for balanced load.

3. Within 1.0 degree for 100 percent unbalanced load.

C. Environmental requirements: 1. Operating ambient temperature:

a. UPS Module: 32 degrees Fahrenheit to 104 degrees Fahrenheit (0 degrees Celsius to 40 degrees Celsius).

b. Battery: 68 degrees Fahrenheit to 86 degrees Fahrenheit (20 degrees Celsius to 30 degrees Celsius).

2.03 COMPONENTS

A. Surge protective devices: 1. MOV-protection with suitable ratings for installation location and voltage.

B. Inverter: 1. SCR/IGBT type with constant voltage/current-limiting control circuitry. 2. Pulse-width modulated AC output signal.

C. Battery rectifier/charger: 1. SCR/IGBT type with constant voltage/current-limiting control circuitry. 2. Sufficient capacity to simultaneously recharge batteries and supply full load

current to the inverter. 3. Phase-controlled, self-regulated, and self-protected. 4. Separate battery current limit, adjustable from 0 to 15 percent of the full load

input current of the charger.


5. Ability to manually limit the battery recharge current to zero when activated, for instances such as generator operation.

D. Protection: 1. Provide circuit breakers at the following locations:

a. Input to rectifier/charger. b. Manual maintenance bypass switch: c. DC output of rectifier/charger. d. AC output inverter. e. Battery system circuit breaker with under voltage release (UVR) and

auxiliary contacts for isolation of the battery pack from the UPS module. Locate disconnect in a separate wall mounted NEMA Type 1 enclosure: 1) Provides manual disconnecting means, short circuit protection, and

overcurrent protection for the battery system. When opened, removes battery voltage within the UPS enclosure.

2) Automatically disconnects the UPS from the battery by opening the breaker when the battery reaches the minimum discharge voltage level.

2. Short circuit on system output under any condition including transfer to the AC line may not cause UPS damage.

3. Additional protection: a. Undervoltage relaying. b. Current limiting fuses. c. Single-phase protection. d. Inverter DC protection:

1) DC overvoltage shutdown: a) If the DC voltage rises to the pre-set limit, UPS shut down

occurs automatically, and initiates an uninterrupted load transfer to the static bypass line.

b) Inverter control logic senses and disconnects the inverter from the critical AC load without the requirement to clear protective fuses.

2) DC undervoltage warning (low battery reserve), user adjustable from 1 to 99 minutes.

3) DC undervoltage shutdown (end of discharge). e. Over-discharge protection:

1) Automatically raise the shutdown voltage setpoint as discharge time increases beyond 15 minutes.

f. Fuse power semiconductors in the rectifier/charger with fast-acting fuses, so that loss of any power semiconductor cannot cause cascading failures.

E. Batteries: 1. VRLA (valve regulated lead acid), sealed, maintenance free. 2. Minimum 3-year float service life at 25 degrees Celsius. 3. Integral to UPS enclosure or housed in a matching enclosure. 4. Provide the capability for additional battery packs for future storage capacity. 5. Hot-swappable. 6. Recharge to 95 percent within 10 times discharge time. 7. Automatically perform routine battery health monitoring and provide visual,

audible, and/or serial warnings if abnormal battery conditions exist. 8. Manufacturers: One of the following or equal:

a. C&D.


b. East Penn. c. CSB. d. Enersys. e. Nife (NiCad).

9. Batteries: a. Lead calcium sealed, UL listed, non-gassing, immobilized electrolyte type. b. Maintenance free, sealed in plastic containers to form a permanent leak-

proof unit. Sealed, valve-regulated. Absorbed glass mat (AGM) design. c. Provided with intercell cables and connectors, stainless steel terminal

lugs, cell lifter, and lug wrenches. d. Covers fitted with spray-proof vent plugs. e. Battery cabinet:

1) Rack enclosed in vented metal cabinet with hinged access doors. 2) Finished to match floor standing rectifier and inverter enclosures

using acid resistant paint. 3) Casters and leveling feet provided with the battery power pack

cabinet for ease of installation. Removable upon installation where seismic design constraints require.

4) Battery accessibility: a) Mount battery cells on slide-out trays for ease of maintenance.

5) Bolt battery cabinet to the UPS cabinet. The interconnecting cables are to be provided, pre-cut and pre-lugged.

6) Battery monitor capable of monitoring battery failure, charge abnormalities, and emergency inverter operation with display capabilities for remote and local monitoring.

F. Static bypass switch: 1. Integral to UPS system. 2. Maximum detect and transfer time of 4-6 milliseconds. 3. Automatic re-transfer without power interruption to critical load. 4. Input shall match input output in phase, voltage, frequency, and grounding. 5. Rated to carry the full input and output current of the UPS. 6. Provide ability for manual operation. 7. Bypass line synch range:

a. Within 0.5 Hz. b. Inhibit automatic transfer of the critical load to the bypass source if any of

the following conditions are present: 1) Inverter/bypass voltage difference exceeding preset limits. 2) Bypass frequency out of limits. 3) Bypass out-of-synchronization range with inverter output. 4) UPS fault condition present.

G. Manual maintenance bypass switch: 1. Provide isolation of the UPS and power to the critical loads for maintenance

purposes, and to prevent personnel exposure during maintenance. 2. Make-before-break design so that UPS can be isolated from the critical loads

by placing these loads on source power without interruption of operation: a. Applies to both transfer to UPS and transfer return to the utility.

3. Rated to carry the full current of the UPS. 4. Include transformer in bypass circuit where UPS output does not match

voltage of UPS input: a. Match input and output in phase, voltage, frequency, and grounding.


5. Input and output circuit breakers.

H. Cooling: 1. Forced air-cooled. 2. Powered by UPS unit. 3. Coordinate thermal and ambient sensors with protective devices such that

component or internal temperature limits are not exceeded: a. Automatic bypass On/Off. b. Maintenance bypass On/Off. c. Input power On. d. Battery testing mode.

I. Monitoring and controls: 1. Front-panel pushbuttons:

a. UPS startup, shutdown, manual bypass (for automatic bypass), and maintenance bypass.

b. Testing. c. Visual/audible alarms reset.

2. Monitoring: a. Microprocessor-based interface with the display and controls section. b. Provide a graphical display showing a single-line diagram as part of the

monitoring and controls sections of the UPS. Display switch positions and power flow.

c. Display monitoring functions such as metering, status, and alarms on the graphical LCD display. Additional features of the monitoring system include: 1) Menu-driven display with pushbutton navigation. 2) Real time clock (time and date). 3) Alarm history with time and date stamp. 4) Battery back-up memory.

3. Status indication: a. Normal operation. b. Load on maintenance bypass. c. Load on UPS (loss of rectifier/utility power). d. Load on static bypass. e. Lamp Test/Reset pushbutton.

4. Metering displays: a. Input AC voltage line-to-line. b. Input AC current for each phase. c. Input frequency. d. Battery voltage. e. Battery charge/discharge current. f. Output AC voltage line-to-line and line-to-neutral for each phase. g. Output AC current for each phase. h. Output frequency. i. Output kVA and kW. j. Battery time left during battery operation.

5. Alarm messages: a. Input power out of tolerance. b. Battery rectifier/charger problem. c. Input phase rotation incorrect. d. Input over/under frequency.


e. Input current limit. f. Battery failed test. g. Low battery warning. h. Low battery shutdown. i. DC bus overvoltage. j. Bypass frequency out of range. k. Excessive retransfers attempted. l. Static switch failure. m. UPS output not synchronized to bypass power. n. Input power phase loss. o. Output undervoltage. p. Output overvoltage. q. Output overcurrent. r. System output overloaded. s. Load transferred to bypass due to overload. t. Static bypass switch overload. u. Overload shutdown. v. Control error. w. Critical power supply failure. x. Load transferred due to internal protection. y. External shutdown (remote EPO activated). z. Ambient overtemperature limit. aa. Fan failure. bb. Overtemperature shutdown pending. cc. Overtemperature timeout shutdown. dd. Time and date of alarm events. ee. Provide audible alarm with Reset pushbutton.

6. On-line battery test: a. Menu-driven. b. If the battery fails the test, the system:

1) Maintains the load through the UPS. 2) Displays a warning message. 3) Sounds an audible alarm.

c. Additional test features: 1) DC bus voltage threshold (pass/fail value). 2) Interval between tests (2 to 9 weeks). 3) Date and time of initial test. 4) Enable/disable test.

J. Alarm contacts: 1. Isolated contact outputs:

a. Contacts rated 5 amperes, 120 VAC. b. Programmable relay board configurable such that any of the UPS alarms

can be programmed onto any channel of the programmable relay board. c. Provide as a minimum, 8 sets of isolated Form C contacts indicating:

1) Normal mode (UPS is supplying power via utility). 2) Emergency mode (UPS is supplying power via batteries). 3) Bypass mode (Static bypass is supplying power). 4) Low battery. 5) AC low inverter voltage. 6) Common (summary) alarm.


7) Provide a 50-foot shielded cable, compliant with NEMA Class 2 for plenum applications, with sub-miniature 9-pin D-type connector.

d. Interconnect these monitoring points to the PCM as well as provide a SCADA screen reflecting the status of the UPS, whether specifically shown on the P&IDs or not.

K. Communications requirements: 1. RS-232. 2. Ethernet - allow remote indication of all alarms and status signals present in

the UPS. 3. USB - allow remote indication of all alarms and status signals present in the

UPS. 4. Provide manufacturer’s software required for communications.

L. DC filter: 1. Maintain voltage ripple to less than 1 percent RMS on the DC bus.

M. Power distribution unit (PDU): As required kilovolt-amperes, main breaker with 120 volts AC power connected to main breaker shunt trip, emergency push buttons located at the room exits as required.

N. UPS enclosure: 1. Single freestanding unit to house all components including rectifier/charger,

inverter, automatic bypass, maintenance bypass, all battery modules, and available space for spare battery modules.

2. Casters and leveling feet. 3. Cleaned, primed, and painted with manufacturer’s standard color. 4. NEMA Type 1 lockable construction.

O. Transformers: 1. Dry-type power transformer suitable for 100 percent nonlinear loads connected

to the UPS, assuming full wave pulse load rectifier technology for each UPS load.

2. Copper windings. 3. K-rated for harmonic loading: K-13 minimum.

P. Input filter: 1. Provide if required to ensure the UPS input THD remains below specified

values.


A. Inspect, functionally test, and endurance load test uninterruptible power supply: 1. For endurance test, subject uninterruptible power supply equipment to at least

2 times the rated duration specified for the battery system at full load at an ambient temperature equal to or greater than the maximum full load ambient temperature specified above: a. Test system in accordance with IEEE C62.41, Categories A and B.

Submit test procedures and results.


PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16271

DRY TYPE MEDIUM-VOLTAGE TRANSFORMERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Cast coil dry type 5kV distribution transformers for use as part of a secondary

unit substation(s).

1.02 REFERENCES

A. Institute of Electrical and Electronic Engineers (IEEE): 1. C57.12.51 - IEEE Standard for Ventilated Dry-Type Power Transformers,

501 kVA and Larger, Three-Phase, with High-Voltage 601 V to 34,500 V, Low-Voltage 208Y/120 to 4160 Volts - General Requirements.

2. C57.12.90 - IEEE Standard Test Code for Liquid-Immersed Distribution, Power, Regulating Transformers Corrigendum 1: Editorial and Technical Corrections.

3. C57.12.91 - IEEE Standard Test Code for Dry-Type Distribution and Power Transformers.

4. C57.94 - IEEE Recommended Practice for Installation, Application, Operation, and Maintenance of Dry-Type General Purpose Distribution and Power Transformers.

5. C57.96 - IEEE Guide for Loading Dry-Type Distribution and Power Transformers.

B. National Electrical Manufacturers Association (NEMA): 1. TR 1 Transformers, Regulators and Reactors.

C. Underwriters' Laboratories, Inc. (UL): 1. 1562 - Standard for Transformers, Distribution, Dry-Type-Over 600 Volts.

D. United States Code of Federal Regulations (CFR): 1. Title 10: Energy:

a. Part 431 - Energy Efficiency Program for Certain Commercial and Industrial Equipment.


A. Furnish dry-type transformers for operation on a 60 hertz system with voltage and kilovolt-ampere ratings as required: 1. Suitable for continuous operation at full load at the project location and

elevation after applying any derating factors.


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Asea Brown Boveri, ABB. 2. General Electric Co. 3. Schneider Electric. 4. Eaton. 5. Cooper Power Systems.

2.02 MATERIALS

A. Windings: 1. Primary and secondary windings shall be high conductivity copper.

2.03 EQUIPMENT

A. Transformers: 1. Fabrication: In accordance with applicable NEMA, and IEEE standards, except

where the requirements of this Section take precedence. 2. The transformer shall be dry type, cast coil. 3. Capable of being overloaded in accordance with C57.96. 4. Capable of being tested in accordance with C57.12.91.

B. Ratings: 1. Three-phase, 60 hertz. 2. Self-cooled. 3. Primary voltage as required. 4. Primary connection as required. 5. Secondary voltage as required. 6. Secondary connection as required. 7. Rating: Kilovolt-ampere, phase, wire, hertz, as required. 8. Primary taps:

a. Two 2-1/2 percent above rated voltage. b. Two 2-1/2 percent below rated voltage. c. With no load tap changer externally operable with a hook stick. d. Located in the primary compartment.

9. Impedance: 5.75 percent nominal, with tolerance of within 7.5 percent. 10. Basic impulse insulation level: 95 kilovolt primary, 10 kilovolt secondary. 11. Sound levels:

a. In accordance with NEMA TR 1. b. Measurement procedure in accordance with IEEE C57.12.90.

12. Efficiency: a. Transformers 2500 kVA and less shall have an efficiency rating in

accordance with CFR Title 10 Part 431.

C. Construction: 1. Secondary unit substation type with side (end) oriented primary and secondary

terminations. 2. Insulation materials:

a. Rated for continuous 220 degrees Celsius total temperature (Class H) duty for the primary and secondary coil assembly.


b. Designed for the specified temperature rise based on a maximum 40 degrees Celsius ambient, not to exceed 30 degrees Celsius average for any 24-hour period.

3. Enclosures: a. Ventilated indoor type. b. Fabricated of heavy gauge, galvanized steel.

4. The transformer shall be supplied in a knockdown case design, for ease in fitting through limited openings, and shall be a sheet steel construction, equipped with removable panels for access to the core and coils. Front and rear panels shall incorporate ventilating grills.

5. The primary terminations are to be designed for close coupling. 6. The secondary terminations are to be designed for close coupling. 7. Transformer shall be installed in a rodent-proof NEMA Type 1 enclosure. This

enclosure shall include special ventilating grills that will restrict rain or spray from entering the enclosure.

8. Provisions shall be made to completely isolate the core and coil from the enclosure. There shall be no metal-to-metal contact. Neoprene rubber vibration isolating pads shall be installed between the core and coil and the enclosure.

2.04 ACCESSORIES

A. Furnish the following standard features and accessories: 1. Diagram instruction plate. 2. Provisions for lifting and jacking. 3. Removable case panel for access to high voltage. 4. Strap type connector taps for de-energized tap changing. 5. 2 ground pads. 6. The transformer unit supplied shall include high voltage flange and low voltage

flange. 7. Base designed for skidding or rolling parallel to either centerline. 8. Connections between the metal enclosed load break switch section, and

transformer shall be flexible bus or fully-insulated cable or utilize flexible connections. Connections between the transformer and the secondary distribution equipment shall utilize flexible connections.

9. Metal-oxide, gapless type distribution class lightning arresters shall be installed by the manufacturer on the high voltage side of the transformer to provide additional protection against high voltage lightning or switching surges.

2.05 FINISHES

A. The entire enclosure to be finished utilizing a continuous process consisting of degreasing, cleaning and phosphatizing, followed by electrostatic deposition of a polymer polyester powder coating and baking cycle to provide uniform coating of all edges and surfaces. 1. The coating color shall be manufacturer’s standard gray.



A. Shop testing: Transformer shall receive standard commercial tests in accordance with IEEE C57.12.91, plus specific sound tests for the unit(s) to be supplied. 1. Verification of performance: Submit test results certified by a registered

engineer.

END OF SECTION


SECTION 16272

DRY-TYPE TRANSFORMERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Enclosed dry-type transformers:

a. Rated 1 to 1,000 kilovolt-amperes, single and 3-phase. b. Primary voltage 600 volts and below.

1.02 REFERENCES

A. Institute of Electrical and Electronics Engineers (IEEE): 1. 389 - IEEE Recommended Practice for Testing Electronics Transformers and

Inductors. 2. C57.12.01 - IEEE Standard General Requirements for Dry-Type Distribution

and Power Transformers Including Those with Solid Cast and/or Resin Encapsulated Windings.

3. C57.12.91 - IEEE Standard Test Code for Dry-Type Distribution and Power Transformers.

4. C57.96 - IEEE Guide for Loading Dry-Type Distribution and Power Transformers.

B. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

C. Underwriters Laboratory (UL): 1. 1561 - Standard for Dry-Type General Purpose and Power Transformers.

D. U.S. Department of Energy (DOE): 1. 10 CFR Part 431 - Energy Efficiency Program for Certain Commercial and

Industrial Equipment.

1.03 DEFINITIONS

A. NEMA: 1. Type 12 enclosure in accordance with NEMA 250.

1.04 SYSTEM DESCRIPTIONS

A. Provide 3-phase or 1-phase, 60 hertz dry-type with voltage ratings, kilovolt-ampere capacities, and connections as required: 1. Transformers shall provide full capacity at the Project elevation and

environmental conditions as specified in the Project Technical Requirements after all derating factors have been applied.

2. Suitable for continuous operation at full rating with normal life expectancy in accordance with IEEE C57.96.


1.05 WARRANTY

A. 3 years.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. General Electric. 2. Schneider Electric. 3. Eaton. 4. ABB.

2.02 MATERIALS

A. Cores: 1. Non-aging, grain-oriented silicon steel. 2. Magnetic flux densities below the saturation point.

B. Windings: 1. High-grade magnet wire. 2. Impregnated assembly with non-hydroscopic, thermo-setting varnish:

a. Cured to reduce hot-spots and seal out moisture. 3. Material electrical grade:

a. Aluminum only with welded connections.

2.03 EQUIPMENT

A. General: 1. 10 kilovolts BIL for 600-volt class windings. 2. Sound levels, in accordance with IEEE 389 test conditions, not to exceed:

Kilovolt-Amperes Range Audible Sound Level (db) 1-9 40

10-50 45 51-150 50

151-300 55 301-500 60 501-700 62

701-1000 64

3. Taps: a. 15 kilovolt-amperes and less:

1) Two 5 percent full capacity primary taps below rated voltage. b. 25 kilovolt-amperes and larger:

1) Four 2.5 percent full capacity primary taps below rated voltage. 2) Two 2.5 percent full capacity primary taps above rated voltage.

c. Operated by a tap changer handle or tap jumpers accessible through a panel.


4. Terminals: a. UL listed for either copper or aluminum conductors. b. Rated for 75 degrees Celsius.

5. Daily overload capacities, at rated voltage and without reduction in life, in accordance with IEEE C57.96.

B. Transformers less than 15 kilovolt-amperes: 1. Insulation class: 185 degrees Celsius. 2. Temperature rise: 115 degrees Celsius.

C. Energy efficient transformers 15 kilovolt-amperes and larger: 1. Insulation class: 220 degrees Celsius. 2. Temperature rise: 50 degrees Celsius, except as noted below:

a. 150-degree Celsius rise for dry-type transformers located in motor control centers.

3. Efficiency: a. In accordance with DOE 10 CFR Part 431.

D. Enclosures: 1. Heavy gauge steel:

a. Outdoor: Moisture and water resistant with rodent screens over all openings and in a weather-protected enclosure, NEMA Type 3R.

b. Indoor: NEMA Type 12. 2. Louvers to limit coil temperature rise to the value stated above, and case

temperature rise to 50 degrees Celsius. 3. Built-in vibration dampeners to isolate the core and coils from the enclosure:

a. Neoprene vibration pads and sleeves.

2.04 ACCESSORIES

A. Nameplates: 1. Non-corrosive metal or UL listed non-metallic:

a. Stamped, engraved or printed with the following information: 1) Phases. 2) Frequency. 3) Kilovolt-ampere rating. 4) Voltage ratings. 5) Temperature rise. 6) Impedance. 7) Insulation class. 8) BIL rating. 9) Connection diagram. 10) Weight. 11) Manufacturer. 12) The identification “transformer”. 13) Classes of cooling. 14) Tap voltage(s). 15) Vector diagram.

2.05 FINISHES

A. Finish to consist of de-greasing, phosphate cleaning, and an electrodeposited manufacturer’s standard gray enamel rust-inhibiting paint.


PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16285

SURGE PROTECTIVE DEVICES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. High-energy surge protective devices.

1.02 REFERENCES

A. Institute of Electrical and Electronics Engineers (IEEE): 1. C62.41.1 - Guide on the Surge Environment in Low-Voltage (1000 V and less)

AC Power Circuits. 2. C62.41.2 - Recommended Practice on Characterization of Surges in Low-

Voltage (1000 V and Less) AC Power Circuits. 3. C62.45 - Recommended Practice on Surge Testing for Equipment Connected

to Low-Voltage (1000 V and Less) AC Power Circuits. 4. C62.62- Standard Test Specifications for Surge Protective Devices (SPDs) for

Use on the Load Side of the Service Equipment in Low Voltage (1000 V and less) AC Power Circuits.

B. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

C. Underwriters Laboratory: 1. 1449, 4th Edition, Standard for Surge Protective Devices.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Liebert. 2. Eaton. 3. Schneider Electric. 4. General Electric.


A. Surge protective devices as an integral component of the electrical equipment or externally mounted as required.


A. Provide Type 1 or Type 2 SPD units as required for the locations.

http://ieeexplore.ieee.org/document/1196924/

http://ieeexplore.ieee.org/document/1196924/


B. Electrical requirements: 1. SPD ratings are to be consistent with the nominal system operating voltage,

phase, and configuration as required. 2. MCOV:

a. For the SPD and all components in the suppression path (including all MOVs, SADs, and selenium cells): Greater than 115 percent of the nominal system operating voltage.

3. Operating frequency: a. 47 to 63 hertz.

4. SCCR: a. 65 kAIC minimum, but not less than the equipment it is connected to as

required. b. The SCCR shall be marked on the SPD in accordance with UL 1449 and

the NEC. 5. Nominal discharge current In:

a. 20 kA. 6. Maximum VPR:

Modes 240/120 208Y/120 480Y/277 480V L-N, L-G, N-G 900 900 1,500 1,500

L-L 1,200 1,200 2000 2,000 7. Peak surge current:

a. Service entrance locations: 1) 240 kA per phase minimum. 2) 120 kA per mode minimum.

b. Branch locations: 1) 120 kA per phase, minimum. 2) 60 kA per mode minimum.

C. Protection modes: 1. Provide multi-mode SPD protection modes as follows:

a. Line to Neutral (L-N) where applicable. b. Line to Ground (L-G). c. Neutral to Ground (N-G), where applicable.

D. Environmental requirements: 1. Storage temperature:

a. -40 degrees to 122 degrees Fahrenheit. 2. Operating temperature:

a. 32 degrees to 140 Fahrenheit. 3. Relative humidity:

a. 5 percent to 95 percent. 4. Audible noise:

a. Less than 45 dBa at 5 feet (1.5 m). 5. Operating altitude:

a. Zero to 12,000 feet above sea level.

E. Provide surge protective devices that are suitable for application in IEEE C62.41.1, C62.41.2 Category A, B and C3 environments, as tested to IEEE C62.45.


2.04 COMPONENTS

A. Enclosure: 1. Located in electrical equipment as required.

B. Internal connections: 1. Provide low impedance copper plates for intra-unit connections:

a. Attach surge modules using bolted connections to the plates for low impedance connections.

2. Size all connections, conductors, and terminals for the specified surge current capacity.

C. Surge diversion modules: 1. MOV:

a. Where multiple MOVs are used in parallel, utilize computer matched MOVs to within 1 volt variance and tested for manufacturer's defects.

D. Overcurrent protection: 1. Individually fuse all components, including suppression, filtering, and

monitoring components: a. Rated to allow maximum specified nominal discharge current capacity. b. Overcurrent protection that limits specified surge currents is not

acceptable.

E. Connections: 1. Provide terminals to accommodate wire sizes up to #2 AWG.

2.05 ACCESSORIES

A. Unit status indicators: 1. Provide red and green solid-state indicators, with printed labels, on the front

cover to redundantly indicate on-line unit status: a. The absence of the green light and the presence of the red light indicate

that surge protection is reduced and service is needed to restore full operation.

b. Indicates the status of protection on each mode or phase.

B. Dry contacts for remote monitoring: 1. Electrically isolated Form C dry contacts (1 A/125 VAC) for remote monitoring

of system integrity, and indication of under voltage, phase and/or power loss.

C. Provide an audible alarm which activates under any fault condition. 1. Provide an alarm On/Off switch to silence the alarm. 2. A visible LED will confirm whether alarm is On or Disabled. 3. Locate both switches and the audible alarm on the unit’s front cover.

D. Provide transient counter to count transient voltage surges: 1. LCD readout located on the unit’s front cover. 2. Counter to utilize batteries with a 10-year nominal life or non-volatile memory

to maintain accurate counts in the event of power loss.

E. Provide an integral disconnect switch located in-line with the SPD enclosure: 1. External manual operator.


2. The switch shall disconnect all ungrounded circuit conductors from the SPD. 3. The integral disconnect switch shall be capable of withstanding, without failure,

the maximum published surge current magnitude and short circuit current without failure or damage to the switch.

F. Interconnection cable: 1. Interconnect the SPD to the power system using a manufacturer furnished

assembly of low impedance coaxial cables installed in flexible conduit. 2. Cable designed to transmit transients with minimal voltage drop. 3. UL listed.

PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16305

ELECTRICAL SYSTEM STUDIES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Short-circuit fault analysis study. 2. Protective device coordination study. 3. Arc-flash hazard study.

1.02 REFERENCES

A. Institute of Electrical and Electronics Engineers (IEEE): 1. 1584 - IEEE Guide for Specification of Scope and Deliverable Requirements

for an Arc-Flash Hazard Calculations Study in Accordance with IEEE Std 1584(TM).

B. National Fire Protection Association (NFPA).


A. General study requirements: 1. Scope:

a. The short-circuit fault analysis, protective device coordination, and arc-flash hazard studies shall include all new and existing equipment in the power distribution system including, but not limited to: 1) Utility equipment. 2) Switchgear. 3) Switchboards. 4) Generators. 5) Transformers:

a) Including all dry-type transformers. 6) Motor control centers. 7) Freestanding variable frequency drives and starters. 8) Disconnect switches. 9) Motors. 10) Panelboards:

a) Including all 240- and 208-volt systems. 11) Vendor control panels. 12) HVAC equipment.

b. Study scenarios: 1) The studies shall include all possible electrical system configurations,

for example: a) Operation on normal (utility) source. b) Operation on generator source. c) Main-breakers closed, tie-breaker open. d) Either main-breaker open, tie-breaker closed.


2. Obtain, for all equipment, the required data for preparation of the study including, but not limited to: a. Transformer kilovolt-ampere (kVA) and impedances. b. Generator impedances. c. Generator decrement curves. d. Bus withstand ratings. e. Cable and bus data. f. Protective device taps, time dials, instantaneous pickups, and time-delay

settings. 3. Obtain the Electric Utility information on the minimum and maximum available

fault current, minimum and maximum utility impedances, utility protective device settings including manufacturer and model number, interrupting ratings, X/R ratios, and model information one level above the point of connection: a. Utility tolerances and voltage variations.

4. The individual performing the studies shall visit the site and collect all necessary field data in order to perform and complete comprehensive electrical system studies.

5. Obtain equipment layouts and configurations from the manufacturer’s final submittal requirements and project layout drawings as required.

6. Bus and conductor data: a. Use impedances of the actual installed or specified conductors, unless

otherwise indicated. b. Use cable and bus impedances calculated at 25 degrees Celsius, unless

otherwise indicated. c. Use 600-volt cable reactance based on typical dimensions of actual

installed or specified conductors, unless otherwise indicated. d. Use bus withstand values for all equipment having buses. e. Use medium-voltage cable reactances based on typical dimensions of

shielded cables with 133-percent insulation levels, unless otherwise indicated.

7. Motors: a. Each motor shall be individually modeled:

1) Grouping of motors for fault contribution current is not acceptable. b. Motors with variable frequency drives may be assumed to have no

contribution to fault current. 8. Use the equipment, bus, and device designations as required for all studies.

B. Short-circuit fault analysis study additional requirements: 1. The short-circuit fault analysis shall be performed and submitted in 2 phases:

a. Initial short-circuit fault analysis: 1) Based on the Contract Documents and Electric Utility information. 2) The initial short-circuit fault analysis study shall indicate the

estimated available short-circuit current at the line side terminals of each piece of equipment covered by the scope of the study.

3) Provide a list of assumptions used in the initial study. b. Final short-circuit fault analysis:

1) The final short-circuit fault analysis shall modify the initial analysis as follows: a) Utilize the actual equipment provided on the project. b) Utilize conductor lengths based on installation.


2. Calculate 3-phase bolted fault, line-to-line fault, line-to-ground fault, double line-to-ground fault, short-circuit 1/2 cycle momentary symmetrical and asymmetrical RMS, 1-1/2 to 4 cycle interrupting symmetrical RMS, and 30-cycle steady-state short-circuit current values at each piece of equipment in the distribution system.

3. Evaluate bus bracing, short-circuit ratings, fuse interrupting capacity and circuit-breaker-adjusted interrupting capacities against the fault currents, and calculate X/R values: a. Identify and document all devices and equipment as either inadequate or

acceptable. 4. Calculate line-to-ground and double line-to-ground momentary short-circuit

values at all buses having ground-fault devices. 5. Provide calculation methods, assumptions, one-line diagrams, and source

impedance data, including utility X/R ratios, typical values, recommendations, and areas of concern.

C. Protective device coordination study additional requirements: 1. Furnish protective device settings for all functions including, but not limited to:

a. Current. b. Voltage:

1) Provide settings for all voltage relays based upon actual utility and generator tolerances and specifications.

c. Frequency: 1) Provide settings for all frequency relays based upon actual utility and

generator tolerances and specifications. d. Negative sequence. e. Reverse power. f. Machine protection functions:

1) Provide settings for all motor and generator protective relays based on the manufacturer’s recommended protection requirements.

2. Provide log-log form time-current curves (TCCs) graphically indicating the coordination proposed for the system: a. Include with each TCC a complete title and one-line diagram with legend

identifying the specific portion of the system covered by the particular TCC: 1) Typical TCCs for identical portions of the system, such as motor

circuits, are acceptable as allowed by the Engineer. b. Include a detailed description of each protective device identifying its type,

function, manufacturer, and time-current characteristics: 1) These details can be included on the TCC.

c. Include a detailed description of each protective device tap, time dial, pickup, instantaneous, and time delay settings: 1) These details can be included on the TCC.

3. TCCs shall include all equipment in the power distribution system where required to demonstrate coordination. Include utility relay and fuse characteristics, medium-voltage equipment protective relay and fuse characteristics, low-voltage equipment circuit breaker trip device characteristics, transformer characteristics, motor and generator characteristics, and characteristics of other system load protective devices: a. Include all devices down to the largest branch circuit and largest feeder

circuit breaker in each motor control center, main breaker in branch panelboards, and fused disconnect switches.


b. Provide ground fault TCCs with all adjustable settings for ground fault protective devices.

c. Include manufacturing tolerances and damage bands in plotted fuse and circuit breaker characteristics.

d. On the TCCs, show transformer full load currents, transformer magnetizing inrush, ANSI transformer withstand parameters, and transformer damage curves.

e. Cable damage curves. f. Terminate device characteristic curves at a point reflecting the maximum

symmetrical or asymmetrical fault current to which the device is exposed based on the short-circuit fault analysis study.

g. Coordinate time interval medium-voltage relay characteristics with upstream and downstream devices to avoid nuisance tripping.

4. Site generation: When site generation (including cogeneration, standby, and emergency generators) is part of the electrical system, include phase and ground coordination of the generator protective devices: a. Show the generator decrement curve and damage curve along with the

operating characteristic of the protective devices. 5. Suggest modifications or additions to equipment rating or settings in a

tabulated form.

D. Arc-flash hazard study additional requirements: 1. Include the calculated arc-flash boundary and incident energy (calories/square

centimeter) at each piece of equipment in the distribution system: a. Perform study with 15 percent arcing fault variation as defined by

IEEE 1584. b. Perform arc-flash calculations at minimum and maximum utility and

generator fault contributions. c. Perform arc-flash calculations for both the line side and load side of the

switchgear, switchboard, motor control center, and panelboard main breakers.

d. Perform arc-flash calculations for all short-circuit scenarios with all motors on for 3 to 5 cycles and with all motors off.

e. Protective device clearing time shall be limited to 2 seconds, maximum. 2. Provide executive summary of the study results:

a. Provide summary based upon worst case results. 3. Provide a detailed written discussion and explanation of the tabulated outputs:

a. Include all scenarios. 4. Provide alternative device settings to allow the Owner to select the desired

functionality of the system: a. Minimize the arc-flash energy by selective trip and time settings for

equipment maintenance purposes. b. Identify the arc-flash energy based upon the criteria of maintaining

coordination and selectivity of the protective devices.

E. Electrical system study meetings: 1. The individual conducting the short-circuit fault analysis, protective device

coordination, and the arc-flash hazard studies shall meet with the Owner and Engineer 3 times.


2. The purpose of the 3 meetings is as follows: a. Initial meeting:

1) Meet with the Owner and Engineer to discuss the scope of the studies.

2) Discuss the Owner’s operational requirements for both normal operation and maintenance.

b. Preliminary results meeting: 1) This meeting will be held after the studies have been completed,

reviewed, and accepted by the Engineer. 2) The purpose of this meeting is to inform the Owner of the results of

the study and impacts on normal operation and maintenance including: a) Protective device coordination problems and recommended

solutions. b) Explanation of the arc-flash hazard study results and its

potential impact on operations. c) Recommendations for reduction of arc-flash category levels

including reduction of protective device settings or changes in operational practices.

c. Final meeting: 1) Discuss changes to the studies based on the previous meeting. 2) Discuss with the Owner how changes to the electrical system may

change the arc-flash hazard category. 3) Deliver the final electrical system studies report.

3. The meetings will be at the Owner’s facility: a. Provide a minimum of 3-weeks notice to the Owner and Engineer in

advance of the projected meeting date. b. Submit a draft of the meeting agenda when each meeting is requested.

4. Meeting materials: a. Prepare and provide the following materials:

1) Meeting agenda. Include, at a minimum, the scope of the meeting, estimated time length for the meeting, and meeting goals.

2) 6 copies of the project one-line diagrams for the initial meeting. 3) 6 copies of the submitted studies.

F. By virtue of the fact that this is a professional study, the Owner reserves the right to modify the requirements of the study to comply with its operational requirements. The protective device coordination study and the arc-flash hazard study shall be modified based on the results of the meetings with the Owner.

1.04 SUBMITTALS


B. Initial studies and reports: 1. Include the following in the initial short-circuit current report:

a. List of all devices included in the studies. b. A description of all operating scenarios. c. Form and format of arc-flash labels.


C. Final studies and reports: 1. Format and quantity:

a. Provide 6 bound copies of all final reports. b. Provide 3 complete sets of electronic files on CD or DVD media, including

the electrical system model(s), configuration files, custom libraries, and any other files used to perform the studies and produce the reports. Also provide an electronic version of the bound reports in PDF format.

c. Provide the number of copies specified in Sections OR-01300 - Submittal Procedures.

2. Include the sections below in the final report: a. Copies of correspondence and data obtained from the electric utility

company. b. Letter certifying the inspection and verification of existing equipment. c. One-line diagrams:

1) The following information shall be included at a minimum: a) Motor horsepower. b) Transformer data:

(1) kVA. (2) Configuration.

c) Cable data: (1) Insulation. (2) Size. (3) Length.

2) One-line diagrams shall be fully legible at 11-inch by 17-inch size. d. Include in the short-circuit fault analysis study:

1) Descriptions, purpose, basis, assumptions, recommendations, and scope of the study.

2) Normal system connections and those that result in maximum fault conditions.

3) Tabulation of circuit breaker, fuse, and other protective device ratings compared to maximum calculated short-circuit duties.

4) Fault current calculations for the cases run including a definition of terms and guide for interpretation of computer software printouts.

e. Protective device coordination study shall include: 1) Descriptions, purpose, basis, assumptions, recommendations, and

scope of the study. 2) List all requirements used in the selection and setting criteria for any

protective devices. 3) Manufacturer’s time-current curves for circuit breakers, fuses, motor

circuit protectors, and other protective devices for all new equipment. 4) TCCs graphically indicating the coordination proposed for the system

on log-log graphs. At least 3 of the copies shall be in color. 5) Tabulation of relay, fuse, circuit breaker, and other protective devices

in graphical form with a one-line diagram to display area coordination.

6) Where coordination could not be achieved, an explanation shall be included in the report to support the statement along with recommendations to improve coordination. Recommended equipment modifications or settings shall be in a tabulated form.

f. Include in the arc-flash hazard study: 1) Descriptions, purpose, basis, assumptions, recommendations, and

scope of the study.


2) Normal system connections and those that result in maximum arc-flash conditions.

3) Arc-flash raw data, calculations, and assumptions. 4) Arc-flash label data:

a) Identifying the content of each label. b) Identifying the location of each label.

D. Certification: 1. Submit written certification, sealed and signed by the professional engineer

conducting the study, equipment supplier, and electrical subcontractor stating that the data used in the study is correct.

E. Submit the credentials of the individual(s) performing the study and the individual in responsible charge of the study.

F. The Engineer will review all studies and reports. After review, the Engineer will make recommendations and/or require changes to be made to the short-circuit fault analysis, protective device coordination, or arc-flash hazard studies. These changes shall be provided as part of the scope of work.

G. Submit course outline for Owner’s training.


A. Qualifications of the entity responsible for electrical system studies: 1. The studies shall be performed, stamped, and signed by a professional

engineer registered in the state where the project is located. 2. A minimum of 5 years of experience in power system analysis is required for

the individual in responsible charge of the studies. 3. The short-circuit fault analysis, protective device coordination, and arc-flash

hazard studies shall be performed with the aid of a digital computer program: a. Point-to-point calculations are not acceptable.

B. The study shall be performed by an independent firm or equipment manufacturer.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Required Electrical system study software: 1. SKM Systems Analysis, Powertools.

2.02 COMPONENTS

A. Arc-flash hazard labels: 1. Dimensions:

a. Minimum 5 inches by 3.5 inches. 2. Materials:

a. Polyester with polyvinyl polymer over-laminate. b. Self-adhesive. c. Resistant to:

1) UV.


2) Chemicals and common cleaning solvents. 3) Scuffing. 4) Wide temperature changes.

3. Contents: a. Short-circuit bus identification. b. Calculated incident energy (calories/square centimeter) range:

1) Based on worst-case study results. c. Site specific personnel protective equipment level number. d. Arc-flash protection boundary. e. Shock hazard boundary:

1) The Contractor may provide separate labels for indication of the shock hazard boundary.

4. Color scheme: a. For locations above 40 calories/square centimeter:

1) White label with red “DANGER” strip across the top. 2) Black lettering.

b. For locations below 40 calories/square centimeter: 1) White label with orange “WARNING” strip across the top. 2) Black lettering.

END OF SECTION


SECTION 16341

5-KILOVOLT MEDIUM VOLTAGE METAL CLAD SWITCHGEAR

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. 5-kilovolt class metal clad switchgear. 2. Vacuum interrupter power circuit breakers.

1.02 REFERENCES

A. Institute of Electrical and Electronic Engineers (IEEE): 1. C37.04 - IEEE Standard for Rating Structure for AC High-Voltage Circuit

Breakers Corrigendum 1. 2. C37.06 - IEEE Standard for AC High-Voltage Circuit Breakers Rated on a

Symmetrical Current Basis - Preferred Ratings and Related Required Capabilities for Voltages Above 1000 V.

3. C37.09 - IEEE Standard Test Procedures for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis - Corrigendum 1.

4. C37.2 - IEEE Standard Electrical Power System Device Function Numbers, Acronyms, and Contact Designations.

5. C37.20.2 - IEEE Standard for Metal-Clad Switchgear. 6. C37.20.6 - IEEE Standard for 4.76 kV Rated Ground and Test Devices Used

in Enclosures. 7. C37.90 - IEEE Standard for Relays and Relay Systems Associated with

Electric Power Apparatus. 8. C57.13 – - IEEE Standard Requirements for Instrument Transformers. 9. C62.11 - IEEE Standard for Metal Oxide Surge Arresters of AC Power Circuits

(> 1 kV).

B. National Electrical Manufacturers' Association (NEMA): 1. SG 2 - High Voltage Fuses. 2. SG 4 - Alternating-Current High-Voltage Circuit Breakers. 3. SG 5 - Power Switchgear Assemblies.


A. General: 1. Metal-clad, 5 kilovolt switchgear designed and manufactured in accordance

with the reference standards listed in this Section. 2. Switchgear and major components to be products of a single manufacturer

including, but not limited to: a. Circuit breakers. b. Related equipment specified in the Contract Documents or indicated on

the Drawings. 3. In addition to the specified basic equipment common to switchgear sections,

equip the various individual sections with instruments, protective relays and control devices as indicated on the Drawings and/or specified below.


4. Arrange the equipped sections side by side to form continuous switchgear lineups as indicated on the Drawings.

B. Description of sections: 1. Incoming line compartment:

a. Hinged door with catch and lockable handle, bolted closed. b. Dimensions, ratings, spacing, and standards must conform to the

requirements of the electric utility. c. Service entrance cables to enter the incoming line compartment, in a

manner as indicated on the Drawings. d. Incoming line termination pads suitable for the size and number of

conductors indicated on the Drawings and/or conduit schedule. e. Lightning arresters.

2. Utility metering compartment: a. Integral utility current and potential transformer cabinet for utility company

metering. b. Switchgear to include space for mounting electric utility’s potential and

current transformers. c. Instrument transformers to be supplied in accordance with the electric

utility’s requirements. d. Switchgear manufacturer to obtain necessary approvals from the utility

company. e. Bolted hinged door with lockable handle. f. Metering compartment barriers, rear, top, bottom, and sides. g. Dimensions, ratings, spacings, and standards must conform to the

requirements of the electric utility. 3. Breaker compartment:

a. Main, tie, or feeder breaker as indicated on the Drawings. b. Protective relays and other protective devices and interlocks as indicated

on the Drawings. c. Multi-function solid state meters as indicated on the Drawings. d. Current transformers: Quantity and ratios as indicated on the Drawings.

4. Grounding breaker: a. Connected to switchgear ground bus by cable or bus:

1) Cable or bus sized to carry 2-second short time rating of equipment in accordance with IEEE C37.20.6.

b. Interlocked with main and tie breakers to prevent the ground breaker from closing when any main or tie breaker feeding the bus is closed and to prevent the main or tie breakers from being closed when the grounding breaker is closed.

c. Voltage interlock to prevent closing the grounding breaker unless the bus voltage is below a pre-set value.

5. Future breaker/space compartments: a. As indicated on the Drawings:

1) Furnish with hardware necessary to accommodate installation of future circuit breakers, instruments, relays, and controls.

2) Wire relay and circuit breaker control power to the compartment and terminate on terminal strips.

6. Transformer compartment: a. Potential transformers: Fused, with quantities, ratio, and configuration as

indicated on the Drawings.


b. Control power transformers: Fused with voltage ratings as indicated on the Drawings.

1.04 SUBMITTALS


B. Product data: 1. Manufacturer of switchgear. 2. Manufacturers of all components and accessories. 3. Weight of each circuit breaker of different frame sizes. 4. Dimensions:

a. Height. b. Length. c. Width. d. Weight.

5. Nameplate schedule. 6. Bill of material. 7. Description of operation:

a. Metering system. b. Protective relaying.

8. Ratings: a. Voltage. b. Phase. c. Current. d. Interrupting rating (circuit breakers and fuses). e. Momentary current rating.

9. List of recommended spare parts. 10. Name of dealer’s repair facility and parts stocking agreement with the factory:

a. Agreement shall outline in detail the manufacturer's parts stocking requirements and the method by which the manufacturer's representative verifies that the stock is at an acceptable level.

b. Agreement shall outline the method by which the manufacturer determines that the service personnel meet factory standards.

11. For equipment installed in structures designated as seismic design category C, D, E, or F submit the following as specified in the Project Technical Requirements: a. Manufacturer’s statement of seismic qualification with substantiating test

data. b. Manufacturer’s special seismic certification with substantiating test data.


a. Provide fully dimensioned, to scale, equipment layout drawings which include: 1) Equipment furnished: Plan, front and side views. 2) Shipping splits. 3) Bus layout. 4) Interfaces with other equipment. 5) Minimum distances to walls and breaker “roll-out” distances. 6) Bottom conduit windows.


b. Complete, detailed, and scaled switchgear layout: 1) Front panel. 2) Sub-panels. 3) Interior panels. 4) Assembly drawings cross-section as a minimum for each cubicle with

major dimensions indicated. 2. Complete electrical wiring diagrams:

a. Indicate wire numbers. 3. Complete interface and point-to-point connection diagrams for metering

system. 4. Internal schematics, elementary diagrams, and wiring diagrams of each unit or

compartment, including wiring identification and terminals. 5. Internal cell-to-cell interconnection wiring diagrams, including wiring

identification and terminal numbers. 6. Complete 1-line and 3-line diagrams for each switchgear line-up:

a. Identify all components comprising the switchgear assembly including, but not limited to, circuit breakers, control power and instrument transformers, meters, relays, control devices, monitoring devices, and terminal blocks.

b. Clearly indicate device electrical ratings on the drawings.

D. Installation instructions: 1. Detail the complete installation of the equipment including rigging, moving, and

setting into place. 2. For equipment installed in structures designated as seismic design category A

or B: a. Provide manufacturer’s installation instructions and anchoring details for

connecting equipment to supports and structures. 3. For equipment installed in structures designated as seismic design category C,

D, E, or F: a. Provide project-specific installation instructions and anchoring details

based on support conditions and requirements to resist seismic and wind loads as specified in the Project Technical Requirements.

b. Submit anchoring drawings with supporting calculations. c. Drawings and calculations shall be stamped by a professional engineer

registered in the state where the Project is being constructed.

E. Operation and maintenance manuals: 1. Operating instructions:

a. Detail the operational functions of custom controls that have been placed on the front panel of the switchgear and internal PLC programming if applicable.

2. Maintenance manual: a. Furnish maintenance manuals with instructions for maintenance of the

equipment and data identifying the parts. b. Include all information needed to maintain the switchgear including but not

limited to the following: 1) Instructions for testing, adjustment, and start-up. 2) Detailed control instructions that outline the function and operation of

every control device. 3) Schematic and wiring diagrams:

a) Showing all internal and external connection. b) Furnish in a reduced 11-inch by 17-inch fully legible format.


F. Test forms and reports: 1. Submit complete factory acceptance test procedures and all forms used during

the test. 2. Furnish a manufacturer’s certified report after the factory tests. 3. Furnish a manufacturer’s written report after the start-up:

a. Report must state that the installation is complete and satisfactory, or list items requiring additional attention and a proposal for the corrective actions.

b. If items require attention after the initial start-up, furnish a final report stating that the installation is complete and satisfactory.

G. Manufacturer’s Certificate of Installation and Functionality Compliance.

H. Calculations: 1. DC power and current requirements needed to operate the 5-kilovolt metal-

clad switchgear circuit breakers and protective relays. 2. Detailed calculations or details of the actual physical testing performed on the

switchgear to prove the switchgear is suitable for the seismic requirements at the project site.

I. Training documents: 1. Submit all training documentation to be used during the Owner’s training

sessions as specified in this Section.


A. Manufacturer shall have supplied at least 4 systems of similar nature and size, which have been installed within a 500-mile radius of the Project location.

B. The manufacturer shall have established an authorized dealer having parts and service facility within a 200-mile radius of the Project: 1. Pre-qualified service personnel available on a 24-hour-a-day basis. The

personnel must be completely familiar with the items supplied so as to return the equipment to service in the shortest possible time.

2. The authorized dealer must have no less than 80 percent of switchgear parts and 100 percent of recommended spare parts, as identified in the product data submittal in its stock at all times: a. A personal inspection of the facility may be made by the Owner to

substantiate claims of available replacement parts.

C. Sections and devices shall be UL listed and labeled.


A. Ship the switchgear and associated equipment to the Project Site on a dedicated air ride vehicle that will allow the Contractor to utilize onsite off-loading equipment:

B. Furnish temporary equipment heaters within the switchgear to prevent condensation from forming.


1.07 SEQUENCING

A. Conduct the initial fault current study as specified in Section 16305 - Electrical System Studies and submit results for Engineer’s review.

B. After successful review of the initial fault current study, submit complete equipment submittal.

C. Ship equipment to Project Site.

D. Install equipment in the field.

E. Conduct final fault current and coordination study.

F. Set all relays per coordination study.

G. Conduct field acceptance test.

H. Submit Manufacturer’s Certification of Installation and Functionality Compliance.

I. Conduct Owner’s training sessions.

J. Commissioning as specified in Section OR-01757 - Commissioning.

1.08 WARRANTY




A. Per manufacturer recommendations.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. General Electric Co. 2. Schneider Electric. 3. ABB. 4. Eaton.

B. Circuit breakers: Same manufacturer as metal-clad switchgear.

2.02 EQUIPMENT

A. Switchgear: 1. Provide medium-voltage 5-kilovolt class metal-clad switchgear as specified in

the Contract Documents and indicated on the Drawings.


2. Provide complete and functional lineups of switchgear with associated controls.

3. Provide devices or accessories not specified in this Section but necessary for the proper installation and operation of the equipment.

B. Voltage ratings: 1. As indicated on the Drawings. 2. Basic impulse insulation level: Minimum 60 kilovolts.

C. Main bus: 1. High conductivity, tin-plated copper:

a. Flat bar with rounded edges. b. Suitably braced and supported on high dielectric strength insulators.

2. Continuous current carrying capacity as indicated on the Drawings. 3. Insulate each bus with fluidized bed epoxy flame retardant and track resistant

insulation. 4. Mount insulated bus on flame retardant, track resistant supports and brace to

withstand magnetic stresses developed by fault currents equal to the close and latch rating of the circuit breakers.

5. Bus connections: a. Plated. b. Bolted with Belleville spring washers. c. Install insulated boot over joint.

6. Document temperature rise of the bus and connections by design tests.

D. Ground bus: 1. Tin-plated copper bar, 1/4 inch by 2 inches minimum, extended through each

section: a. Firmly secure to each vertical section. b. Provide termination lugs for termination of copper ground cable at each

end of the bus. 2. Ground each section directly to ground bus. 3. Connect switchgear ground bus to relay panel ground bus by:

a. A Number 6 AWG insulated green copper wire or, b. A 1/2-inch by 1/8-inch tin-plated copper bus bar.

E. Stationary structure: 1. Utilize unit type construction in formation of housing in order to provide a rigid,

self-supporting and self-contained enclosure for each circuit breaker unit and other units comprising switchgear: a. Fabricate each stationary structure of heavy, formed, smooth, and level

steel sheets and structural members, bolted or welded to form a rigid assembly with hinged steel panel suitable for mounting of instruments, meters, relays, and control devices.

b. Provide bolted, hinged front and rear cubicle doors with locks. 2. Dead front construction with rear access via lockable, hinged doors. 3. Sections shall be approximately 95 inches high, 36 inches wide, front and rear

aligned: a. Maximum dimensions as indicated on the Drawings.


4. Isolate circuit breaker units, bus, instrument and control transformers, and outgoing cables within separate compartments formed by sheet steel barriers: a. Mount heavy close-fitting bus supports at bus openings between units:

1) The supports shall form a barrier to isolate each unit from adjacent units.

b. Provide each compartment with a separate cover for individual servicing without exposing the circuit in adjacent compartment.

5. Provide automatic shutters to isolate the circuit breaker compartment from the bus when the circuit breaker unit is moved to the TEST or WITHDRAWN position.

6. NEMA type: a. NEMA Type 1 gasketed:

1) Switchgear sections shall have an open bottom in the rear for cable terminations.

b. NEMA Type 3R, non-walk-in enclosure: 1) Hinged doors front and back. 2) Peaked or slanting roof. 3) Enclosing NEMA Type 1 gasketed switchgear. 4) Switchgear sections shall have removable plates in the rear bottom

for field drilling of conduit openings. c. NEMA Type 3R, walk-in enclosure:

1) Hinged doors front and back. 2) Peaked or slanting roof. 3) Protected aisle. 4) Enclosing NEMA Type 1 gasketed switchgear. 5) Switchgear sections shall have removable plates in the rear bottom

for field drilling of conduit openings. 7. Front access to devices accessible through a formed, bolted, hinged

removable cover: a. Captive knurled type knob screws are to hold covers in place.

8. Provide switchgear with lifting channels having provisions for attachment of crane slings to facilitate lifting and handling each shipping-assembly unit: a. Remove lifting channels after equipment is installed.

F. Cable compartment: 1. Support circuit breaker disconnecting contacts by means of flame-retardant,

track-resistant polyester glass or porcelain supports. 2. Provide cable terminals:

a. NEMA 4-hole pads suitable for connection and termination of 5 kilovolt shielded cables.

3. Design switchgear so that high voltage, low voltage, control and instrumentation cables can enter the switchgear from either the top or bottom.

4. Provide cable supports with provisions for stress relief cones and cable bends.

G. Removable element: 1. Provide a racking screw and moving block for breaker insertion and

withdrawal: a. The racking screw shall be capable of holding the breaker in the

CONNECTED position. 2. Utilize master jigs to determine accurately the correct stud locations of the

removable and the stationary elements.


3. Provide means for mechanically locking the removable element in any position: a. Lock shall not interfere with the operation of the breaker and its

mechanism. 4. Provide a ground shoe to ground the breaker in all positions. 5. Provide breaker “CONNECTED” position indication. 6. Provide interlock on each circuit breaker unit to prevent circuit breaker from

being removed from CONNECTED position and from being placed in CONNECTED position while breaker is closed: a. If the circuit breaker is closed, the interlock shall trip the breaker before it

can be placed into or removed from the CONNECTED position. 7. Accurately align stud and socket primary disconnecting devices:

a. Furnish tin-to-tin pressure contacts to prevent harmful temperature rise due to oxidation, together with nonmagnetic corrosion-resisting springs to provide high-pressure line contacts.

b. Mount stationary contact in a 1-piece glass, polyester, or porcelain shell to provide ample insulation from the framework.

c. Mount movable contact on the circuit breaker stud to ensure direct contact.

8. Provide secondary disconnecting devices for bringing control leads to circuit breaker operating mechanism and auxiliary switches on removable element: a. Spring mount self-aligning receptacles on stationary framework. b. Mount the plugs on the removable element. c. Contacts in the receptacles shall be recessed to ensure against accidental

short-circuit of control or secondary wiring. 9. Mechanism-operated compartment switch:

a. Provide up to 12 normally closed and up to 15 normally open contacts. b. Switches shall be activated by breaker mechanism.

10. Truck operated cell switch: a. Provide normally closed switch contacts to indicate the breaker is in the

“CONNECTED” position.

2.03 COMPONENTS

A. Circuit breakers: 1. Power circuit breaker unit including:

a. One set of primary disconnecting devices with automatic shutters. b. One set of secondary disconnecting devices.

2. Oilless, vacuum Type 3 pole: a. Horizontal draw-out type capable of being withdrawn on rails. b. Electrically and mechanically trip-free with anti-pumping features.

3. Ratings: In accordance with IEEE C37.06, with the following minimum ratings, for indoor breaker with K equal to 1: a. Voltage:

1) Operating voltage: As indicated on the Drawings. 2) Maximum design voltage: 4.76 kilovolts. 3) 60 hertz withstand test voltage: 60 kilovolts. 4) Basic impulse insulation level: 60 kilovolts minimum.

b. Current: 1) Continuous current rating: As indicated on the Drawings.


4. Operation: a. Operable by means of a stored-energy mechanism, normally charged by

a universal motor, which can be charged by a manual handle for emergency closing or test.

b. The mechanism closing speed of the contacts to be independent of both control voltage and operator.

c. Provide contact wear gap indicator for each vacuum interrupter to indicate available contact life, which requires no tools and is easily visible when breaker is removed from its compartment.

5. Provide secondary disconnecting contacts that automatically engage in the OPERATING and TEST position to complete circuits as required.

6. Provide 2 sets of normally open, “a”, and 2 sets of normally closed, “b”, circuit breaker auxiliary contacts wired to terminal strips.

7. Breaker control voltage: a. As indicated on the Drawings.

B. Direct current battery systems: 1. As specified in Section 16240 - Battery Systems.

C. Relays and instrument transformers: 1. Provide protective relays complete with devices and associated circuitry

necessary to perform the required functions specified in the Contract Documents or indicated on the Drawings.

D. Control power transformers: 1. Provide on rollout drawers in designated cells as an integral part of the

switchgear assembly as indicated on the Drawings. 2. Sized by the switchgear manufacturer to have a minimum capacity of

125 percent of the load served. 3. Protected by both primary and secondary fuses. Protect primary side with

current limiting fuses.

E. Control wiring: 1. Switchgear wire:

a. Type SIS, single-conductor, stranded copper, rated 600 volts. b. Provide flexible stranding for swinging panels. c. Minimum wire size:

1) Number 14 for control circuits. 2) Number 12 for potential and current transformer circuits.

2. Route outgoing control wires to master terminal blocks with suitable numbering strips numbered in agreement with the manufacturer's detailed wiring diagrams: a. Terminate control wiring in molded, screw-type terminal blocks. b. Provide a minimum of 10 percent spare terminal blocks for each unit. c. Compression type terminal blocks are not acceptable.

3. Terminate foreign circuits entering the switchgear on "pull-apart" terminal blocks.

4. Number wiring with machine-printed tag devices at both ends consistent with the manufacturer's detailed wiring diagrams: a. Duplication of wire numbers and terminal block numbers is not

acceptable. b. Uniquely number every wire.


5. When a power source other than the source that is interrupted is present in the switchgear compartment, provide a switch for each remote source inside the compartment to isolate the source in compliance with the NEC.

6. Terminate control wire with insulated barrel, ring type connectors. a. Manufacturers: The following or equal:

1) Stakon.

F. Lightning arresters: 1. Heavy-duty distribution class MOV type surge arresters, 5-kilovolt class, for

installation on the specified nominal voltage system. 2. Provide brackets, wiring, and other hardware as necessary for cubicle

mounting. 3. Designed and manufactured in accordance with the latest edition of IEEE

C62.11.

G. Miscellaneous: 1. Furnish wiring, potential bus, necessary fuses, and terminal blocks within each

unit. 2. Requirements for items mounted on panels:

a. Semi-flush mounting for 1/8 inch panels unless otherwise noted.

2.04 ACCESSORIES

A. Metering system: 1. Provide metering as indicated on the Drawings.

B. Nameplates: 1. Provide nameplates to identify:

a. Switchgear units: 1) Label front and rear doors of each cubicle.

b. Door mounted components. c. Interior mounted devices.

2. Engraved with the circuit number and circuit name as indicated on the Drawings.

C. Warning signs: 1. Voltage:

a. Provide a minimum of 2 warning signs on the front of the switchgear lineup and 2 on the back.

b. Red laminated plastic engraved with white letters approximately 1/2-inch high.

c. Signs shall read: 1) "WARNING-HIGH VOLTAGE-KEEP OUT".

2. Arc flash: a. Provide 1 warning sign for each switchgear compartment. b. Signs shall have read a minimum of:

1) “DANGER ELECTRIC ARC FLASH HAZARD”. 2) Signs shall meet the requirements of the NEC.

D. Space heaters: 1. Fused, thermostatically controlled, strip type, operated at half voltage:

a. Power 500-volt or 250-volt rated heaters at 240 volts or 120 volts, respectively.


2. Power space heaters from the switchgear control power transformer as indicated on the Drawings.

3. Provide each space heater with a dedicated circuit breaker. 4. Sized to prevent condensation from developing in the switchgear.

E. Lights and receptacles: 1. Provide lights, mounted and switched inside the outer NEMA Type 3R shell. 2. Provide GFCI receptacles mounted inside the NEMA Type 3R shell. 3. Powered from a control power transformer as indicated on the Drawings.

F. Portable lifting device for removing the breaker from the breaker cell.

G. One circuit breaker remote control station for opening and closing the circuit breakers with 20-foot, minimum, cord and plug.

H. Remote circuit breaker racking mechanism: 1. Cord and plug: 50-foot, minimum. 2. Connection of the mechanism shall be made with the circuit breaker

compartment door closed: a. Mechanism shall rack the breaker to the disengaged position with the

compartment door closed.

I. Manual levering crank.

J. Rail extensions and rail clamps: 1 set.

K. Ground and test device: 1. Designed for insertion into the switchgear for the following functions:

a. Grounding circuits for maintenance work. b. Apply potential for cable testing. c. Provides access to bus and line circuits for phase testing.

2. The stored energy closing mechanism shall be the same as the circuit breakers.

3. Furnish with a remote close device with a 50-foot cable. 4. Provide front panel indication of contact status. 5. Momentary and 4-second current carrying capacities equal to or greater than

the breakers. a. No automatic tripping of the device shall be provided.

L. Secondary couplers for operating a power circuit breaker in the DISCONNECTED position.

M. Mimic bus: 1. Laminated plastic material fastened to the front surface of the switchgear

reflecting bus routing and power devices.

N. Test blocks and plugs: 1. Molded polycarbonate material. 2. Make-before-break connections for CT circuits. 3. Provide cover for each test block. 4. Manufacturers: One of the following or equal:

a. Multilin, PK-2. b. ABB, FT-1.


O. Circuit breaker indicating lights and control switches: 1. Indicating lights:

a. Low voltage LED: 1) Green for "OPEN.” 2) Red for "CLOSED.”

2. Control switches: a. Rotary cam operated switchgear rated type with means for maintaining

contact position. b. Contacts to be silver-to-silver, enclosed in removable protective covers. c. Manufacturers: One of the following or equal:

1) General Electric Co., Type SB. 2) Electroswitch.

P. Provide preformed insulating boots for all cable landing pads and lugs. Cable termination boots shall have the same dielectric withstand rating as the switchgear.

2.05 FINISHES

A. Manufacturer’s standard epoxy paint applied to chemically-cleaned and primed steel for internal and external parts: 1. Coating to have corrosion resistance of 300 hours to 5 percent salt spray. 2. Paint complete assembly with a 1.5- to 2.0-mil thick exterior finish spray coat

of Manufacturer’s standard gray paint before shipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install the equipment in accordance with the accepted installation instructions and anchorage details to meet the seismic and wind load requirements at the Project site.

B. General: 1. Furnish cables, conduit, lugs, bolts, expansion anchors, sealants, and other

accessories needed to complete the installation of the switchgear. 2. Assemble and install the switchgear in the location and layout indicated on the

Drawings. 3. Make bus splice connections. 4. Perform Work in accordance with manufacturer’s instructions and shop

drawings. 5. Furnish components and equipment as required to complete the installation. 6. Replace hardware lost or damaged during the installation or handling to

provide a complete installation. 7. Install the switchgear on a 3-1/2-inch raised concrete housekeeping pad:

a. Provide structural leveling channels in accordance with the manufacturer's recommendations to provide proper alignment of the units.

b. Weld and/or bolt switchgear frame to leveling channels embedded in the concrete housekeeping pad.

C. Provide the services of a qualified manufacturer’s representative to: 1. Make control connections across the shipping splits. 2. Install and align all circuit breakers.


3.02 COMMISSIONING


B. Source testing (Factory Acceptance Tests): 1. Owner and Engineer will witness the factory acceptance test. 2. Test the complete switchgear at the manufacturer’s establishment.

a. Completely assemble, wire and test the switchgear: 1) Detailed inspections before and after assembly to ensure correctness

of design and workmanship. 2) Provide groups of wires leaving the shipping-assembled equipment

with terminal blocks with suitable numbering strips. 3. Provide Manufacturer’s Certificate of Installation and Functionality Compliance

as specified in Section OR-01757 - Commissioning.

C. Owner training: 1. As specified in Section OR-01757 - Commissioning.


A. Provide the services of a qualified manufacturer’s representative to: 1. Be present at the Project Site when the switchgear arrives. 2. Act as an advisor in assisting the Contractor regarding the unloading and

move-in operations. 3. Furnish the services of a factory-certified technician during the start-up and

adjustment period to ensure that items furnished are in proper operating condition: a. Technician must be completely knowledgeable in the operation,

maintenance, and start-up of the electrical system. 4. Before start-up, furnish written certification that the entire installation and

electrical connections have been inspected and are proper and consistent with Drawings and Specifications.

5. Furnish a written report after start-up signed by the manufacturer: a. Report must state that the installation is complete and meets the

manufacturer’s requirements. b. List items requiring additional attention.

3.04 ADJUSTING

A. Make all adjustments as necessary and recommended by the manufacturer, Engineer, or testing firm.

B. Provide the services of a qualified manufacturer’s representative to: 1. Adjust the carriages and racking mechanisms. 2. Adjust doors for proper operation. 3. Adjust shutters for proper operation.

END OF SECTION


SECTION 16342

15-KILOVOLT MEDIUM VOLTAGE METAL CLAD SWITCHGEAR

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. 15-kilovolt class metal clad switchgear. 2. Vacuum interrupter power circuit breakers.

1.02 REFERENCES

A. Institute of Electrical and Electronic Engineers (IEEE): 1. C37.04 - IEEE Standard for Rating Structure for AC High-Voltage Circuit

Breakers Corrigendum 1. 2. C37.09 - IEEE Standard Test Procedures for AC High-Voltage Circuit

Breakers Rated on a Symmetrical Current Basis – Corrigendum 1. 3. C37.2 - IEEE Standard Electrical Power System Device Function Numbers,

Acronyms, and Contact Designations. 4. C37.20.2 - IEEE Standard for Metal-Clad Switchgear. 5. C37.06 - IEEE Standard for AC High-Voltage Circuit Breakers Rated on a

Symmetrical Current Basis - Preferred Ratings and Related Required Capabilities for Voltages Above 1000 V.

6. C37.20.6 - IEEE Standard for 4.76 kV to 38 kV Rated Ground and Test Devices Used in Enclosures.

7. C37.90 -IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus.

8. C62.11 - IEEE Standard for Metal Oxide Surge Arresters of AC Power Circuits (>1kV).

B. National Electrical Manufacturers' Association (NEMA): 1. SG 2 - High Voltage Fuses. 2. SG 4 - Alternating-Current High-Voltage Circuit Breakers. 3. SG 5 - Power Switchgear Assemblies.


A. General: 1. Metal-clad, 15 kilovolt switchgear designed and manufactured in accordance

with the reference standards listed in this Section. 2. Switchgear and major components to be products of a single manufacturer

including, but not limited to: a. Circuit breakers. b. Related equipment specified in the Contract Documents or indicated on

the Drawings. 3. In addition to the specified basic equipment common to switchgear sections,

equip the various individual sections with instruments, protective relays and control devices as indicated on the Drawings and/or specified below.



B. Description of sections: 1. Incoming line compartment:

a. Hinged door with lockable handle, bolted closed. b. Dimensions, ratings, spacing, and standards must conform to the

requirements of the electric utility. c. Service entrance cables to enter the incoming line compartment, in a

manner as indicated on the Drawings. d. Incoming line termination pads suitable for the size and number of

conductors as indicated on the Drawings and/or conduit schedule. e. Lightning arresters.

2. Utility metering compartment: a. Integral utility current and potential transformer cabinet for utility company

metering. b. Switchgear to include space for mounting electric utility’s potential and

current transformers. c. Instrument transformers to be supplied in accordance with the electric

utility’s requirements. d. Switchgear manufacturer to obtain necessary approvals from the utility

company. e. Bolted hinged door with lockable handle. f. Metering compartment barriers, rear, top, bottom, and sides. g. Dimensions, ratings, spacings, and standards must conform to the

requirements of the electric utility. h. Current and potential transformers.

3. Breaker compartment: a. Main, tie, or feeder breaker as indicated on the Drawings. b. Protective relays and other protective devices and interlocks as indicated

on the Drawings. c. Multi-function solid state meters as indicated on the Drawings. d. Current transformers: Quantity and ratios as indicated on the Drawings.

4. Grounding breaker: a. Connected to switchgear ground bus by cable or bus:

1) Cable or bus sized to carry 2-second short time rating of equipment in accordance with IEEE C37.20.6.

b. Interlocked with main and tie breakers to prevent the ground breaker from closing.

c. Voltage interlock to prevent closing the grounding breaker unless the bus voltage is below a pre-set value.

5. Future breaker/space compartments: a. As indicated on the Drawings:

1) Furnish with hardware necessary to accommodate installation of future circuit breakers, instruments, relays, and controls.

2) Wire relay and circuit breaker control power to the compartment and terminate on terminal strips.


indicated on the Drawings. b. Control power transformers: Fused with voltage ratings as indicated on

the Drawings.


1.04 SUBMITTALS


B. Product data: 1. Manufacturer of switchgear. 2. Manufacturers of all components and accessories. 3. Weight of each circuit breaker of different frame sizes. 4. Dimensions:


5. Nameplate schedule. 6. Bill of material. 7. Description of operation:

a. Metering system. b. Protective relaying.

8. Ratings: a. Voltage. b. Phase. c. Current. d. Interrupting rating (circuit breakers and fuses). e. Momentary current rating.

9. List of recommended spare parts. 10. Name of dealer’s repair facility and parts stocking agreement with the factory:

a. Agreement shall outline in detail the manufacturer's parts stocking requirements and the method by which the manufacturer verifies that the stock is at an acceptable level.

b. Agreement shall outline the method by which the manufacturer determines that the service personnel meet factory standards.




a. Furnish fully dimensioned, to scale, equipment layout drawings which include: 1) Equipment furnished: Plan, front and side views. 2) Shipping splits. 3) Bus layout. 4) Interfaces with other equipment. 5) Minimum distances to walls and breaker “roll-out” distances. 6) Bottom conduit windows.

b. Complete, detailed, and scaled switchgear layout: 1) Front panel. 2) Sub-panels. 3) Interior panels.


4) Assembly drawings, cross-section as a minimum for each cubicle with major dimensions indicated.

2. Complete electrical wiring diagrams: a. Indicate wire numbers.

3. Complete interface and point-to-point connection diagrams for metering system.

4. Internal schematics, elementary diagrams, and wiring diagrams of each unit or compartment, including wiring identification and terminals.

5. Internal cell-to-cell interconnection wiring diagrams, including wiring identification and terminal numbers.

6. Complete 1-line and 3-line diagrams for each switchgear line-up: a. Identify all components comprising the switchgear assembly including, but

not limited to, circuit breakers, control power and instrument transformers, meters, relays, control devices, monitoring devices, and terminal blocks.

b. Clearly indicate device electrical ratings on the drawings.

D. Installation instructions: 1. Detail the complete installation of the equipment including rigging, moving, and





based on support conditions and requirements to resist seismic and wind loads as specified in the Project Technical Requirements.



E. Operation and maintenance manuals: 1. Operating instructions:

a. Detail the operational functions of custom controls that have been placed on the front panel of the switchgear and internal PLC programming, if applicable.

2. Maintenance manual: a. Furnish maintenance manuals with instructions for maintenance of the

equipment and data identifying the parts. b. Include all information needed to maintain the switchgear including but not

limited to the following: 1) Instructions for testing, adjustment, and start-up. 2) Detailed control instructions that outline the function and operation of

every control device. 3) Schematic and wiring diagrams:

a) Showing all internal and external connections. b) Furnished in a reduced 11-inch by 17-inch fully legible format.

F. Test forms and reports: 1. Submit complete factory acceptance test procedures and all forms used during

the test.


2. Furnish a manufacturer’s certified report after the factory tests. 3. Furnish a manufacturer’s written report after the start-up:



G. Calculations: 1. DC power and current requirements needed to operate the 15 kilovolts

metal-clad switchgear circuit breakers and protective relays. 2. Detailed calculations or details of the actual physical testing performed on the

switchgear to prove the switchgear is suitable for the seismic requirements at the Project Site.

H. Training documents: 1. Submit all training documentation to be used during the Owner’s training



A. Manufacturer shall have supplied at least 4 systems of similar nature and size, which have been installed within a 500-mile radius of the Project location.

B. The manufacturer shall have established an authorized dealer having a parts and service facility within a 200-mile radius of the Project: 1. Pre-qualified service personnel available on a 24-hour-a-day basis. The

personnel must be completely familiar with the items supplied so as to return the equipment to service in the shortest possible time.

2. The authorized dealer must have no less than 80 percent of switchgear parts and 100 percent of all recommended spare parts, as identified in the product data submittal in its stock at all times: a. A personal inspection of the facility may be made by the Owner to

substantiate claims of available replacement parts.

C. Sections and devices shall be UL listed and labeled.


A. Ship the switchgear and associated equipment to the Project Site on a dedicated air ride vehicle that will allow the Contractor to utilize onsite off-loading equipment.


1.07 SEQUENCING




C. Conduct factory acceptance test and submit certified test results for Engineer’s review.

D. Ship equipment to Project Site after successful completion of factory acceptance test.

E. Assemble equipment in the field.

F. Conduct final fault current and coordination study.

G. Set all relays per coordination study.

H. Conduct field acceptance test and submit results for Engineer’s review.

I. Submit manufacturer’s certification that equipment has been properly installed and is fully functional for Engineer’s review.

J. Conduct Owner’s training sessions.

K. Commissioning as specified in Section OR-01757 - Commissioning.

1.08 WARRANTY




A. Per manufacturer recommendations.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. General Electric Co. 2. Schneider Electric. 3. ABB. 4. Eaton.

B. Circuit breakers: Same manufacturer as metal-clad switchgear.

2.02 EQUIPMENT

A. Switchgear: 1. Provide medium voltage 15 kilovolt class metal-clad switchgear as specified in

the Contract Documents and indicated on the Drawings. 2. Provide complete and functional lineups of switchgear with associated

controls. 3. Provide devices or accessories not specified in this Section but necessary for

the proper installation and operation of the equipment.


B. Voltage ratings: 1. As indicated on the Drawings. 2. Basic impulse insulation level: Minimum 95 kilovolts.

C. Main bus: 1. High conductivity, tin-plated copper:

a. Flat bar with rounded edges. b. Suitably braced and supported on high dielectric strength insulators.

2. Continuous current carrying capacity as indicated on the Drawings. 3. Insulate each bus with fluidized bed epoxy flame retardant and track resistant

insulation. 4. Mount insulated bus on flame retardant, track resistant supports and brace to

withstand magnetic stresses developed by fault currents equal to the close and latch rating of the circuit breakers.

5. Bus connections: a. Plated. b. Bolted with Belleville spring washers. c. Install insulated boot over joint.

6. Document temperature rise of the bus and connections by design tests.

D. Ground bus: 1. Tin-plated copper bar, 1/4 inch by 2 inches minimum, extended through each

section: a. Firmly secure to each vertical section. b. Provide termination lugs for termination of copper ground cable at each

end of the bus. 2. Ground each section directly to ground bus.

E. Stationary structure: 1. Utilize unit type construction in formation of housing in order to provide a rigid,

self-supporting and self-contained enclosure for each circuit breaker unit and other units comprising switchgear: a. Fabricate each stationary structure of heavy, formed, smooth, and level

steel sheets and structural members, bolted or welded to form a rigid assembly with hinged steel panel suitable for mounting of instruments, meters, relays, and control devices.

b. Provide bolted, hinged front and rear cubicle doors with locks. 2. Dead-front construction with rear access via lockable hinged doors. 3. Approximately 95 inches high, widths as required, front and rear aligned:

a. Maximum dimensions as indicated on the Drawings. 4. Isolate circuit breaker units, bus, instrument and control power transformers,

and outgoing cables within separate compartments formed by sheet steel barriers: a. Mount heavy close-fitting bus supports at bus openings between units:

1) The supports shall form a barrier to isolate each unit from adjacent units.

b. Provide each compartment with a separate cover for individual servicing without exposing the circuit in adjacent compartment.

5. Provide automatic shutters to isolate the circuit breaker compartment from the bus when the circuit breaker unit is moved to the TEST or WITHDRAWN position.


6. NEMA Type: a. NEMA Type 1 gasketed:

1) Switchgear sections shall have an open bottom in the rear for cable terminations.

b. NEMA Type 3R, non-walk-in enclosure: 1) Hinged doors front and back. 2) Peaked or slanting roof. 3) Enclosing NEMA Type 1 gasketed switchgear. 4) Switchgear sections shall have removable plates in the rear bottom

for field drilling of conduit openings. c. NEMA Type 3R, walk-in enclosure:

1) Hinged doors front and back. 2) Peaked or slanting roof. 3) Protected aisle. 4) Enclosing NEMA Type 1 gasketed switchgear.

7. Switchgear sections shall have removable plates in the rear bottom for field drilling of conduit openings. Front access to devices through a formed, bolted, hinged removable cover: a. Captive knurled type knob screws are to hold covers in place.

8. Provide switchgear with lifting channels having provisions for attachment of crane slings to facilitate lifting and handling each shipping-assembly unit: a. Remove lifting channels after equipment is installed.

F. Cable compartment: 1. Support circuit breaker disconnecting contacts by means of flame-retardant,

track-resistant polyester glass or porcelain insulator. 2. Provide cable terminals:

a. NEMA 4-hole pads suitable for connection and termination of 15 kilovolt shielded cables.

3. Design switchgear so that high voltage, low voltage, control and instrumentation cables can enter the switchgear from either the top or bottom.

4. Provide cable supports with provisions for stress relief cones and cable bends.

G. Removable element: 1. Provide a racking screw and moving block for breaker insertion and

withdrawal: a. The racking screw shall be capable of holding the breaker in the

CONNECTED position. 2. Utilize master jigs to determine accurately the correct stud locations of the

removable and the stationary elements. 3. Provide means for mechanically locking the removable element in any

position: a. Lock shall not interfere with the operation of the breaker and its

mechanism. 4. Provide a ground shoe to ground the breaker in all positions. 5. Provide breaker “CONNECTED” position indication. 6. Provide interlock on each circuit breaker unit to prevent circuit breaker from

being removed from CONNECTED position and from being placed in CONNECTED position while breaker is closed: a. If the circuit breaker is closed, the interlock shall trip the breaker before it

can be placed into or removed from the CONNECTED position.


7. Accurately align stud and socket primary disconnecting devices: a. Furnish tin-to-tin plated pressure contacts to prevent harmful temperature

rise due to oxidation, together with nonmagnetic corrosion-resisting springs to provide high-pressure line contacts.

b. Mount movable contact on the circuit breaker stud to ensure direct contact.

8. Provide secondary disconnecting devices for bringing control leads to circuit breaker operating mechanism and auxiliary switches on removable element: a. Spring mount self-aligning receptacles on stationary framework. b. Mount the plugs on the removable element. c. Contacts in the receptacles shall be recessed to ensure against accidental

short-circuit of control or secondary wiring. 9. Mechanism-operated compartment switch:

a. Provide up to 12 normally closed and up to 15 normally open contacts. b. Switches shall be activated by breaker mechanism.

10. Truck operated cell switch: a. Provide normally closed switch contacts to indicate the breaker is in the

“CONNECTED” position.

2.03 COMPONENTS

A. Circuit breakers: 1. Power circuit breaker unit including:

a. Primary disconnecting devices with automatic shutters. b. Secondary disconnecting devices.

2. Oilless, vacuum type 3 pole. 3. Horizontal draw-out type capable of being withdrawn on rails. 4. Electrically and mechanically trip-free with anti-pumping features. 5. Ratings: In accordance with IEEE C37.06, with the following minimum ratings

for indoor breakers with K equal to 1: a. Voltage:

1) Operating voltage: As indicated on the Drawings. 2) Maximum design voltage: 15 kilovolts RMS. 3) Withstand test voltage: 60 hertz, 36 kilovolts. 4) Basic impulse insulation level: 95 kilovolts minimum.

b. Current: 1) Continuous current rating: As indicated on the Drawings. 2) Short circuit current/peak closing and latching current at rated

maximum kilovolts: a) As required.

6. Operation: a. Operable by means of a stored-energy mechanism, normally charged by

a universal motor, which can be charged by a manual handle for emergency closing or test.

b. The mechanism closing speed of the contacts to be independent of both control voltage and operator.

c. Provide contact wear gap indicator for each vacuum interrupter to indicate available contact life, which requires no tools and is easily visible when breaker is removed from its compartment.

7. Provide secondary disconnecting contacts that automatically engage in the “OPERATING” and “TEST” position to complete circuits as required.


8. Provide 2 sets of normally open, “a”, and 2 sets of normally closed, “b”, circuit breaker auxiliary contacts wired to terminal blocks.

9. Breaker control voltage: a. As indicated on the Drawings.

10. Circuit breakers of equal rating shall be interchangeable.

B. Direct current battery systems: 1. As specified in Section 16240 - Battery Systems.

C. Relays and instrument transformers: 1. Provide protective relays complete with devices and associated circuitry

necessary to perform the required functions specified or indicated on the Drawings.

D. Control power transformers: 1. Provide on rollout drawers in designated cells as an integral part of the

switchgear assembly as indicated on the Drawings. 2. Sized by the switchgear manufacturer to have a minimum capacity of

125 percent of the load served. 3. Protected by both primary and secondary fuses. Protect primary side with

current limiting fuses.

E. Control wiring: 1. Switchgear wire:

a. Type SIS, single-conductor, stranded copper, rated 600 volts. b. Provide flexible stranding for swinging panels. c. Minimum wire size:

1) Number 14 for control circuits. 2) Number 12 for potential and current transformer circuits.

2. Route outgoing control wires to master terminal blocks with suitable numbering strips numbered in agreement with the manufacturer's detailed wiring diagrams: a. Terminate control wiring in molded, screw-type terminal blocks. b. Provide a minimum of 10 percent spare terminal blocks for each unit. c. Compression type or insulation displacement type terminal blocks are not

acceptable. 3. Terminate foreign circuits entering the switchgear on "pull-apart" terminal

blocks. 4. Number wiring with machine-printed tag devices at both ends consistent with

the manufacturer's detailed wiring diagrams: a. Duplication of wire numbers and terminal block numbers is not

acceptable. b. Uniquely number every wire.

5. When a power source other than the source that is interrupted is present in the switchgear compartment, provide a switch for each remote source inside the compartment to isolate the source in accordance with the NEC.

6. Terminate control wire with insulated barrel, ring type connectors. a. Manufacturers: The following or equal:

1) Stakon.


F. Lightning arresters: 1. Heavy-duty distribution class MOV type surge arresters, 15-kilovolt class, for

installation on the specified nominal voltage system. 2. Provide brackets, wiring, and other hardware as necessary for cubicle

mounting. 3. Designed and manufactured in accordance with the latest edition of

IEEE C62.11.

G. Miscellaneous: 1. Furnish wiring, potential bus, necessary fuses, and terminal blocks within each

unit. 2. Requirements for items mounted on panels:

a. Semi-flush mounting for 1/8-inch panels unless otherwise noted.

2.04 ACCESSORIES

A. Metering system: 1. Provide metering as indicated on the Drawings.




2. As specified in the Project Technical Requirements. 3. Engraved with the circuit number and circuit name as indicated on the

Drawings.

C. Warning signs: 1. Voltage:

a. Provide a minimum of 2 warning signs on the front of the switchgear lineup and 2 on the back.

b. Red laminated plastic engraved with white letters approximately 1/2-inch high.


2. Arc flash: a. Provide 1 warning sign for each switchgear compartment. b. Signs shall have read a minimum of:


D. Space heaters: 1. Fused, thermostatically controlled, strip type, operated at half voltage:

a. Power 500-volt or 250-volt rated heaters at 240 volts or 120 volts, respectively.

2. Power space heaters from the switchgear control power transformer as indicated on the Drawings.

3. Provide each space heater with a dedicated circuit breaker. 4. Sized to prevent condensation from developing in the switchgear.


E. Lights and receptacles: 1. Provide lights, mounted and switched inside the outer NEMA Type 3R shell. 2. Provide GFCI receptacles mounted inside the NEMA Type 3R shell. 3. Powered from a control power transformer as indicated on the Drawings.

F. Portable lifting device for removing the breaker from the breaker cell.

G. One circuit breaker remote control station for opening and closing the circuit breakers with 20-foot, minimum, cord and plug.

H. Remote circuit breaker racking mechanism: 1. Cord and plug: 50-foot minimum. 2. Connection of the mechanism shall be made with the circuit breaker

compartment door closed: a. Mechanism shall rack the breaker to the disengaged position with the

compartment door closed.

I. Manual levering crank.

J. Rail extensions and rail clamps: 1 set.

K. Ground and test device: 1. Designed for insertion into the switchgear for the following functions:

a. Grounding circuits for maintenance work. b. Apply potential for cable testing. c. Provides access to bus and line circuits for phase testing.

2. The stored energy closing mechanism shall be the same as the circuit breakers.

3. Furnish with a remote close device with a 50-foot cable. 4. Provide front panel indication of contact status. 5. Momentary and 4-second current carrying capacities equal to or greater than

the breakers. a. No automatic tripping of the device shall be provided.

L. Secondary couplers for operating a power circuit breaker in the “DISCONNECTED” position.

M. Circuit breaker indicating lights and control switches: 1. Indicating lights:

a. Low voltage LED: 1) Green for “OPEN.” 2) Red for “CLOSED.”

b. Control switches: 1) Rotary cam-operated switchgear-rated type with means for

maintaining contact position. 2) Contact silver-to-silver, enclosed in removable protective covers. 3) Manufacturers: One of the following or equal:

a) General Electric Co., Type SB. b) Electroswitch.

N. Mimic bus: 1. Laminated plastic material fastened to the front surface of the switchgear

reflecting bus routing and power devices.


O. Test blocks and plugs: 1. Molded polycarbonate material. 2. Make-before-break connections for CT circuits. 3. Provide cover for each test block. 4. Manufacturers: One of the following or equal:

a. Multilin, PK-2. b. ABB, FT-1.

P. Provide preformed insulating boots for all cable landing pads and lugs. Cable termination boots shall have the same dielectric withstand rating as the switchgear.

2.05 FINISHES

A. ANSI 61 paint applied to chemically-cleaned and primed steel for internal and external parts: 1. Coating to have corrosion resistance of 300 hours to 5 percent salt spray. 2. Paint complete assembly with a 1.5- to 2.0-mil thick exterior finish spray coat

of manufacturer’s standard gray paint before shipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install the switchgear per the manufacturer’s guidelines and submitted installation instructions to meet the seismic requirements at the Project Site.


accessories needed to complete the installation of the switchgear. 2. Assemble and install the switchgear in the location and layout indicated on the

Drawings and in complete conformance with the manufacturer's recommended procedures.

3. Make bus splice connections. 4. Perform Work in accordance with manufacturer’s instructions and shop

drawings. 5. Furnish components and equipment as required to complete the installation. 6. Replace hardware lost or damaged during the installation or handling to

provide a complete installation. 7. Install the switchgear on a 3-1/2-inch raised concrete housekeeping pad:

a. Provide structural leveling channels in accordance with the manufacturer's recommendations to provide proper alignment of the units.

b. Weld and/or bolt switchgear frame to leveling channels embedded in the concrete housekeeping pad.


3.02 COMMISSIONING



B. Factory tests: 1. Owner and Engineer will witness the factory acceptance test. 2. Test the complete switchgear at the manufacturer’s establishment.



with terminal blocks with suitable numbering strips.

C. Owner training: 1. As specified in Sections OR-01757 - Commissioning.


A. Provide the services of a qualified manufacturer’s representative to: 1. Be present at the Project Site when the switchgear arrives. 2. Act as an advisor in assisting the Contractor regarding the unloading and

move-in operations. 3. Furnish the services of a factory-certified technician during the start-up and

adjustment period to ensure that items furnished are in proper operating condition: a. Technician must be completely knowledgeable in the operation,

maintenance, and start-up of the electrical system. 4. Before start-up, furnish written certification that the entire installation and

electrical connections have been inspected and are proper and consistent with the Drawings and Specifications.

5. Furnish a written report after start-up signed by the manufacturer: a. Report must state that the installation is complete and meets the

manufacturer’s requirements. b. List items requiring additional attention.

3.04 ADJUSTING

A. Make adjustments as necessary and recommended by the manufacturer, Engineer, or testing firm.

B. Provide the services of a qualified manufacturer’s representative to: 1. Adjust the carriages and racking mechanisms. 2. Adjust doors for proper operation. 3. Adjust shutters for proper operation.

END OF SECTION


SECTION 16346

5-KILOVOLT MEDIUM VOLTAGE METAL-ENCLOSED INTERRUPTER SWITCHGEAR

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. 5 kilovolt class metal-enclosed interrupter switchgear. 2. Load interrupter switches.

1.02 REFERENCES

A. ASTM International (ASTM): 1. B117 - Practice for Operating Salt Spray (Fog) Apparatus. 2. D522 - Standard Test Methods for Mandrel Bend Test of Attached Organic

Coatings. 3. D2794 - Standard Test Method for Resistance of Organic Coatings to the

Effects of Rapid Deformation (Impact). 4. D3363 - Standard Test Method for Film Hardness by Pencil Test.

B. Institute of Electrical and Electronics Engineers (IEEE): 1. C37.20.3 - IEEE Standard for Metal-Enclosed Interrupter Switchgear.


A. Factory assembled, factory wired and factory tested dead-front completely metal-enclosed switchgear. Switchgear and major components to be products of a single manufacturer including, but not limited to: 1. Load interrupter switches. 2. Fuses. 3. Transformers. 4. Instruments. 5. Meters. 6. Relays. 7. Control devices. 8. Incoming and outgoing connections. 9. Other equipment of the number, rating and type specified or supplemented by

data indicated on the Drawings.

B. Arrange the equipped sections side by side to form continuous switchgear lineups as indicated on the Drawings.

C. Description of sections: 1. Incoming line compartment:

a. Hinged door with catch and lockable handle, bolted closed. b. Dimensions, ratings, spacing, and standards must conform to the

requirements of the electric utility.


c. Service entrance cables to enter the incoming line compartment, in a manner as indicated on the Drawings.

d. Incoming line termination pads suitable for the size and number of conductors indicated on the Drawings and/or conduit schedule.

e. Lightning arresters. 2. Utility metering compartment:

a. Integral utility current and potential transformer cabinet for utility company metering.

b. Switchgear to include space for mounting electric utility’s potential and current transformers.

c. Instrument transformers to be supplied in accordance with the electric utility’s requirements.

d. Switchgear manufacturer to obtain necessary approvals from the utility company.

e. Bolted hinged door with lockable handle. f. Metering compartment barriers, rear, top, bottom, and sides. g. Dimensions, ratings, spacing, and standards must conform to the

requirements of the electric utility. h. Current and potential transformers.

3. Future switch/space compartments: a. As indicated on the Drawings:

1) Furnish with hardware necessary to accommodate installation of future circuit switches, instruments, relays, and controls.


indicated on the Drawings. b. Control power transformers: Fused with voltage ratings as indicated on

the Drawings.

1.04 SUBMITTALS

A. Product data: 1. Manufacturer of switchgear. 2. Manufacturers of all components and accessories. 3. Weight of each switch of different frame sizes. 4. Dimensions:


5. Nameplate schedule. 6. Bill of material. 7. Ratings:

a. Voltage. b. Phase. c. Current. d. Fuse interrupting rating. e. Momentary current rating.

8. List of recommended spare parts.




B. Shop drawings: 1. Plan, front, and side view drawing including overall dimensions and bus layout

of each switchgear lineup. Identify shipping splits and show conduit stub-up area locations.

2. Internal schematics (elementary diagrams) and wiring diagrams of each unit or compartment, including wiring identification and terminal numbers.

3. Internal cell-to-cell interconnection wiring diagrams, including wiring identification and terminal numbers.

4. Complete 1-line diagrams for each switchgear lineup and complete 3-line diagrams for each cubicle. a. Drawings shall indicate devices comprising the switchgear assembly

including, but not limited to, load interrupter switches, fuses, control power and instrument transformers, meters, relays, control devices, and monitoring devices.

b. Clearly indicate device electrical ratings on Drawings. 5. Assembly drawings (cross-section as a minimum) for each cubicle with major

layout dimensions indicated. 6. Complete bill of material list and equipment data sheets identifying appropriate

information specific to switchgear being supplied. 7. Nameplate schedule.

C. Installation instructions: 1. Detail the complete installation of the equipment including rigging, moving, and





based on support conditions and requirements to resist seismic and wind loads.



D. Operation and maintenance manuals: 1. Operating instructions. 2. Maintenance manual:

a. Furnish maintenance manuals with instructions for maintenance of the equipment and data identifying the parts.

b. Include all information needed to maintain the switchgear including but not limited to the following: 1) Instructions for testing, adjustment, and start-up.


2) Detailed control instructions that outline the function and operation of every control device.

3) Schematic and wiring diagrams: a) Showing all internal and external connection. b) Furnish in a reduced 11-inch by 17-inch fully legible format.

E. Test forms and reports: 1. Submit complete factory acceptance test procedures and all forms used during

the test. 2. Furnish a manufacturer’s certified report after the factory tests. 3. Furnish a manufacturer’s written report after the start-up:



F. Calculations: 1. Detailed calculations or details of the actual physical testing performed on the

switchgear to prove the switchgear is suitable for the seismic requirements at the project site.

G. Training documents: 1. Submit all training documentation to be used during the Owner’s training



A. All sections and devices shall be UL listed and labeled.


A. Ship the switchgear and associated equipment to the Project Site on a dedicated air ride vehicle that will allow the Contractor to utilize onsite off-loading equipment.


1.07 SEQUENCING

A. Conduct fault current study as specified in Section 16305 - Electrical System Studies and submit results for Engineer’s review.


C. Conduct factory acceptance test and submit certified test results for Engineer’s review.

D. Ship equipment to project site after successful completion of factory acceptance test.

E. Assemble equipment in the field.


F. Conduct final fault current and coordination study.

G. Conduct field acceptance test and submit results for Engineer’s review.

H. Submit manufacturer’s certification that equipment has been properly installed and is fully functional for Engineer’s review.

I. Conduct Owner’s training sessions.

J. Commissioning as specified in Section OR-01757 - Commissioning.

1.08 WARRANTY





1.10 MAINTENANCE

A. Spare parts: 1. Provide a spare fuse element (refill) for each fuse furnished. 2. Provide 1 spare fuse holder.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Switchgear: One of the following or equal: 1. Eaton. 2. General Electric. 3. Schneider Electric. 4. S&C Electric Co. 5. Federal Pacific.

B. Load interrupter switch: Same manufacturer as metal-enclosed switchgear.

2.02 EQUIPMENT

A. Switchgear: 1. Provide metal-enclosed switchgear with the required voltage Class for the

indicated voltage. 2. Provide complete and functional lineups of switchgear and respective controls.

Provide devices or accessories not described in this Section but necessary for the proper installation and operation of the equipment.

3. Provide one terminal pad per phase suitable for connecting 2 conductors per phase of the sizes indicated on the Drawings. a. Provide sufficient space for electrical stress relief termination devices as

required.


B. Voltage ratings: 1. Design and construct switchgear for use on the electrical system indicated on

the Drawings. 2. Basic insulation level shall be consistent with the applicable system voltage.

C. Main bus and insulation systems: 1. Fabricate buses of high conductivity, flat, tin-plated copper bar having rounded

edges. 2. NEMA-rated for the voltage class specified. 3. Buses to have a continuous current-carrying capacity of not less than that

indicated on the Drawings. 4. Splice plates and ends of buses shall be tin-plated. 5. Mount bus on insulated supports with coordinated dielectric properties and

with strength to withstand magnetic stresses developed by current at least equal to the momentary withstand rating of the load interrupter switch.

6. Fabricate bus insulated supports from insulation possessing flame-retardant and self-extinguishing, dielectric and anti-hydroscopic properties.

D. Ground bus: 1. Tin-plated copper bar, 1/4 inch by 2 inch minimum:

a. Extended through all cubicles. b. Firmly secure to each vertical section. c. Provide termination lugs for termination of copper ground cable at each

end of the bus. d. Ground each section directly to ground bus.

E. Stationary structure: 1. Provide a rigid, self-supporting and self-contained enclosure with sloped

weatherproof roof for the switchgear assembly. a. Fabricate structure of heavy, formed, smooth and level steel sheets, at

least 11 gauge for doors and 14 gauge for all other sheets. b. Structural members bolted or electrically welded to form a rigid assembly

with hinged steel panel suitable for mounting of instruments, meters, relays, and control devices.

2. Provide walls between adjoining bays with gasket seals at top and sides of adjoining bays to keep water out from between the walls.

3. Provide each switch cubical with a single, full length, flanged front door over the switch and/or fuse assembly.

4. Flanged door: Closing over a projecting doorframe; equipped with high strength latches to seal the door; with 3 concealed hinges and a high impact glass or high impact polycarbonate sheet observation window.

5. Provide tamper-resistant padlockable door handles. 6. Provide 3 spare power fuses in the front door for each fused switch. 7. Fuse assemblies: Individual isolating barriers between phases and phase-to-

ground. 8. Fuses: Positive clamped in position with provision for easy removal or

installation from the front. 9. Hinge the door in front of fuses and interlock it with the switch mechanism so

that the switch must be opened before access to the fuses is possible and the door must be closed before the switch can be closed.


10. Adequately brace each unit. Each unit to contain sufficient volume to prevent distortion of the cubicle under normal operating conditions as well as interruption of short circuit currents.

11. Provide adequate lifting means to roll and move into the switchgear installation position. Bolt directly to the floor.

12. Provide adequate conduit space. Coordinate conduit space with conduit layout drawings.


14. Openings: Screened to prevent the entrance of vermin.

F. Cable compartment: 1. Provide NEMA bolt hole pads at incoming and outgoing terminals:

a. Suitable for connection and termination of shielded cables as required. b. Number of holes in accordance with IEEE C37.20.3 requirements.

2.03 COMPONENTS

A. Load interrupter switch: 1. Multipurpose formed hard copper blade, 2-position (open-close), quick-make,

quick-break, 3-pole, gang-operated load-break interrupter switch with manually recharged stored-energy operating mechanism, and permanent "open-closed" position indicators; rated 5 kilovolts.

2. Accomplish circuit interruption by use of an interrupter that is positively sequenced with the blade position. a. Circuit interruption to take place completely within the interrupter with no

external arc or flame. b. Vent exhaust in a controlled manner. Interrupter switches to have a

readily visible open gap when in the open position to allow positive verification of switch position.

3. Duty cycle: 1 time. a. As a minimum, the switch (fused or un-fused) shall be capable of closing

once against a 3-phase fault with asymmetrical current in at least one phase equal to the rated value with the switch remaining operable and able to carry and interrupt rated current.

4. Provide maintenance provision for slow closing of the switch to check switch blade engagement.

5. Provide provisions on the enclosure at the switch operating handle for installing a portable mechanism that provides the ability to operate the switch remotely.

B. Power fuses: 1. Provide 3 power fuses mounted with fuses accessible without exposure to

energized terminals of switch when switch is open and with a hinged door mechanically interlocked with interrupter switch so that the switch must be open before door can be opened.

C. Control wiring: 1. Wire switchgear to satisfy the requirements of the operation specified.


2. Switchgear wiring: NEC Type SIS, single-conductor, stranded copper, rated 600 volts. Provide flexible stranding for swinging panels. a. Minimum wire size: Number 14 for control circuits, and Number 12 for

potential and current transformer circuits. 3. Route outgoing control wires to master terminal blocks with suitable numbering

strips numbered in agreement with the manufacturer's detailed wiring diagrams and the drawings.

4. Terminate control wiring in molded, screw-type terminal blocks acceptable to the Engineer. a. Provide a minimum of 10 percent spare terminal blocks for each unit. b. Compression type terminal blocks are not acceptable.

5. Terminate foreign circuits entering the switchgear on "pull-apart" terminal blocks that meet the requirements of the state where the Project is located.

6. Identify wiring as required.

D. Miscellaneous: 1. Furnish wiring, bus, necessary fuses, and terminal blocks within each unit. 2. Requirements for items mounted on panels:

a. Semi-flush mounting for 1/8 inch panels unless otherwise noted.

2.04 ACCESSORIES

A. Fuse handling tools and insulated poles as recommended by Manufacturer.




2. Engraved with the circuit number and circuit name as indicated on the Drawings.

C. Warning signs: 1. Exterior:

a. Provide a minimum of 2 signs on the front of the switchgear lineup and 2 on the back.

b. Orange banner on laminated plastic engraved with white letters of appropriate size.

c. Signs shall read "WARNING-HIGH VOLTAGE-KEEP OUT" in black letters on white background.

2. Interior: a. Provide a danger sign on each inner door of each cubicle (or bay). b. Red banner on laminated plastic engraved with white letters of

appropriate size. 3. Arc flash:

a. Provide 1 warning sign for each switchgear compartment. b. Signs shall have read a minimum of:



D. Provide preformed insulating boots for all cable landing pads and lugs. Cable termination boots shall have the same dielectric withstand rating as the switchgear.

2.05 FINISHES

A. Before assembly, all enclosing steel shall be cleaned and phosphatized or a Zirconization™ application. 1. For indoor switchgear, apply a powder coating electrostatically, then fused on

by baking in an oven. 2. Coating thickness shall not be less than 1.5 mils. 3. For outdoor switchgear, apply a second powder coating electrostatically for

protection against ultraviolet radiation, and bake on with a combined coating thickness of not less than 3 mils.

4. Finish shall have the following properties: a. Impact resistance (ASTM D2794): 60 direct/60 indirect. b. Pencil hardness (ASTM D3363): H. c. Flexibility (ASTM D522): Pass 1/8-inch mandrel. d. Salt Spray (ASTM B117): 600 hours. e. Color: Manufacturer’s standard gray.

PART 3 EXECUTION

3.01 INSTALLATION



accessories needed to complete the installation of the switchgear. 2. Physically assemble and install the switchgear in the location and layout

indicated on the Drawings. 3. Make bus splice connections. 4. Furnish components and equipment as required to complete the installation. 5. Perform work in accordance with the manufacturer’s instructions and shop

drawings. 6. Replace hardware lost or damaged during the installation or handling to

provide a complete installation. 7. Weld and/or bolt switchgear frame to leveling channels embedded in the

concrete housekeeping pad: a. Provide structural leveling channels in accordance with manufacturer's

recommendations to provide proper alignment of the units. b. The installation shall meet the seismic requirements of the site.



3.02 COMMISSIONING


B. Factory tests: 1. Owner and Engineering will witness the factory acceptance test. 2. Test the complete switchgear at the manufacturer’s establishment.



with terminal blocks with suitable numbering strips.


A. Manufacturer’s services: 1. Provide technical assistance to the Contractor during installation, connection,

and testing. 2. Inspect the complete installation and provide a certificate stating that the

equipment was properly installed before energizing the equipment.

B. Submit copies of field tests in accordance with the submittal requirements specified in Section OR-01300 - Submittal Procedures.

3.04 ADJUSTING

A. Make all adjustments as necessary and recommended by the manufacturer, Engineer, or testing firm.

END OF SECTION


SECTION 16347

MEDIUM VOLTAGE AUTOMATIC TRANSFER SWITCHES

PART 1 GENERAL

1.01 SUMMARY

A. Medium voltage transfer switches conforming to UL1008A, having the ratings, features/accessories and enclosure as specified herein and as shown on the contract drawings.

1.02 REFERENCES

A. The metal-clad switchgear used for automatic transfer switch application shall be designed, manufactured and tested in accordance with the following standards: 1. UL1008A dated March 2012– Standard for Medium Voltage Transfer

Switches. 2. IEEE C37.20.2 dated1999 standard for metal-clad switchgear. 3. IEEE C37.20.7 dated 2007, guide for testing metal-enclosed switchgear for

internal arcing faults, when internal arc short-circuit rating and accessibility type is specified under section 2.05, ratings.

4. ANSI C37.55 dated 2002 – Conformance test procedures. 5. NEMA SG-5 – Power Switchgear Assemblies. 6. CSA C22.2 No. 31-04 dated January 2004 – CSA standard for switchgear

assemblies. 7. ANSI and IEEE standards for High Voltage AC Circuit Breakers, IEEE C37.04-

1999, ANSI C37.06-2000 and 2009, and IEEE C37.09-1979 and 2009.

B. Medium Voltage Transfer Switch described under this specification shall be seismically tested or qualified by analysis based on actual testing done on similar equipment to exceed the requirements of 2009 International Building Code (IBC) parameters, and CBC 2010.

1.03 SUBMITTALS – FOR REVIEW/APPROVAL

A. The following information shall be submitted to the Engineer: 1. Master drawing index. 2. Front view elevation. 3. Floor plan. 4. Top view. 5. Single line. 6. Schematic diagram. 7. Nameplate schedule. 8. Component list. 9. Conduit entry/exit locations. 10. Assembly ratings including:

a. Short-circuit rating. b. Voltage. c. Continuous current.


d. Basic impulse level for equipment over 600 Volts. 11. Major component ratings including:

a. Voltage. b. Continuous current. c. Interrupting ratings.

12. Cable terminal sizes.

B. Where applicable, the following additional information shall be submitted to the Engineer: 1. Busway connection. 2. Connection details between close-coupled assemblies. 3. Composite floor plan of close-coupled assemblies. 4. Key interlock scheme drawing and sequence of operations. 5. Descriptive bulletins. 6. Product data sheets.

1.04 SUBMITTALS – FOR CONSTRUCTION

A. The following information shall be submitted for record purposes: 1. Final as-built drawings and information for items listed in Section 1.04, and

shall incorporate all changes made during the manufacturing process. 2. Wiring diagrams. 3. Certified production test reports. 4. Installation information including equipment anchorage provisions. 5. Seismic certification as specified.

1.05 QUALIFICATIONS

A. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly.

B. For the equipment specified herein, the manufacturer shall be ISO 9001 or 9002 certified.

C. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

D. Provide Seismic tested equipment as follows: 1. The equipment and major components shall be suitable for and certified by

actual seismic testing to meet all applicable seismic requirements of the latest International Building Code (IBC).

2. The Project Structural Engineer will provide site specific ground motion criteria for use by the manufacturer to establish SDS values required.

3. The IP rating of the equipment shall be 1.5. 4. The Structural Engineer for the Site will evaluate the SDS values published on

the Manufacturer’s website to ascertain that they are "equal to" or "greater than" those required for the Project Site.

5. The following minimum mounting and installation guidelines shall be met, unless specifically modified by the above referenced standards. a. The Contractor shall provide equipment anchorage details, coordinated

with the equipment mounting provision, prepared and stamped by a


licensed civil engineer in the state. Mounting recommendations shall be provided by the manufacturer based upon the above criteria to verify the seismic design of the equipment.

b. The equipment manufacturer shall certify that the equipment can withstand, that is, function following the seismic event, including both vertical and lateral required response spectra as specified in above codes.

c. The equipment manufacturer shall document the requirements necessary for proper seismic mounting of the equipment. Seismic qualification shall be considered achieved when the capability of the equipment, meets or exceeds the specified response spectra.

1.06 DELIVERY, STORAGE AND HANDLING

A. Equipment shall be handled and stored in accordance with manufacturer’s instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment.

B. Shipping groups shall be designed to be shipped by truck, rail or ship. Breakers and accessories shall be packaged and shipped separately.

C. Switchgear shall be equipped to be handled by crane. Where cranes are not available, switchgear shall be suitable for skidding in place on rollers using jacks to raise and lower the groups.

D. Switchgear being stored prior to installation shall be stored so as to maintain the equipment in a clean and dry condition. If stored outdoors indoor gear shall be covered and heated, and outdoor gear shall be heated.

1.07 WARRANTY AND OPERATION AND MAINTENANCE MANUALS

A. Equipment operation and maintenance manuals shall be provided with each assembly shipped, and shall include instruction leaflets and instruction bulletins for the complete assembly and each major component.

B. Provide 3 year warranty to cover all parts and labor.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Eaton.

B. GE/ABB.

C. Siemens.

D. Square D.

E. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in


their entirety. Products in compliance with the specification and manufactured by others not named will be considered only if pre-approved by the Engineer ten (10) days prior to bid date.

2.02 RATINGS

A. The switchgear, used for the medium voltage vacuum breaker transfer switch, described in this specification, shall be designed for operation on a 15 kV, 3-phase system.

B. Each MV ATS shall have the following major ratings: 1. Rated Maximum Voltage: .15 kV rms.

C. Circuit Breaker Rated short circuit current at rated max voltage as required.

D. Rated Voltage Range Factor, K as required.

E. Rated Impulse Withstand BIL as required.

F. Circuit Breaker rated interrupting time as required.

G. Continuous Current as required.

H. Rated 2-sec SC current withstand as required.

I. Rated Momentary SC current withstand as required.

J. UL1008A Operating Duty Class A (2000 operations).


K. Table 16495-1:

(1) Circuit breakers are rated to standards for HVAC Circuit Breakers, ANSI/EEE C37.04, C37.06, and C37.09. (2) Please note that use of certain current transformers (for example, bar type CTs) and protective devices may limit the

duration to a value less than 2 second. (3) These values exceed 2.6*K*l required by IEEE C37.20.2-1999 and ANSI C37.06-2000. (4) These values exceed 1.55*K*l required by IEEE C37.20.2-1999.

L. The transfer switch shall be 100 percent equipment rated for continuous duty.

M. All pilot devices and relays shall be of the industrial type, with 20 ampere rated contacts.

N. The transfer switch shall be rated to protect inductive and resistive loads, from loss of continuity of power, without de-rating, either open or enclosed.

2.03 CONSTRUCTION

A. The metal-clad switchgear, used for the transfer switch shall consist of individual vertical sections housing various combinations of circuit breakers and auxiliaries, bolted to form a rigid metal-clad automatic transfer switch. Metal side sheets shall provide grounded barriers between adjacent structures and solid removable metal barriers shall isolate the major primary sections of each circuit.

B. The stationary primary contacts shall be silver-plated and recessed within insulating tubes. A steel shutter shall automatically cover the stationary primary disconnecting contacts when the breaker is in the disconnected position or out of the cell. Provide


rails to allow withdrawal of each 15 kV circuit breaker for inspection and maintenance without the use of a separate lifting device.

C. When specified under 2.05, ratings, the switchgear assembly shall be of arc resistant construction that provides Type-2B accessibility around the perimeter (front, sides, and rear) of the line-up in accordance with IEEE C37.20.7.

D. Each individual vertical section of the switchgear shall include integral and top mounted pressure release flaps to facilitate a controlled upward release of arc created overpressures, smoke, and gasses. Individual vertical sections shall be of a unitized design to allow removal of a damaged vertical section after a fault incident, without requiring the removal of the adjacent vertical sections.

E. An enclosed arc-chamber with arc duct exit shall be furnished for installation above the switchgear. Arc-duct exit location shall be as shown on the drawing. Arc exhaust shall be vented from the arc-chamber to the exit location via arc-duct as shown on the drawings. Field assembly of the arc-chamber and arc-duct shall be by installing contractor.

F. Circuit breakers shall be capable of being operated manually under full load conditions.

G. Each circuit breaker shall be electrically interlocked to prevent simultaneous closing of both sources under either automatic or manual operation, unless closed transition transfer is specified.

H. A microprocessor-based transfer control device shall utilize electronic components mounted on printed circuit boards to accomplish functions such as timing, time delays, and voltage and frequency monitoring. LEDs shall be furnished to indicate the operation of each solid-state function. Modifications shall be available for field installation.

2.04 BUS

A. The main bus shall be copper and have fluidized bed epoxy flame-retardant and track-resistant insulation. The bus supports between units shall be flame-retardant, track-resistant, glass polyester for 5 and 15 kV class. The switchgear shall be constructed so that all buses, bus supports and connections shall withstand stresses that would be produced by currents equal to the momentary ratings of the circuit breakers. A set of insulated copper main bus shall be provided and have provisions for future extension. All bus joints shall be plated, bolted and insulated with easily installed boots. The bus shall be braced to withstand fault currents equal to the close and latch rating of the breakers. The temperature rise of the bus and connections shall be in accordance with ANSI standards and documented by design tests.

B. A 1/4-inch by 2-inch copper ground bus shall extend the entire length of the switchgear.

2.05 WIRING/TERMINATIONS

A. The switchgear manufacturer shall provide suitable terminal blocks for secondary wire terminations. One control circuit cutout device shall be provided in each circuit


breaker housing. Switchgear secondary wire shall be #14 AWG, type SIS rated 600 volt, 90 degrees C, furnished with wire markers at each termination. Wires shall terminate on terminal blocks with marker strips numbered in agreement with detailed connection diagrams.

B. Incoming line and feeder cable lugs of the type and size indicated elsewhere shall be furnished.

2.06 CIRCUIT BREAKERS

A. The circuit breakers shall be horizontal drawout type, capable of being withdrawn on rails. The breakers shall be operated by a motor-charged stored energy spring mechanism, charged normally by a universal electric motor and in an emergency by a manual handle. The primary disconnecting contacts shall be silver-plated copper.

B. Each circuit breaker shall contain three vacuum interrupters separately mounted in a self-contained, self-aligning pole unit, which can be removed easily. The vacuum interrupter pole unit shall be mounted on glass polyester supports for 15 kV class. A contact wear gap indicator for each vacuum interrupter, which requires no tools to indicate available contact life, shall be easily visible when the breaker is removed from its compartment. The current transfer from the vacuum interrupter moving stem to the breaker main conductor shall be a non-sliding design. The breaker front panel shall be removable when the breaker is withdrawn for ease of inspection and maintenance.

C. The secondary contacts shall be silver-plated and shall automatically engage in the breaker operating position, which can be manually engaged in the breaker test position.

D. Interlocks shall be provided to prevent closing of a breaker between operating and test positions, to trip breakers upon insertion or removal from housing and to discharge stored energy mechanisms upon insertion or removal from the housing. The breaker shall be secured positively in the housing between and including the operating and test positions.

E. The breakers shall be electrically operated by the following control voltages: 1. 120 Vac close and ac capacitor trip. 2. The dc supply when used, shall be furnished by the purchaser. The ac control

voltage when used, shall be derived from potential transformers connected on the line side of each breaker.

F. Each breaker shall be complete with control switch and red and green indicating lights to indicate breaker contact position.

2.07 SEQUENCE OF OPERATION – OPEN TRANSITION TRANSFER

A. Open Transition Transfer: 1. The system shall normally operate from the normal source. The normal source

is defined as the source that is preferred. The transfer controller shall indicate real-time values for volts and frequency via front panel LED display, along with an indication of the power source currently in use. The transfer controller shall continuously monitor either single-phase or three-phase voltages for Source 1


and Source 2. The transfer controller shall allow system configuration selection for Source 1/Source 2 as Utility/Generator, or Utility/Utility.

2. When the Source 1 voltage or frequency is detected to be below the user programmed set points, transfer to Source 2 shall be initiated. When the Source 2 voltage and frequency are detected to be within the programmed parameters, the transfer shall occur.

3. While the Load is connected to Source 2, the controller shall continue to monitor Source 1. As soon as the Source 1 voltage and frequency return to within the programmed limits of Source 1, and after a programmed time delay, the Load transfer back to Source 1 shall be initiated. The Load transfer back to Source 1 shall be Open type, that is, the Source 2 breaker shall be opened first, then only the Source 1 breaker shall close.

4. The programming set points and various standard and optional control parameters shall be as described under Transfer Controller section.

2.08 PROTECTIVE RELAYS

A. The switchgear manufacturer shall furnish and install, in the metal-clad switchgear, the quantity, type and rating of protection relays as indicated on the drawings and described hereafter in this specification.

B. Microprocessor-Based Protective Relay.

2.09 MICROPROCESSOR-BASED TRANSFER CONTROL DEVICE

A. The following logic and options shall be supplied: 1. The logic of the transfer switch shall function via a microprocessor. Where

shown on the drawings, provide microprocessor-based automatic transfer control. The set points shall be field adjustable without the use of special tools. LED lights shall be included on the exterior of the switch to show: a. Normal Source Available. b. Emergency Source Available. c. Normal Source Connected. d. Emergency Source Connected. e. Load Energized.

2. A digital readout shall display each option as it is functioning. Readouts shall display actual line-to-line voltage, line frequency and timers. When timers are functioning, the microprocessor shall display the timer counting down. All set points can be reprogrammed from the front of the transfer switch when the control device is in the program mode. A test pushbutton shall be included as part of the microprocessor. The microprocessor shall be compatible with a Eaton PowerNet communications system. The control device shall include the following: a. Provide a time delay transfer from the normal power source to the

emergency power source (0 seconds to 30 minutes). This option does not affect the engine start circuit.

b. Provide a timer to override a momentary power outage or voltage fluctuation (0 seconds to 120 seconds).

c. Provide a time delay transfer from the emergency power source to the normal power source (0 seconds to 30 minutes).

d. Provide a timer to allow the generator to run unloaded after retransfer to the normal power supply (1 second to 30 minutes).


e. Provide single-phase undervoltage and underfrequency sensing on the emergency power source. Voltage shall be factory set at 90 percent pickup and 80 percent dropout. Frequency sensing shall be set at 58 Hz pickup and 56 Hz dropout.

f. Provide a pilot light to indicate that the switch is in the normal position as an integral part of the microprocessor.

g. Provide a pilot light to indicate that the switch is in the emergency position as an integral part of the microprocessor.

h. Provide a pilot light to indicate that the normal power is available as an integral part of the microprocessor.

i. Provide a pilot light to indicate that the emergency power is available as an integral part of the microprocessor.

j. Provide auxiliary relay contacts that are energized when the power is available on the normal source.

k. Provide auxiliary relay contacts that are energized when the power is available on the emergency source.

B. The following features shall be provided: 1. Time delay normal to emergency, adjustable Time delay emergency to normal,

adjustable. 2. Green pilot light to indicate switch in normal position and red pilot light to

indicate switch in emergency position. 3. White pilot lights marked ‘‘Normal Source’’ and ‘‘Emergency Source’’ to

indicate that respective source voltages are available. 4. Tripped position indicating lights for both sources. 5. Relay auxiliary contacts (Form C) to indicate availability of each source.

C. When the alternate source is an engine generator, the following features shall also be provided: 1. Time delay engine start, adjustable. 2. Time delay engine cool off, adjustable. 3. Engine start contact. 4. Frequency/voltage relay for emergency source, frequency adjustable from 45

to 60 Hz and voltage fixed at 90 percent pickup, 70 percent dropout. 5. Delayed transition time delay, adjustable from 0 to 120 seconds, to allow

disconnection of the load during transfer in either direction to prevent excessive inrush currents due to out-of-phase switching of large inductive loads.

6. Four-position selector switch permitting four (4) modes of transfer switch operation: TEST (simulates normal power outage), AUTO (standard automatic operation), OFF (de-energizes control relays and opens the engine start circuit for maintenance purposes), ENGINE START (retains transfer switch in normal position and initiates a testing of the engine start circuit). Furnish white pilot light for OFF indication.

D. A transfer switch position indicator shall be visible from the front of the switch.

E. Provide load sequencing (0 to 10 devices).

F. Provide plant exerciser (selectable load no-load transfer).

G. Provide preferred source selector (source 1 or source 2, or none).


2.10 COMMUNICATIONS

A. Provide in the transfer switch a microprocessor-based unit capable of communicating phase and ground current, peak demand, present demand, energy consumption, contact status and mode of trip. The transfer switch shall respond to open and close commands from a master control unit via a communications network. Communication network shall be Cutler-Hammer PowerNet.

B. Provide communications capability to monitor the normal and emergency switch position and normal and emergency source availability. Additional communications capability shall be provided to bypass time delays during transfer or retransfer, and to initiate engine start for no-load or load testing of the transfer switch from a remote master computer.

2.11 AUXILIARY DEVICES

A. Ring type current transformers shall be furnished. The thermal and mechanical ratings of the current transformers shall be coordinated with the circuit breakers. Their accuracy rating shall be equal to or higher than ANSI standard requirements. The standard location for the current transformers on the bus side and line side of the 15 kV breaker units shall be front accessible to permit adding or changing current transformers without removing high voltage insulation connections. Shorting terminal blocks shall be furnished on the secondary of all the current transformers.

B. Voltage and control power transformers of the quantity and ratings indicated in the detail specification shall be supplied. Voltage transformers shall be mounted in drawout drawers contained in an enclosed auxiliary compartment. Control power transformers (CPTs) up to 15 kV, 15 kVA, single-phase shall be mounted in drawout drawers. Rails shall be provided for each drawer to permit easy inspection, testing and fuse replacement. Shutters shall isolate primary bus stabs when drawers are withdrawn.

C. A mechanical interlock shall be provided to require the secondary breaker to be open before the CPT drawer can be withdrawn.

2.12 OWNER METERING

A. Provide owner metering devices where shown on the drawings. Where indicated provide a separate owner metering compartment with front hinged doors. Include associated instrument transformers.

B. Provide current transformers as shown on the drawings. Current transformers shall be wired to shorting type terminal blocks.

C. Potential transformers including primary and secondary fuses with disconnecting means for metering as shown on the drawings.

D. Microprocessor-Based Metering System.

2.13 ENCLOSURES

A. The switchgear described in these specifications shall be indoor construction, with devices arranged as shown on contract drawings. When internal arc enclosure


short-circuit ratings and accessibility types are specified under section 2.02, Ratings, the switchgear described shall be of arc-resistant design.

B. Where outdoor switchgear is shown, each vertical section of outdoor switchgear shall be provided with space heaters. Tubular type heaters operated at half voltage for long life shall be supplied. 500 Volt or 250 Volt rated heaters shall be used at 240 or 120 Volts, respectively. Power for space heaters shall be furnished from a control power transformer mounted in the switchgear.

C. Heaters shall be wired to provide temporary heating during storage.

2.14 NAMEPLATES

A. Engraved nameplates, mounted on the face of the assembly, shall be furnished for all main and feeder circuits as indicated on the drawings. Nameplates shall be laminated plastic; black characters on white background, and secured with screws. Characters shall be 3/16-inch high, minimum. Furnish master nameplate for each switchgear lineup providing information in accordance with IEEE standard C37.20.2-1999, Section 7.4.1. Circuit nameplates shall be provided with circuit designations as shown on purchaser’s single-line diagrams. Provide all required markings and labels in accordance with UL1008A.

B. Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on manufacturer's wiring diagrams.

2.15 FINISH

A. The finish shall consist of a coat of gray (ANSI-61), thermosetting, polyester powder paint applied electrostatically to pre-cleaned and phosphatized steel and aluminum for internal and external parts. The coating shall have corrosion resistance of 600 hours to 5 percent salt spray.

2.16 ACCESSORIES

A. The switchgear manufacturer shall furnish accessories for test, inspection, maintenance and operation, including: 1. One – Maintenance tool for manually charging the breaker closing spring and

manually opening the shutter. 2. One – Levering crank for moving the breaker between test and connected

positions. 3. One – Test jumper for electrically operating the breaker while out of its

compartment. 4. One – Breaker lifting yoke used for attachment to breaker for lifting breaker on

or off compartment rails, when applicable. 5. One – Set of rail extensions and rail clamps, when applicable. 6. One – Portable lifting device for lifting the breaker on or off the rails. 7. One – Ramp for rolling breaker mounted in lower compartment directly onto

the floor. 8. One – Test cabinet for testing electrically operated breakers outside housing. 9. One – ‘‘Dockable’’ transport dolly for moving breaker about outside its

compartment. 10. One – Electrical levering device.


2.17 PARTIAL DISCHARGE SENSING EQUIPMENT

A. All medium voltage switchgear lineups shall be equipped with Partial Discharge Sensors to measure partial discharges within the cubicles, as well as external electrical noise.

2.18 BILLS OF MATERIAL

A. The transfer switch circuit breaker section shall include the following for the Source 1 breaker: 1. One – Drawout power circuit breaker. 2. Three – Current transformers. 3. One – Microprocessor-based three-phase and ground overcurrent relay, ANSI

device number 50/51 and 51/50/N, dual powered, if ac control is specified. 4. One – Microprocessor-based transfer switch controller, Open Transition

Transfer. 5. One – Nameplate. 6. One – Set of cable lugs. 7. One – TOC switch. 8. One – MOC switch. 9. One – ac capacitor trip device (required for ac control only). 10. Three – .15 kV, class surge arresters. 11. One – Microprocessor-based multifunction-based metering system. 12. Other relays as shown on the drawings.

B. The transfer switch circuit breaker section shall include the following for Source 2 breaker: 1. One – Drawout power circuit breaker rated. 2. Three – Current transformers. 3. One – Microprocessor-based three-phase and ground overcurrent relay, ANSI

device number 50/51 and 51/50/N, dual powered if ac control is specified. 4. One – Nameplate. 5. One – Set of cable lugs. 6. One – TOC switch. 7. One – MOC switch. 8. One – ac capacitor trip device (required for ac control only). 9. Three –.15 kV, Class Surge Arresters. 10. One – Microprocessor-based multifunction-based metering system. 11. Other relays as shown on the drawing.

C. The transfer switch auxiliary section shall include the following: 1. Two – Line-to-line, Three – Line-to-ground voltage transformers, to be

connected on the source side of the Source 1 supply. 2. Two – Line-to-line, Three – Line-to-ground voltage transformers, to be

connected on the source side of the Source 2 supply. 3. One – Set of Load cable lugs. 4. One Control Power Transformer, to be connected on the Load bus for lights,

receptacles, space heaters etc., when shown on the drawings.


PART 3 EXECUTION

3.01 FACTORY TESTING

A. The following standard factory tests shall be performed on the circuit breaker element provided under this section. All tests shall be in accordance with the latest version of ANSI standards. 1. Alignment test with master cell to verify all interfaces and interchangeability. 2. Circuit breakers operated over the range of minimum to maximum control

voltage. 3. Factory setting of contact gap. 4. One-minute dielectric test per ANSI standards. 5. Final inspections and quality checks.

B. The following production tests shall be performed on each breaker housing: 1. Alignment test with master breaker to verify interfaces. 2. One-minute dielectric test per ANSI standards on primary and secondary

circuits. 3. Operation of wiring, relays and other devices verified by an operational

sequence test. 4. Final inspection and quality check.

C. The manufacturer shall provide three (3) certified copies of factory test reports.

D. Factory tests as outlined above under 3.02.B shall be witnessed by the owner’s representative. 1. The manufacturer shall notify the owner two (2) weeks prior to the date the

tests are to be performed. 2. The manufacturer shall include the cost of transportation and lodging for up to

three (3) owner’s representatives. The cost of meals and incidental expenses shall be the owner’s responsibility.


A. Provide the services of a qualified factory-trained manufacturer’s representative to assist the Contractor in installation and start-up of the equipment specified under this section for a period of 10 working days. The manufacturer’s representative shall provide technical direction and assistance to the contractor in general assembly of the equipment, connections and adjustments, and testing of the assembly and components contained therein.

B. The Contractor shall provide three (3) copies of the manufacturer’s field start-up report.

3.03 MANUFACTURER’S CERTIFICATION

A. A qualified factory-trained manufacturer’s representative shall certify in writing that the equipment has been installed, adjusted and tested in accordance with the manufacturer’s recommendations.

B. The Contractor shall provide three (3) copies of the manufacturer’s representative’s certification.


3.04 TRAINING

A. The Contractor shall provide a training session for up to five (5) owner’s representatives for 3 normal workdays at a job site location determined by the owner.

B. The training session shall be conducted by a manufacturer’s qualified representative. Training program shall include instructions on the assembly, circuit breaker, protective devices, and other major components.

3.05 INSTALLATION

A. The Contractor shall install all equipment per the manufacturer’s recommendations and contract drawings.

B. All necessary hardware to secure the assembly in place shall be provided by the Contractor.

3.06 FIELD ADJUSTMENTS

A. The relays shall be set in the field by: 1. A qualified representative of the manufacturer, retained by the Contractor, in

accordance with settings designated in a coordinated study of the system as required elsewhere in the contract documents.

3.07 FIELD TESTING

A. Per manufacturers recommendations.

END OF SECTION


SECTION 16411

DISCONNECT SWITCHES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Fusible and non-fusible disconnect switches.

1.02 REFERENCES

A. National Electric Manufacturer’s Association (NEMA): 1. 250 - Enclosures for Electrical Equipment. 2. KS 1-2001 - Enclosed and Miscellaneous Distribution Equipment Switches

(600 Volts Maximum).

B. Underwriters Laboratories Inc. (UL): 1. 20 - General-Use Snap Switches. 2. 98 - Enclosed and Dead-Front Switches. 3. 508 - Standard for Industrial Control Equipment.

1.03 DEFINITIONS

A. Specific definitions: 1. Safety switches and disconnect switches are to be considered synonymous.


A. Provide heavy-duty type disconnect switches as indicated on the Drawings and specified in the Contract Documents.

B. Provide disconnect switches with the number of poles, voltage, current, short circuit, and horsepower ratings as required by the load and the power system.

C. Provide a local horsepower rated disconnect switch.

1.05 SUBMITTALS


B. Product data: 1. Manufacturer. 2. Manufacturer's specifications and description. 3. Ratings:

a. Voltage. b. Current. c. Horsepower. d. Short circuit rating.

4. Fused or non-fused.


5. NEMA enclosure type. 6. Dimensions:

a. Height. b. Width. c. Depth.

7. Weight. 8. Cross-referenced to the disconnect schedule indicated on the Drawings.

C. Shop drawings: 1. Manufacturer's installation instructions:

a. Indicate application conditions and limitations of use stipulated by product testing agency specified under Quality Assurance, Regulatory Requirements below.

b. Include instructions for storage, handling, protection, examination, preparation, installation, and operation of product.

2. Identify motor or equipment served by each switch; indicate nameplate inscription.

D. Installation instructions: 1. Provide anchorage instructions and requirement based on the seismic

requirements at the Project Site as specified in the Project Technical Requirements and calculations: a. Stamped by a professional engineer registered in the state where the

Project is being constructed.


A. Regulatory requirements: 1. NEMA KS1- Enclosed and Miscellaneous Distribution Switches (600 V

Maximum). 2. UL 98 - Enclosed and Dead-Front Switches.

B. Disconnect switches shall be UL listed and labeled.

1.07 SEQUENCING



1.08 WARRANTY

A. 3 year parts and labor.




PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Schneider Electric. 2. Eaton. 3. General Electric. 4. Siemens. 5. Appleton. 6. Crouse-Hinds.

2.02 EQUIPMENT

A. Switch mechanism: 1. Quick-make, quick-break heavy-duty operating mechanisms:

a. Provisions for padlocking the switch in the Off position. b. A minimum of 90-degree handle travel position between Off and On

positions: 1) Provide handle position indicators to identify the handle position.

c. Full cover interlock to prevent opening of the switch door in the On position and to prevent closing the switch mechanism with the door open: 1) With an externally operated override.

B. Switch interior: 1. Switch blades visible when the switch is Off and the cover is open. 2. Lugs:

a. Front accessible. b. Removable. c. UL listed for 60/75-degree Celsius copper conductors.

3. Current carrying parts completely plated to resist corrosion. 4. Removable arc suppressors to facilitate easy access to line side lugs. 5. Furnish equipment ground kits for every switch.

C. Fused switches: 1. Furnish with fuses as indicated on the Drawings:

a. Provide fuses as specified in the Project Technical Requirements. 2. UL approved for field conversion from standard Class H fuse spacing to

Class J fuse spacing: a. Ratings 100 amperes through 600 amperes at 240 volts. b. Ratings 30 amperes through 600 amperes at 600 volts. c. Provide spring reinforced and plated fuse clips.

D. Ratings: 1. UL horsepower rated for AC or DC with the rating not less than the load

served. 2. Current:

a. 30 to 1,200 amperes. 3. Voltage:

a. 250 volts AC, DC. b. 600 volts (30 A to 200 A, 600 volts DC).

4. Poles: a. 2, 3, 4, and 6 poles.


5. UL listed short circuit ratings: a. 10,000 RMS symmetrical amperes when used with or protected by

Class H or K fuses (30-600 amperes). b. 200,000 RMS symmetrical amperes when used with or protected by

Class R or J fuses (30-600 amperes employing appropriate fuse rejection).

c. 200,000 RMS symmetrical amperes when used with or protected by Class L fuses (800-1,200 amperes).

6. Where not indicated on the Drawings, provide switches with the NEMA ratings specified in the Project Technical Requirements for the installed location.

E. Size, fusing and number poles as indicated on the Drawings or as required: 1. Provide solid neutral where indicated on the Drawings.

2.03 ACCESSORIES

A. Disconnect switches to have provisions for a field installable “B” type electrical interlock for position indication as indicated on the Drawings.

B. Disconnect switches to have provisions for a field installed insulated groundable neutral kit as indicated on the Drawings.

C. NEMA Type 7 and 9 enclosures furnished with drain and breather kit when used in outdoor applications.

PART 3 EXECUTION

3.01 INSTALLATION


B. General: 1. Use Myers hubs or bolt-on hubs for all conduit penetrations on NEMA

Type 12, Type 4, and Type 4X enclosures. 2. Provide all mounting brackets, stands, supports and hardware as required:

a. Match finish and materials for all brackets, stands, and hardware with the switch installed.

b. Provide adequate supporting pillar(s) for disconnect switches in accordance with the approved seismic calculations, and locate aboveground or above decks, where there is no structural wall or surface for box.

3. When possible, mount switches rigidly to exposed building structure or equipment structural members: a. For NEMA Type 4 and Type 4X locations, maintain a minimum of 7/8 inch

air space between the enclosure and supporting surface. b. When mounting on preformed channel, position channel vertically so that

water may freely run behind the enclosure. 4. Provide a nameplate for each disconnect switch:

a. Provide per requirements specified in the Project Technical Requirements.


b. Identify voltage, circuit, fuse size, and equipment served on the nameplate.

3.02 COMMISSIONING




3.04 CLEANING


END OF SECTION


SECTION 16412

LOW VOLTAGE MOLDED CASE CIRCUIT BREAKERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Low voltage molded case circuit breakers.

1.02 REFERENCES

A. National Electrical Manufacturers Association (NEMA): 1. AB 3. - Molded Case Circuit Breakers and Their Application.

B. Underwriter’s Laboratories (UL): 1. 489 - Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-

Breaker Enclosures. 2. 943 - Ground Fault Circuit Interrupters.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Eaton. 2. General Electric Co. 3. Schneider Electric. 4. ABB.


A. General: 1. Conforming to UL 489. 2. Operating mechanism:

a. Quick-make, quick-break, non-welding silver alloy contacts. b. Common Trip, Open and Close for multi-pole breakers such that all poles

open and close simultaneously. c. Mechanically trip free from the handle. d. Trip indicating handle - automatically assumes a position midway between

the manual ON and OFF positions to clearly indicate the circuit breaker has tripped.

e. Lockable in the "OFF" position. 3. Arc extinction:

a. In arc chutes. 4. Voltage and current ratings:

a. Minimum ratings as required. b. Minimum frame size 100A.


5. Interrupting ratings: a. Minimum ratings as required. b. Modify as required to meet requirements of the short circuit fault analysis -

as specified in Section 16305 - Electrical System Studies. c. Not less than the rating of the assembly (panelboard, switchboard, motor

control center, etc.).

B. Motor circuit protectors: 1. Instantaneous only circuit breaker as part of a listed combination motor

controller. 2. Each pole continuously adjustable in a linear scale with ‘LO’ and ‘HI’ settings

factory calibrated.

2.03 COMPONENTS

A. Terminals: 1. Line and load terminals suitable for the conductor type, size, and number of

conductors in accordance with UL 489.

B. Case: 1. Molded polyester glass reinforced. 2. Ratings clearly marked.

C. Trip units: 1. Provide thermal magnetic or solid-state trip units as required. 2. Thermal magnetic:

a. Instantaneous short circuit protection. b. Inverse time delay overload. c. Ambient or enclosure compensated by means of a bimetallic element.

3. Solid state: a. With the following settings as required.

1) Adjustable long time current setting. 2) Adjustable long time delay. 3) Adjustable short time pickup. 4) Adjustable short time delay. 5) Adjustable instantaneous pickup. 6) Adjustable ground fault pickup as required. 7) Adjustable ground fault delay as required.

D. Provide ground fault trip devices as required.

E. Molded case circuit breakers for use in panelboards: 1. Bolt-on type:

a. Plug-in type breakers are not acceptable. 2. Ground fault trip devices as required.

2.04 ACCESSORIES

A. Shunt trip: 1. Provide a trip coil to remotely open breaker as required.


B. Undervoltage trip: 1. Electrically trips breaker when control circuit voltage falls to a preset voltage as

required.

C. Auxiliary switches: 1. Provide open/closed status switches for remote monitoring of breaker as

required.

D. Alarm switches: 1. Provide normally open contact that is actuated when breaker trips as required.

E. Lockable handle: 1. Provide assembly to lock operating handle in ‘OPEN’ position. 2. Where a molded case circuit breaker is located in a dedicated enclosure,

provide a lockable handle. Reference the Electrical Specifications for additional locking requirements associated with other mounting installations.

F. Key interlocks: 1. Provide key operated interlocks to ensure safe switching procedures as

required.

G. Electrical motorized operator: 1. Provide motorized breaker operator as required.


A. Test breakers in accordance with: 1. UL 489. 2. Manufacturer’s standard testing procedures.

END OF SECTION


SECTION 16413

LOW VOLTAGE INSULATED CASE CIRCUIT BREAKERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Low voltage insulated case circuit breakers.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. C37.13 - Standard for Low Voltage AC Power Circuit Breakers Used in

Enclosures. 2. C37.16 - Low Voltage Power Circuit Breakers and AC Power Circuit Breakers -

Preferred Ratings, Related Requirements, and Application Recommendations. 3. C37.17 - Standard for Trip Devices for AC and General Purpose DC Low

Voltage Power Circuit Breakers. 4. C37.50 - Low Voltage AC Power Circuit Breakers Used in Enclosures - Test

Procedures.

B. National Electrical Manufacturers Association (NEMA): 1. Standard No. AB 1. - Molded Case Circuit Breakers, Molded Case Switches,

and Circuit Breaker Enclosures. (Adopted as UL 489).

C. Underwriter’s Laboratories (UL): 1. UL 1066 - Standard for Safety for Low Voltage AC and DC Power Circuit

Breakers Used in Enclosures.


A. Insulated case circuit breakers and connect to form a completed system: 1. Used to open and close a circuit, and to open a circuit automatically on a

predetermined overload or overcurrent, without damage to itself when properly applied within its ratings.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Eaton. 2. General Electric Co. 3. Schneider Electric. 4. ABB.



A. Operating mechanism: 1. Manual or electric as required:

a. The circuit breaker closing spring is energized by no more than 6 operations of the constant-force charging handle. 1) Pushing the “CLOSE (ON)” button will close the breaker’s contacts

and pushing the “OPEN (OFF)” button will open the breaker’s contacts.

2) The opening springs are automatically charged when the breaker is closed.

b. Quick-make, quick-break, non-welding silver alloy contacts. c. Common trip, open and close for multi-pole breakers such that all poles

open and close simultaneously. d. Mechanically trip free from the handle. e. Trip indicating handles - automatically assumes a position midway

between the manual ON and OFF positions to clearly indicate the circuit breaker has tripped.

f. Lockable in the "OFF" position.

B. Arc extinction: 1. In arc chutes.

C. Voltage and current ratings: 1. Minimum ratings as required.

D. Interrupting ratings: 1. Minimum ratings as required.

a. Modify as required to meet requirements of Contractor’s Short Circuit Fault Analysis as specified in Section 16305 - Electrical System Studies.

2. Matching the rating of the assembly.

E. Circuit breaker mounting shall be as required and consist of one of the following configurations: 1. Draw out type capable of being racked to the disconnect position with the door

closed: a. Interlocks shall be provided to prevent connecting or disconnecting the

circuit breaker unless the breaker is in the open position. b. The breaker shall be prevented from being closed during any racking

operation. c. A test position shall be provided to permit operating the breaker while it is

disconnected from the power circuit. d. Equipped with interlocks to discharge stored energy spring before the

circuit breaker is withdrawn from the cell. 2. Plug-in (stationary) type capable of being removed with the main bus power

off. 3. Individually mounted in a separate enclosure.

2.03 COMPONENTS

A. Terminals: 1. Line and load terminals suitable for the conductor type, size, and number of

conductors in accordance with UL 489.


B. Case: 1. Molded polyester glass reinforced. 2. Double level of insulation between primary current-carrying parts and

operating personnel. 3. Ratings clearly marked. 4. Open contact indication. 5. Closed contact indication. 6. Charging spring charged indication. 7. Charging spring discharged indication. 8. Open pushbutton. 9. Close pushbutton. 10. Retractable charging handle.

C. Trip units: 1. Microprocessor based with positive action flux-shifting trip device and a solid-

state type with the following functions: a. Adjustable ampere setting:

1) To determine the value of current that the breaker will carry indefinitely.

b. Adjustable long time delay: 1) Varies the time it will take the breakers to trip under sustained

overload. c. Adjustable short time pickup:

1) Controls the level of high current the breaker will carry for short periods.

d. Adjustable short time delay: 1) Controls the length of time the breaker will carry a high current

without tripping. e. Adjustable instantaneous pickup:

1) Controls level at which immediate tripping of breaker occurs. f. Adjustable ground fault pickup:

1) Controls the level at which the breaker will trip under a ground fault condition.

g. Adjustable ground fault delay: 1) Controls the time that a ground fault can exist without tripping the

breaker. h. Long time pickup indicator:

1) Provides a visual indication that the breaker is experiencing an overload condition.

D. Fault indicators: 1. Powered from a lithium battery. 2. LED indicators for:

a. Overcurrent fault trip on long-time feature. b. Overcurrent fault trip on short-time feature. c. Short circuit fault trip on the instantaneous feature. d. Ground fault trip.


2.04 ACCESSORIES

A. Provide circuit breakers with the following accessories as required for proper operation of the control system: 1. Electrical operator. 2. Undervoltage release, instantaneous with an adjustable time delay module. 3. Neutral current sensor for use when the ground-fault option is selected on

3-phase, 4-wire 480Y/277 VAC power systems. 4. Remote close solenoid. 5. Shunt trip device. 6. Overload bell alarm to signal a remote device of “breaker tripped” status. 7. Key interlock device. 8. Anti-pump provision to prevent closing or reclosing operations when used with

a normally closed contact in the ‘close’ circuit. 9. Auxiliary switch to signal the breaker’s opened or closed status. 10. Number of contacts available shall be 8 NO/NC (SPDT). 11. Remote charge indicator. 12. Terminal blocks. 13. Operations counter.


A. Test breakers in accordance with: 1. UL 489. 2. Manufacturer’s standard testing procedures.

END OF SECTION


SECTION 16422

MOTOR STARTERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Motor starters and contactors.

1.02 REFERENCES

A. International Electrotechnical Commission (IEC): 1. 60 947-4 - Low-Voltage Switchgear and Control Gear. 2. 801-1 - Electromagnetic Compatibility for Industrial-Process Measurement and

Control Equipment - Part 1: General Information.

B. National Electrical Manufacturer's Association (NEMA): 1. ICS 2 - Industrial Control and Systems: Controllers, Contactors, and Overload

Relays Rated 600 V.

C. Underwriters Laboratories (UL): 1. 508 - Standard for Industrial Control Equipment. 2. 508A - Standard for Industrial Control Panels.

1.03 DEFINITIONS

A. Specific definitions and abbreviations: 1. FVNR: Full voltage non-reversing. 2. FVR: Full voltage reversing. 3. TS1W: 2 speed 1 winding (consequent pole). 4. TS2W: 2 speed 2 winding. 5. PWS: Part winding start. 6. RVAT: Reduced voltage auto transformer. 7. RVSS: Reduced voltage solid state. 8. Overload relay class: A classification of an overload relay time current

characteristic by means of a number which designates the maximum time in seconds at which it will operate when carrying a current equal to 600 percent of its current rating.


A. General requirements: 1. Starters for motor control centers, individual enclosed starters, or control

panels.


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. NEMA starters and contactors:

a. Allen-Bradley. b. Schneider Electric. c. General Electric. d. Eaton.


A. General: 1. Provide combination type starters with motor circuit protector or thermal-

magnetic circuit breaker and control power transformer with ratings as required.

2. NEMA size, design, and rated: a. NEMA Size 1 minimum.

3. Coordinate motor circuit protector, thermal magnetic circuit breaker, or fusible disconnect, and overload trip ratings with nameplate horsepower and current ratings of the installed motor.

4. Provide starters NEMA Size 2 and larger with arc quenchers on load breaking contacts.

5. Mount extended overload reset buttons to be accessible for operation without opening starter enclosure door.

B. Full voltage starters (FVNR, FVR, TS1W, TS2W): 1. Across-the-line full voltage magnetic starters. 2. Rated for 600 volts. 3. Electrical characteristics as required. 4. Provide positive, quick-make, quick-break mechanisms, pad lockable

enclosure doors. 5. Furnish starter with solid state electronic overload relays. 6. Double-break silver alloy contacts. 7. Reversing starters provided with both mechanical and electrical interlocks to

prevent line shorts and energizing both contactors simultaneously. 8. Provide 2-speed, 2-winding motor starters consisting of two 3-pole contactors

and 2 sets of overload relays assembled together: a. Provided with contactors that are both mechanically and electrically

interlocked to prevent energizing both contactors simultaneously. 9. Provide 2-speed, 1 winding variable torque starter consisting of one 5-pole and

one 3-pole contactors and 2 sets of overload relays assembled together: a. Provided with contactors that are both mechanically and electrically

interlocked to prevent energizing both contactors simultaneously.

C. RVSS: 1. Manufactured and tested in accordance with the applicable requirements of

IEEE, UL, and NEMA, including the following: a. Dielectric withstand per UL 508. b. Noise and RF immunity per NEMA ICS-2-230.


2. Furnish with a motor circuit protector or thermal magnetic circuit breaker as required.

3. Provide protection against internal faults and high SCR temperature during operation of the motor including starting, running (except when bypassed), and stopping modes.

4. Capable of continuously delivering full rated current of the motor plus the motor service factor in ambient temperatures from 0 degrees Celsius to 40 degrees Celsius at the installed altitude.

5. Provide a magnetically operated bypass contactor in parallel with the solid state starter: a. The bypass contactor to energize when the motor has reached full speed:

1) The electronic overload protection circuits must be fully functional with the bypass contactor closed.

6. RVSS control module requirements: a. Microcomputer based, and contains the required circuitry to drive the

power semiconductors in the power section of the starter. b. Integrally mounted on the power section and requires no additional panel

space or wiring. c. Mounted for easy wiring, testing, service, and replacement. d. Provide 3-phase current sensing. e. Quick disconnect plug-in connectors for current transformer inputs, line

and load voltage inputs, and SCR gate firing output circuits. f. Operates on power supplied from a control power transformer. g. Phase insensitive or with phase rotation protection. h. Control modes:

1) Soft start with adjustable linear ramp time and a “kick start” or “boost” feature to provide a short time (typically 0.1 seconds) application of approximately full voltage.

2) Soft start with adjustable linear ramp time, with a current limit: a) The current limit shall be adjustable over the range of 2 to

4 times normal full load current. 3) Across the line starting. 4) Reverse voltage ramp (line voltage to zero voltage):

a) Adjustable from 2 to 30 seconds to provide smooth stop. b) Automatic shutdown at end of voltage ramp.

i. Protective functions: 1) Single phase protection. 2) Under voltage protection. 3) Short circuit electronic trip overcurrent protection. Time not to exceed

3 cycles. 4) Inverse time running overcurrent protection. 5) Auxiliary trip circuitry. 6) Gate firing circuit lockout protection on trip. 7) Jam and stall detection. 8) Fault relay lockout protection. 9) 100 percent to 130 percent full load running current trip adjustment. 10) 100 percent to 450 percent of starting current limit adjustment. 11) Dwell time at current limit with ramp continuation after acceleration. 12) Individual light emitting diodes (LEDs) for trip and phase loss. 13) Minimum and maximum initial starting voltage adjustments. 14) Initial torque adjustment.


7. RVSS power section requirements: a. 3 sets of back-to-back phase controlled power semiconductors:

1) Minimum repetitive peak inverse voltage of 1,500 volts at 480 VAC. 2) Resistor/capacitor snubber networks to prevent false firing of the

SCRs. 3) Equipped with individual heat sink assemblies. 4) Provide high-speed fuses for protection of the SCR stacks against

short circuit conditions. b. Provide metal oxide varistors for surge protection on the line and load side

power terminal connections: 1) Rated for a minimum of 120 joules.

c. Capable of supplying the following current levels: 1) 600 percent of full load current for a minimum of 10 seconds. 2) 450 percent of full load for a minimum of 30 seconds.

d. Furnish ground lugs, one for incoming and one for outgoing ground connections.

e. Furnish pressure type terminals for top or bottom entry power terminations.

8. Remote indicators: a. Provide Form C dry contacts for remote indication of:

1) Internal fault error. 2) Undervoltage. 3) Overvoltage. 4) Phase reversal. 5) Phase loss. 6) Overload. 7) Frequency out of range. 8) Excessive starts per hour. 9) Drive electronics over temperature. 10) Stall. 11) Jam. 12) System failure. 13) Starter failure. 14) Run status. 15) Full speed.

9. Metering: a. 3-phase motor current. b. Power in kW. c. Power factor. d. 3-phase voltage. e. Power usage in kWh.

10. Phase re-balance: a. Continuously monitor the incoming 3-phase line voltage balance and

adjust the output voltage to automatically balance the 3-phase currents supplied to the motor.

D. Manual motor starters: 1. General:

a. Provide with number of poles as required by the connected load. b. Provide handles that clearly indicate the On and Off (with lockout),

positions. c. Switch shall have positive, quick-make, quick-break mechanisms.


2. Thermal overload switches: a. Provide thermal overloads in manual motor starters where integral

overloads are not furnished with the motor. b. Size heater elements for approximately 115 percent of the nameplate full

load current, for motors with a 1.15 service factor. c. Thermal overload units in all phase legs. d. Overload conditions interrupts all ungrounded conductors.

3. Enclosure: a. Provide the NEMA enclosure type required for conditions.

E. Integral self-protected starters: 1. IEC rated device consisting of:

a. Circuit breaker. b. Contactor. c. Dual-function overload relay.

2. Designed to use the same contacts for contactor and breaker operation: a. Contactor and breaker operations shall be independent of each other.

3. Ratings: a. Voltage: 480 VAC. b. Current:

1) 18 amps. 2) 32 amps. 3) 63 amps.

4. Furnish overload relay modules capable of independently adjustable thermal and magnetic trips: a. Provide one normally open and one normally closed contact associated

with motor overload contact block per starter. 5. Provide surge protection devices across the coil of each magnetic starter. 6. Furnish local status indication. 7. Terminal wiring located behind recessed plastic housing. 8. DIN rail mounted. 9. With molded bus structure for line side power bussing. 10. Minimum life expectancy:

a. 1.5 million operations. b. After interrupting 100 times rated current ten times, minimum expected life

shall not be less than 0.5 million operations. 11. UL 508, Category E listed and labeled.

2.03 COMPONENTS

A. Molded case circuit breakers: 1. Provide as specified in Section 16412 - Low Voltage Molded Case Circuit

Breakers.

B. Contactors: 1. NEMA size as required. 2. Electrically held:

a. For lighting loads designed to withstand the initial inrush currents of ballast and lamp loads.

3. Factory adjusted and chatter free.


4. Auxiliary contacts: a. Contact ratings as per NEMA A 600 rating:

1) Auxiliary contacts rated 10 amps at 600 volts. b. Provide all contacts, and any additional contacts required for proper

operation. c. Provide at least 1 normally open and 1 normally closed spare auxiliary

contact. 5. Constructed in accordance with the following standards:

a. UL 508. b. IEC 947-4:

1) Type 1 coordination when protected by a circuit breaker. 2) Type 2 coordination when protected by a suitable UL listed fuse.

c. IEC 801-1 parts 2 through 6.

C. Overloads: 1. Solid state electronic:

a. Selectable Class 10, 20, 30 protection. b. Ambient insensitive:

1) Operating temperature: -20 to 70 degrees Celsius. c. Thermal memory. d. Protective functions:

1) Motor overcurrent. 2) Phase unbalance (adjustable.) 3) Phase loss. 4) Ground fault protection.

e. Self-powered. f. Provide current transformers for metering of motor current. g. Visible trip indicator. h. Push-to-trip test. i. Isolated normally open alarm contact. j. Normally closed trip contact. k. Automatic reset.

D. Network communications: EtherNet I/P, DeviceNet, Profibus DP, and Modbus TCP.

E. Control power transformer: 1. Furnish integral control power transformer. 2. Primary and secondary fusing. 3. Control power transformer secondary voltage.

F. Enclosures for individually enclosed starters: 1. NEMA type specified for the location as required. 2. Flange-mounted handle mechanism to operate disconnect switch or circuit

breaker: a. Door mounted operators or operator handles are not acceptable. b. Handle mechanism features:

1) Engaged with the disconnect device at all times as an integral part of the unit independent of the door position.

2) Lockable in the Off position.


3) Mechanically interlocked so that the disconnect cannot be switched to the On position with the door open: a) Provide a means for qualified personnel to defeat this interlock

during maintenance and testing. 4) Lockable in the On position:

a) This feature shall not prevent the circuit breaker from operating during a fault condition.

3. Provide a thermostatically controlled space heater for equipment located outdoors or in unheated areas: a. Powered from the control power transformer.

2.04 ACCESSORIES

A. Lugs and terminals: 1. For all external connections of No. 6 AWG and larger. 2. UL listed for either copper or aluminum conductors.

B. Surge protective devices: 1. Furnish surge protection devices across the coil of each starter, contactor, and

relay.

C. Pilot devices: 1. Provide pilot lights, switches, elapsed time meters, and other devices as

specified or as required.

D. Conformal coating: 1. Provide conformal coating material applied to electronic circuitry and printed

circuit boards to act as protection against moisture, dust, temperature extremes, and chemicals such as H2S and chlorine.

END OF SECTION


SECTION 16441

GROUP-MOUNTED CIRCUIT BREAKER SWITCHBOARDS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Free standing, metal clad, arc resistant, dead-front type metal-enclosed

distribution, low voltage switchboards, utilizing group mounted circuit protective devices.

1.02 REFERENCES

A. National Electrical Manufacturers' Association (NEMA): 1. PB-2 - Dead-front Distribution Switchboards.

B. Underwriters' Laboratories, Inc. (UL): 1. 50 - Standard for Enclosures for Electrical Equipment. 2. 891 - Switchboards.


A. Factory assembled, wired, and tested switchboards, with major components being products of a single manufacturer, including but not limited to, circuit breakers, bus and enclosure with accessories and features specified in this Section.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Metal Clad, Arc Resistant. 2. Eaton, "Pow-R-Line C.” 3. General Electric Co., "Spectra Series.” 4. Schneider Electric, “Power-Style QED.”

B. Circuit breakers: Same manufacturer as the switchboard.

2.02 EQUIPMENT

A. Switchboard: 1. Furnish low voltage Class 2 switchboards. 2. Provide complete and functional switchboards with required controls. 3. Furnish and install devices or accessories not described in this Section but

necessary for the proper installation and operation of the equipment.


B. Voltage ratings: 1. Voltage level and configuration: As required. 2. Frequency: 60 hertz.

C. Bus: 1. General:

a. Tin-plated copper. b. Bus cross-section in accordance with UL heat rise requirements. c. Current density of 1,000 amperes per square inch. d. Mounted on supports of high-impact, non-tracking insulators. e. Phase A-B-C bus arrangement:

1) Top-to-bottom, left-to-right, front-to-back throughout the switchboard. f. Symmetrical short circuit current bracing of as required. g. Continuous current rating as required.

2. Horizontal bus: a. Provisions for future connections to additional switchboard sections.

3. Ground bus: a. Rated at 100 percent of incoming capacity.

4. Neutral bus: a. Sized for 100 percent of power bus rating.

D. Metal Clad Enclosure: 1. General:

a. Self-supporting structures bolted together to form the required line-up. b. All sections rear aligned. c. Dead-front. d. Conduit entry:

1) Open-bottom. 2) Removable top cover.

2. Frame: a. Die-formed 12 gauge steel.

3. Covers: a. Bolt-on. b. Code gauge steel. c. Removable front covers.

1) Held in place by captive screws. 4. Rating:

a. NEMA Type 1.

2.03 COMPONENTS

A. Circuit breakers: 1. General:

a. Molded case circuit breakers as specified in Section 16412 - Low Voltage Molded Case Circuit Breakers.

b. Insulated case circuit breakers as specified in Section 16413 - Low Voltage Insulated Case Circuit Breakers.

2. Main circuit breaker: a. Frame, trip and short circuit ratings as required. b. 100 percent rated. c. Drawout mounted insulated case.


3. Feeder breakers: a. Frame, trip and short circuit ratings as required.

B. Wiring: 1. Provide all necessary internal wiring, fuse blocks, and terminal blocks as

required. 2. Number all wires at each end and indicate wire numbers on shop drawings. 3. Type SIS switchboard wire with at least 26 strands. 4. Minimum wire size:

a. No. 14 for control circuits. b. No. 12 for potential and current transformer circuits.

5. Numbered and labeled in accordance with the Project Technical Requirements.

2.04 ACCESSORIES

A. Infrared (IR) Windows: 1. Provide two IR windows. Iris, Flir, or Fluke.

B. Metering system: 1. Provide GE PQM-II monitor with wave form capture and ether (multi-net)

converter, or approved equal.

C. Surge protective devices: 1. Provide surge protective devices as specified in Section 16285 - Surge

Protective Devices.

D. Nameplates: 1. Provide engraved plastic nameplates to identify:

a. Switchboard units. b. Door mounted components. c. Interior mounted devices.

2. As specified in the Project Technical Requirements. 3. Engraved with the circuit number and circuit name. 4. Manufacturers labels:

a. Each vertical section shall have a label identifying: 1) Serial number. 2) Shop order number. 3) Bus rating. 4) Vertical section reference number. 5) Date of manufacture.

E. Warning signs: 1. Voltage:

a. Provide a minimum of 2 warning signs on the front of the switchboard lineup and 2 on the back.

b. Red laminated plastic engraved with white letters approximately 1/2 inch high.


2. Arc flash: a. Provide one warning sign for each switchboard compartment.


b. Signs shall have read a minimum of: 1) “DANGER ELECTRIC ARC FLASH HAZARD.” 2) Signs shall meet the requirements of NFPA 70E and NEC Article

110.16.

F. Space heaters: 1. Fused, thermostatically controlled, strip-type, operated at half voltage for long

life: a. 500 volt or 250 volt rated heaters at 240 volt or 120 volt, respectively.

2. Powered from the switchboard control power transformer. 3. Each space heater shall be powered through its own dedicated circuit breaker.

G. Direct current battery systems: 1. As specified in Section 16240 - Battery Systems.

H. Lugs: 1. For all external connections of No. 6 AWG or larger. 2. UL listed for copper or aluminum conductors. 3. Rated for 75-degree Celsius conductors. 4. Lugs shall be of the compression type in design requiring a hydraulic press

and die for installation.

2.05 FINISHES

A. Chemically clean all steel surfaces before painting.

B. Exterior color manufacturer’s standard gray over phosphate-type rust inhibitor.

PART 3 EXECUTION

3.01 COMMISSIONING


END OF SECTION


SECTION 16444

LOW VOLTAGE MOTOR CONTROL CENTERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Low voltage motor control centers.

1.02 REFERENCES

A. National Electrical Manufacturer's Association (NEMA): 1. ICS 18-2001 - Motor Control Centers.

B. Underwriters Laboratories (UL): 1. 845 - Motor Control Centers.


A. Factory assembled, factory wired and factory tested motor control centers: 1. Motor control centers and major components to be products of a single

manufacturer.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Allen-Bradley. 2. Eaton. 3. General Electric. 4. Schneider Electric.

2.02 EQUIPMENT

A. General: 1. Furnish motor control centers as required. 2. Arrange the equipped sections to form continuous motor control center lineups

as required: a. Identify any deviations from the Drawings in writing and submit for

approval. 3. Provide wire markers at each end of every wire. 4. Provide complete and functional motor control centers. 5. Provide devices or accessories not specified in this Section but necessary for

the proper installation and operation of the equipment.

B. Design and construct motor control center to operate at the voltage level and configuration as required.


C. Bus system: 1. Material:

a. Tin-plated copper. b. Short-circuit rating:

1) As required by studies. c. Bus bar supports:

1) High impact strength, non-tracking glass-polyester material that is impervious to moisture and gases.

2. Horizontal power bus: a. Current-carrying capacity as required. b. Mounting:

1) Mount horizontal bus bars edgewise, one above the other, and fully isolated from all wireways and units.

c. Temperature rise: 1) In accordance with UL 845. 2) De-rate the temperature rating of the bus for the specified conditions

of ambient temperature and altitude. 3. Vertical power bus:

a. Current-carrying capacity of not less than 600 amps. b. Mounting:

1) Enclose the vertical bus in a polyester-glass cover with small openings to permit unit stabs to mate with the bus: a) Provide a shutter mechanism to cover the stab openings when

plug-in units are removed. 2) Provide top and bottom bus covers for insulation and isolation of the

ends of the bus. c. Isolated from the unit compartments by a full height barrier.

4. Neutral bus: a. Provided in 4-wire motor control centers. b. Current carrying capacity of 100 percent of horizontal power bus. c. Mounting:

1) Bus shall extend the full width of the motor control center. d. Pre-drilled and furnished with lugs for attachment of neutral conductors:

1) Furnish a minimum of 50 percent spare lugs in each vertical section of motor control center.

5. Ground bus: a. Horizontal ground bus:

1) Current-carrying capacity: a) 300 amps when the horizontal bus is 2,000 amps or less. b) 600 amps when the horizontal bus is greater than 2,000 amps.

2) Mounting: a) Full-width, firmly secured to each vertical section structure:

(1) Located in the top or bottom wireway. b) Pre-drilled and furnished with lugs for connection to equipment

ground wires: (1) Furnish a minimum of 10 lugs per vertical section of MCC.

b. Vertical ground bus. 1) Mounting:

a) Furnish in each vertical section. b) Bolted to the horizontal ground bus. c) Install parallel to the vertical power bus.


d) Mount vertical ground bus such that plug-in units engage the ground bus before any connection to the power bus is made. Upon removal of plug-in units, ground stabs are disconnected from the ground bus after the power stabs have been disconnected.

6. Bus splice bars: a. Provided to join the bus at the splits. b. Connected to each horizontal bus bar with a minimum of two bolts. c. Employ conical or spring washers at connections, designed to maintain

constant pressure against the splice joint. d. Same ampacity rating as the horizontal bus.

7. Provide bus system configured for back-to-back MCCs, where required.

D. Enclosures: 1. Each motor control center shall consist of 1 or more vertical sections bolted

together: a. Freestanding. b. Totally enclosed. c. Dead-front assembly. d. Designed for modification and/or addition of future vertical sections. e. Form each vertical section of heavy gauge steel. f. Designed for back-to-back arrangement installation, where required.

2. Enclosure rating: a. Indoor:

1) NEMA Type 1 gasketed. b. Outdoor:

1) NEMA Type 3R non-walk-in with separate interior enclosure: a) Interior enclosure:

(1) NEMA Type 12 gasketed. 3. Standard section dimensions:

a. Nominal height: 90 inches. b. Nominal depth: 20 inches. c. Vertical section width as required.

4. Wireways: a. Provide each vertical section with a horizontal wireway at the top and

bottom of the section: 1) Arranged to provide a full-width metal enclosed wiring trough across

the entire motor control center assembly. b. Provide each vertical section with a full-height vertical wireway. c. Completely isolated from the vertical and horizontal bus bars. d. Provide a removable, hinged door.

5. Shipping splits: a. No more than 3 vertical sections and not more than 60 inches in width. b. Solid bussing between vertical sections in a shipping split is not

acceptable. 6. Lifting angles:

a. Furnish each vertical section and/or shipping split with a removable lifting angle mounted to the top of the enclosure: 1) Extending the entire width of the shipping split.

7. Mounting channels: a. Mount each vertical section and/or shipping split on an external 1.5-inch

by 3-inch mounting channel.


E. Units: 1. A plug-in unit consists of:

a. Unit assembly. b. Unit support pan. c. Unit door assembly.

2. Completely enclosed and isolated from adjacent units, buses, and wireways, except for conductor entries into the unit, by a metal enclosure.

3. Constructed so that any fault will be contained in the unit compartment. 4. Supported and guided by a removable unit support pan:

a. Re-arrangement of units and the removal of a unit so that a new and possibly larger unit can be added without the removal of an in-service unit to gain access to the unit support pan.

5. Held in place by screws or other positive locking means after insertion. 6. Provide a test position with the unit supported in the structure but disengaged

from the bus. 7. Integral plug-in ground stab. 8. Stabs:

a. Free floating. b. Self-aligning. c. Backed by spring steel clips to ensure high pressure contacts: d. Electrolytically tin-plated copper.

9. Handle: a. Provide a flange mounted handle mechanism to operate each disconnect

switch or circuit breaker. b. Door mounted operators or operator handles are not acceptable. c. Engaged with the disconnect device at all times as an integral part of the

unit independent of the door position. d. Lockable in the “OFF” position with up to 3 padlocks. e. Mechanically interlocked so that the door cannot be opened with the

handle in the “ON” position. 1) Provide a means for qualified personnel to defeat this interlock.

f. Interlocked so the unit cannot be inserted or withdrawn with the handle in the “ON” position.

g. Lockable in the “ON” position: 1) This shall not prevent the circuit breaker from operating and opening

the contacts in the event of a fault condition. h. Color-coded to indicate position. i. Located so the center of the grip when it is in its highest position is not

more than 6 feet 7 inches above the finished floor, including the height of the housekeeping pad and mounting channels.

10. Where required, provide units for spaces and future equipment: a. Equip these units to accept a future plug-in unit without modification to the

vertical sections.

F. Communication equipment: 1. Furnish motor control centers with a factory installed communications network.

a. The network shall include a complete and tested cabling system compliant with applicable standards.

2. Network cable: a. As required.


3. Accessories: a. Managed Ethernet switch:

1) Port count (minimum): 12 10/100 Ethernet. 2) Redundant 24VDC power supplies.

b. Provide the motor control center with a 24 volt DC power supply to provide power to all devices in the motor control center. 1) Installed in a motor control center compartment with Ethernet switch.

2.03 COMPONENTS

A. Provide components contained within the motor control center as indicated in: 1. Identification for Electrical Systems. 2. 600-Volt or Less Wires and Cables. 3. Low Voltage Wire Connections. 4. Electrical Power Monitoring. 5. Surge Protective Devices. 6. Motor Starters.

2.04 ACCESSORIES

A. Infrared (IR) windows: Provide two factory installed infrared (IR) windows per MCC section. Factory located IR windows for maximum viewing of bus, conductor, breaker, and other termination points. Iris, Flir, or Fluke.

B. Wiring: 1. Wire the motor control center in accordance with the following NEMA Class

and Type as defined by NEMA ICS 18-2001: a. NEMA Class II-S:

1) Furnish wiring diagrams for individual units consisting of drawings that identify electrical devices, electrical connections, and indicate terminal numbering designations.

2) Furnish individual unit diagrams with each unit and include inter-wiring between units, i.e. electrical interlocking, etc., as specifically specified in the Contract Documents.

3) Provide custom drawings with unique terminal numbering designations in lieu of standard manufacturer drawings.

b. NEMA Type B wiring: 1) Control wiring:

a) Type B-T pull-apart terminal blocks. 2) Power wiring:

a) Type B-T for Size 1 starters. b) Type B-T or B-D for Size 2 and 3 starters. c) Type B for Size 4 and larger starters and feeder units.

c. Control wiring shall be tin plated copper.

C. Lugs and terminals: 1. For all external connections of No. 6 AWG wire or larger:

a. UL listed for copper or aluminum conductors. 2. Compression type, requiring a hydraulic press and die for installation. 3. Provide 20 percent spare control block terminals.


D. Nameplates: 1. Provide nameplates:

a. Identifying the motor control center designation. 2. Identifying each vertical section:

a. Mounted and centered on the top horizontal wireway of the vertical section.

3. Furnish individual nameplates for each unit: a. 1 nameplate to identify the unit designation. b. 1 nameplate to identify the load served. c. Furnish space units with blank nameplates.

4. Manufacturer’s labels: a. Furnish each vertical section with a label identifying:

1) Serial number. 2) Bus rating. 3) Vertical section reference number. 4) Date of manufacture. 5) Catalog number of section.

2.05 FINISHES

A. Finish metal surfaces and structural parts with phosphatizing, or equal, treatment before painting.

B. Finish interior surfaces including bus support angles, control unit back plates, and top and bottom barrier plates with baked white enamel.

C. Finish exterior of enclosure with manufacturer’s standard gray. 1. Finish NEMA Type 3R exterior cabinets with ultraviolet resistant enamel paint

that is UL recognized for outdoor use.

END OF SECTION


SECTION 16950

FIELD ELECTRICAL ACCEPTANCE TESTS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Responsibilities for testing the electrical installation. 2. Adjusting and calibration. 3. Acceptance tests.

B. Copyright information: 1. Some portions of this Section are copyrighted by the InterNational Electrical

Testing Association, Inc. (NETA). See NETA publication ATS for details.

1.02 REFERENCES

A. American National Standards Institute (ANSI).

B. ASTM International (ASTM): 1. D877 - Standard Test Method for Dielectric Breakdown Voltage of Insulating

Liquids Using Disk Electrodes. 2. D923 - Standard Practices for Sampling Electrical Insulating Liquids. 3. D924 - Standard Test Method for Dissipation Factor (or Power Factor) and

Relative Permittivity (Dielectric Constant) of Electrical Insulating Liquids. 4. D971 - Standard Test Method for Interfacial Tension of Oil Against Water by

the Ring Method. 5. D974 - Standard Test Method for Acid and Base Number by Color-Indicator

Titration. 6. D1298 - Standard Test Method for Density, Relative Density, or API Gravity of

Crude Petroleum and Liquid Petroleum Products by Hydrometer Method. 7. D1500 - Standard Test Method for ASTM Color of Petroleum Products (ASTM

Color Scale). 8. D1524 - Standard Test Method for Visual Examination of Used Electrical

Insulating Liquids in the Field. 9. D1816 - Standard Test Method for Dielectric Breakdown Voltage of Insulating

Liquids Using VDE Electrodes. 10. D2285 - Standard Test Method for Interfacial Tension of Electrical Insulating

Oils of Petroleum Origin Against Water by the Drop Weight Method. 11. D3612 - Standard Test Method for Analysis of Gases Dissolved in Electrical

Insulating Oil by Gas Chromatography.

C. Institute of Electrical and Electronics Engineers (IEEE): 1. 43 - IEEE Recommended Practice for Testing Insulation Resistance of

Rotating Machinery. 2. 81 - IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and

Earth Surface Potentials of a Grounding System. 3. 95 - IEEE Recommended Practice for Insulation Testing of AC Electric

Machinery (2300 V and Above) With High Direct Voltage.


4. 421.3 - IEEE Standard for High-Potential Test Requirement for Excitation Systems for Synchronous Machines.

5. 450 - IEEE Recommended Practice for Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries for Stationary Applications.

6. 1106 - IEEE Recommended Practice for Installation, Maintenance, Testing, and Replacement of Vented Nickel-Cadmium Batteries for Stationary Applications.

7. 1188 - IEEE Recommended Practice for Maintenance, Testing, and Replacement of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Applications.

8. C57.13 - IEEE Standard Requirements for Instrument Transformers. 9. C57.13.1 - IEEE Guide for Field Testing of Relaying Current Transformers. 10. C57.13.3 - IEEE Guide for Grounding of Instrument Transformer Secondary

Circuits and Cases. 11. C57.104 - IEEE Guide for the Interpretation of Gases Generated in Oil-

Immersed Transformers.

D. Insulated Cable Engineer’s Association (ICEA).

E. InterNational Electrical Testing Association (NETA). 1. ATS- Standard for Standard for Acceptance Testing Specifications for

Electrical Power Equipment and Systems.

F. International Electrotechnical Commission (IEC).

G. Manufacturer’s testing recommendations and instruction manuals.

H. National Fire Protection Association (NFPA): 1. 70 - National Electrical Code (NEC). 2. 110 - Standard for Emergency and Standby Power Systems.

I. National Institute of Standards and Technology (NIST).

J. Specification sections for the electrical equipment being tested.

K. Shop drawings.

1.03 DEFINITIONS

A. Specific definitions: 1. Testing laboratory: The organization performing acceptance tests.


A. Testing of all electrical equipment installed under this Contract in accordance with the manufacturer’s requirements and as specified in this Section.

B. Conduct all tests in the presence of the Engineer or the Engineer’s representative: 1. Engineer will witness all visual, mechanical, and electrical tests, and

inspections.

C. The testing and inspections shall verify that the equipment is operational within the tolerances required and expected by the manufacturer, and these Specifications.


D. Responsibilities: 1. Contractor responsibilities:

a. Ensure that all resources are made available for testing, and that all testing requirements are met.

2. Electrical subcontractor responsibilities: a. Perform routine tests during installation. b. Demonstrate operation of electrical equipment. c. Commission the electrical installation. d. Provide the necessary services during testing, and provide these services

to the testing laboratory, Contractor, and other subcontractors, including but not limited to: 1) Providing electrical power as required. 2) Operating of electrical equipment in conjunction with testing of other

equipment. 3) Activating and shutting down electrical circuits. 4) Making and recording electrical measurements. 5) Replacing blown fuses. 6) Installing temporary jumpers.

3. Testing laboratory responsibilities: a. Perform all acceptance tests specified in this Section. b. Provide all required equipment, materials, labor, and technical support

during acceptance tests.

1.05 SUBMITTALS


B. LAN cable test form: 1. LAN cable test reports:

a. Submit 3 copies of test reports showing the results of all tests specified in this Section: 1) Test type. 2) Test location. 3) Test date. 4) Cable number. 5) Cable length. 6) Certification that the cable meets or exceeds the specified standard.

b. Furnish hard copy and electronic copy for all traces.

C. Manufacturers’ testing procedures: 1. Submit manufacturers’ recommended testing procedures and acceptable test

results for review by the Engineer prior to beginning testing.

D. Test report: 1. Include the following:

a. Summary of Project. b. Description of equipment tested. c. Description of tests performed. d. Test results. e. Conclusions and recommendations. f. Completed test forms. g. List of test equipment used and calibration dates.


h. LAN cable test reports.

E. Test data records: 1. Include the following:

a. Identification of the testing organization. b. Equipment identification. c. Nameplate data. d. Humidity, temperature and or other conditions that may affect the results

of the tests and or calibrations. e. Dates of inspections, tests, maintenance and or calibrations. f. Indication of the inspections, tests, maintenance, and or calibrations to be

performed and recorded. g. Expected results when calibrations are to be performed. h. Indication of as-found and as-left results as applicable. i. Indication of all test results outside specified tolerances.

F. Testing laboratory qualifications: 1. Submit a complete resume and statement of qualifications from the proposed

testing laboratory detailing their experiences in performing the tests specified: a. This statement will be used to determine whether the laboratory is

acceptable, and shall include: 1) Corporate history and references. 2) Resume of individual performing test. 3) Equipment list and test calibration data.

G. Division of responsibilities: 1. Submit a list identifying who is responsible for performing each portion of the

testing.


A. Testing laboratory qualifications: 1. The testing laboratory may be qualified testing personnel from the electrical

subcontractor’s staff or an independent testing company. 2. NETA certification required. 3. Selection of the testing laboratory and testing personnel is subject to approval

by the Engineer based on testing experience and certifications of the individuals and testing capabilities of the organization.

1.07 SEQUENCING

A. At least 30 days before commencement of the acceptance tests, submit the manufacturer’s complete field testing procedures to the Engineer and to the testing laboratory, complete with expected test results and tolerances for all equipment to be tested.

B. Perform testing in the following sequence: 1. Perform routine tests as the equipment is installed including:

a. Insulation-resistance tests. b. Continuity tests. c. Rotational tests.

2. Adjusting and preliminary calibration. 3. Acceptance tests.


4. Demonstration. 5. Commissioning and plant start-up.

1.08 WARRANTY

A. Minimum of 3 years parts and labor unless a longer duration is indicated in individual spec sections.

PART 2 PRODUCTS

Not Used.

PART 3 EXECUTION

3.01 PREPARATION

A. Test instrument calibration: 1. Utilize a testing laboratory with a calibration program which maintains all

applicable test instrumentation within rated accuracy. a. The calibrating standard shall be of better accuracy than that of the

equipment tested. 2. The accuracy shall be traceable to the NIST in an unbroken chain. 3. Calibrate instruments in accordance with the following frequency schedule:

a. Field instruments: 6 months maximum. b. Laboratory instruments: 12 months maximum. c. Leased specialty equipment where the accuracy is guaranteed by the

lessor (such as Doble): 12 months maximum. 4. Dated calibration labels shall be visible on all test equipment. 5. Maintain an up-to-date instrument calibration record for each test instrument:

a. The records shall show the date and results of each calibration or test. 6. Maintain an up-to-date instrument calibration instruction and procedure for

each test instrument.

B. Do not begin testing until the following conditions have been met: 1. All instruments required are available and in proper operating condition. 2. All required dispensable materials such as solvents, rags, and brushes are

available. 3. All equipment handling devices such as cranes, vehicles, chain falls and other

lifting equipment are available or scheduled. 4. All instruction books, calibration curves, or other printed material to cover the

electrical devices are available. 5. Data sheets to record all test results are available.

C. Engine generator tests: 1. The following individuals must be present and remain at the site during the

entire field testing of the engine generator: a. Manufacturer’s field engineer for the voltage regulator. b. Manufacturer’s field engineer for the governor and governor controller. c. Manufacturer’s field engineer for the switchgear. d. Load bank operator. e. Electrical contractor.


3.02 INSTALLATION

A. Test decal: 1. The testing laboratory shall affix a test decal on the exterior of equipment or

equipment enclosure of protective devices after performing electrical tests. 2. The test decal shall be color coded to communicate the condition of

maintenance of the protective. The color scheme for condition of maintenance of overcurrent protective devices shall be: a. White: electrically and mechanically acceptable. b. Yellow; minor deficiency not affecting fault detection and operation, but

minor electrical or mechanical condition exists. 3. The decal shall include the following information at a minimum:

a. Testing organization. b. Project identifier. c. Test date. d. Technician identifier.

3.03 COMMISSIONING


B. Testing and Training Phase: Installation Testing: 1. Also called "Field Acceptance Testing". 2. Panelboards:

a. Cleaning: 1) Visually inspect panelboard for evidence of discoloration, abnormal

dust accumulation, metal shards, or any other indication of overheating, wear, or other abnormal conditions prior to cleaning.

2) Clean cabinet with a brush, vacuum cleaner, or clean, dry, lint-free rags to remove any accumulation of dust, dirt, or other foreign matter. Do not use liquids, solvents or detergents when cleaning panelboards or components.

3) Avoid blowing dust into panelboards. Do not use a blower or compressed air.

4) Clean Supports, terminals, and other major insulating surfaces with clean, dry, lint-free rags or soft bristled brushes.

5) Remove dust, soot, grease, moisture, and foreign material from surface of circuit breakers.

b. General: 1) Compare equipment nameplate data with the Contract Documents. 2) Check panelboard circuit schedule for accuracy. 3) Verify appropriate anchorage, required area clearances, and correct

alignment. 4) Inspect overall general condition for physical damage. Check for

broken studs and loose or damaged wires, connector, terminations, etc. Check all bolts, nuts, washer, and pins for tightness. Tighten or use manufacture’s replacement parts as required.

5) Inspect cabinets for signs of rust, corrosion, or deteriorating paint. Inspect cabinets for evidence of localized heat damage to the paint. Investigate sources of heat. Repair painted surfaces.

6) Check that covers are in place and fastened. Plug any open unused knockouts.


7) Inspect panelboard for moisture. Seal off any cracks or openings which have allowed moisture to enter the cabinet. Inspect all component devices. Replace any components that show evidence of damage from moisture.

8) Look for any recent changes in sprinklers or other plumbing that might expose indoor panelboards to a source of liquids. Eliminate sources of water, moisture, or liquids, or provide adequate barriers to protect panelboards from sources of water, moisture, or liquids.

9) Inspect panelboards and internal components for evidence of overheating, arc spatter, sooty deposits, and tracking. Investigate and correct sources of arcing or overheating. Consult the panelboard manufacturer for recommendations.

10) Verify that fuse and/or circuit breaker sizes and types correspond to record drawings, if available, as well as to the circuit breaker’s address for microprocessor communications packages, if equipped.

11) Set adjustable circuit breakers in accordance with engineering coordination study supplied by contractor.

c. Terminations, Connections, and Lugs: 1) Inspect bolted electrical connections for high resistance using one of

the following methods: a) Use of low-resistance ohmmeter.

(1) Compare bolted connection resistance values to values of similar connections: (a) Investigate values which deviate from those of similar

bolted connections by more than 50 percent of the lowest value.

b) Verify tightness of accessible bolted electrical connections by the calibrated torque wrench method: (1) Refer to manufacturer’s instructions for proper foot-pound

levels or NETA ATS tables. 2) Inspect terminations, connection, and lugs for alignment, physical

damage, burns, corrosion, discoloration, flaking, heat damage, arcing, pitting, melting, deterioration, carbonization, cracks, chips, breaks, partial discharge, or moisture. Investigate and eliminate sources of any damage.

3) Follow manufacturer recommendations for cleaning, repairing, and replacing damaged parts.

4) Replace overheated connections. Tighten connections to proper to proper torque levels as specified above.

d. Conductors and raceways: 1) Inspect supply conductors and terminations for overheating,

discoloration, and oxidation. Investigate and correct any deficiencies. 2) Ensure the conductors are protected within their ampacities. 3) Visually check panelboard, cables, and raceways for proper bonding

and grounding. Correct improper bonding and grounding. 4) Inspect conductors for discoloration, arcing, pitting, melting, flaking of

insulation and/or metal parts. Repair or replace damaged components in accordance with manufacturer’s recommendations.

5) Inspect for frayed or broken wires. Replace or repair damaged components in accordance with manufacturer recommendations.

6) Inspect for frayed or broken wires. Replace or repair conductors as necessary.


7) Inspect conduits for moisture. Seal conduits which are a source of moisture and provide means to drain moisture away from the panelboard.

e. Circuit breakers: 1) Breakers rated less than 100 A:

a) Operate circuit breakers several times in order to exercise the mechanisms and the contacts, and to ensure smooth operation. Do not oil or grease parts of molded case circuit breakers.

b) Visually check circuit breakers for evidence of overheating and thermal damage. Investigate and eliminate sources of overheating.

c) Check circuit breakers for visual defects, chipping, cracks, breaks, burns, and deterioration. Replace damaged circuit breakers.

d) Verify correct operation of any auxiliary features such as trip and pickup indicators, zone interlocking, electrical close and trip operation, trip-free, and antipump function.

e) Inspect interchangeable trip-unit circuit breakers for tightness of trip units.

f) Check circuit breaker terminals and connections for tightness as specified above.

2) Breakers rated 100 A and higher: a) Perform visual and mechanical inspection as specified in this

Section. b) Perform electrical tests as specified in this Section.

3. Switchgear and switchboard: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding and required area

clearances. 4) Verify the unit is clean and all shipping bracing, loose parts, and

documentation shipped inside cubicles have been removed. 5) Verify that circuit breaker/fuse sizes and types correspond to the

approved submittals and the coordination study as well as to the circuit breakers address for microprocessor-communication packages.

6) Verify that current and voltage transformer ratios correspond to those indicated on the Drawings.

7) Verify that wiring connections are tight and that wiring is secure to prevent damage during routine operation of moving parts.

8) Inspect bolted electrical connections for high resistance using one of the following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by

the calibrated torque wrench method: (1) Refer to manufacturer’s instructions for proper foot-pound

levels or NETA ATS tables. 9) Verify operation and sequencing of interlocking systems:

a) Attempt closure on locked-open devices. b) Attempt to open locked-closed devices. c) Make/attempt key-exchanges in all positions.


10) Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.

11) Inspect insulators for evidence of physical damage or contaminated surfaces.

12) Verify correct barrier and shutter installation and operation. 13) Exercise all active components. 14) Inspect mechanical indicating devices for correct operation. 15) Verify that filters are in place and/or vents are clear. 16) Perform visual and mechanical inspection of instrument transformers

as specified in this Section. 17) Perform visual and mechanical inspection of surge arresters as

specified in this Section. 18) Inspect control power transformers:

a) Inspect for physical damage, cracked insulation, broken leads, tightness of connections, defective wiring, and overall general condition.

b) Verify that primary and secondary fuse/circuit breaker ratings match the submittal drawings.

c) Verify correct functioning of drawout disconnecting contacts grounding contacts, and interlocks.

b. Electrical tests: 1) Perform resistance measurements through bolted connections with a

low-resistance ohmmeter. 2) Perform insulation-resistance tests on each bus section, phase-to-

phase and phase-to-ground for 1 minute. a) Perform test in accordance with NETA ATS tables.

3) Perform a dielectric withstand voltage test on each bus section, each phase-to-ground with phases not under test grounded, in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. b) The test voltage shall be applied for 1 minute.

4) Perform insulation-resistance tests on control wiring with respect to ground. Applied potential shall be 500 VDC for 300-volt rated cable and 1,000 VDC for 600-volt rated cable. Apply the test voltage for 1 minute: a) For solid state devices that cannot tolerate the applied voltage,

follow the manufacturer’s recommendation. 5) Perform electrical tests on instrument transformers as specified in

this Section. 6) Perform ground-resistance tests:

a) Perform point-to-point tests to determine the resistance between the main grounding system and all major electrical equipment frames, system neutral and derived neutral points.

7) Test metering devices as specified in this Section. 8) Control power transformers:

a) Perform insulation-resistance tests. Perform measurements from winding-to-winding and each winding-to-ground: (1) Test voltages shall be in accordance with NETA ATS tables

or as specified by the manufacturer. (2) Perform a turns-ratio test on all tap positions.


b) Perform secondary wiring integrity test: (1) Disconnect transformer at secondary terminals and connect

secondary wiring to a rated secondary voltage source: (a) Verify correct potential at all devices.

c) Verify correct secondary voltage by energizing primary winding with system voltage: (1) Measure secondary voltage with the secondary wiring

disconnected. 9) Perform current injection tests on the entire current circuit of each

switchgear or switchboard: a) Perform current tests by secondary injection with magnitudes

such that a minimum current of 1.0 ampere flows in the secondary circuit: (1) Verify the correct magnitude of current at each device in the

circuit. 10) Perform system function tests. 11) Verify operation of space heaters. 12) Perform electrical tests of surge arresters as specified in this Section.

c. Test values: 1) Compare bolted connection resistance values to values of similar

connections: a) Investigate values which deviate from those of similar bolted

connections by more than 50 percent of the lowest value. 2) Bolt-torque levels shall be in accordance with manufacturer’s

published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 3) Insulation-resistance values of bus insulation shall be in accordance

with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. b) Investigate insulation values less than the allowable minimum. c) Do not proceed with dielectric withstand voltage tests until

insulation-resistance values are above minimum values. 4) If no evidence of distress or insulation failure is observed by the end

of the total time of voltage application during the dielectric withstand test, the test specimen is considered to have passed the test.

5) Instrument transformer test values shall be as specified in this Section.

6) Meter test values shall be as specified in this Section. 7) Investigate grounding system point-to-point resistance values that

exceed 0.5 ohm. 8) Control power transformers:

a) Insulation-resistance values of control power transformers shall be in accordance with manufacturer’s published data: (1) Refer to NETA ATS tables in the absence of manufacturer’s

published data. (2) Investigate insulation values less than the allowable

minimum.


b) Turns-ratio test results shall not deviate by more than 1/2 percent from either the adjacent coils or the calculated ratio. (1) Do not proceed with dielectric withstand voltage tests until

insulation-resistance values are above minimum values. c) Secondary wiring shall be as indicated on the Drawings and

specified in the Specifications. d) Secondary voltage shall be as indicated on the Drawings.

9) Current-injection tests shall prove current wiring is as indicated on the Drawings and specified in the Specifications.

10) Results of system function tests shall match the drawings and Specifications.

11) Heaters shall be operational. 12) Phasing checks shall prove the switchgear or switchboard phasing is

correct and in accordance with the system design. 13) Results of electrical tests on surge arresters shall be as specified in

this Section. 4. Dry type transformers:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify that resilient mounts are free and that any shipping brackets

have been removed. 5) Inspect equipment for cleanliness. 6) Inspect bolted electrical connections for high resistance using one of

the following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 7) Verify that as-left tap connections are as specified.


low-resistance ohmmeter. 2) Perform insulation-resistance tests winding-to-winding and each

winding-to-ground: a) Apply voltage in accordance with manufacturer’s published data.

(1) Refer to NETA ATS tables in the absence of manufacturer’s published data.

3) Calculate dielectric absorption ration or polarization index. 4) Verify correct secondary voltage, phase-to-phase and phase-to-

neutral after energization and before loading. c. Test values:

1) Compare bolted connection resistance values to values of similar connections: a) Investigate values which deviate from those of similar bolted



published data.


3) Tap connections are left as found unless otherwise specified. 4) Minimum insulation-resistance values of transformer insulation shall

be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. b) Investigate insulation values less than the allowable minimum.

5) The dielectric absorption ratio or polarization index shall not be less than 1.0.

6) Turns-ratio results should not deviate more than 1/2 percent from either the adjacent coils or calculated ratio.

7) Phase-to-phase and phase-to-neutral secondary voltages shall be in agreement with nameplate data.

5. Liquid-filled transformers: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect impact recorder before unloading. 4) Test dew point of tank gases if applicable. 5) Inspect anchorage, alignment, grounding and required clearances. 6) Verify the presence of PCB content labeling. 7) Verify removal of any shipping bracing after placement. 8) Verify the bushings are clean. 9) Verify that alarm, control and trip settings on temperature and level

indicators are as specified. 10) Verify operation of alarm, control, and trip circuits from temperature

and level indicators, pressure relief device, gas accumulator, and fault pressure relay, if applicable.

11) Verify that cooling fans operate correctly and that fan motors have correct overcurrent protection.



levels or NETA ATS tables. 13) Verify correct liquid level in tanks and bushings. 14) Verify valves are in the correct operating position. 15) Verify that positive pressure is maintained on gas-blanketed

transformers. 16) Perform inspections and mechanical tests as recommended by the

manufacturer. 17) Test load tap-changer in accordance with NETA ATS requirements. 18) Verify presence of transformer surge arresters. 19) Verify de-energized tap-changer position is left as specified.


low-resistance ohmmeter.


2) Perform insulation-resistance tests winding-to-winding and each winding-to-ground: a) Apply voltage in accordance with manufacturer’s published data:


b) Calculate polarization index. 3) Perform turns ratio tests at all tap positions. 4) Perform insulation power-factor or dissipation-factor tests on all

windings in accordance with test equipment manufacturer’s published data.

5) Perform power-factor or dissipation-factor tests on each bushing equipped with a power-factor/capacitance tap: a) In the absence of a power-factor/capacitance tap perform hot-

collar tests. b) Perform tests in accordance with test equipment manufacturer’s

published data. 6) Perform excitation-current tests in accordance with test equipment

manufacturer’s published data. 7) Perform sweep frequency response analysis tests. 8) Measure the resistance of each primary winding in each no-load tap

changer position. Measure the resistance of each secondary winding in each no-load tap changer position.

9) Remove a sample of insulating liquid in accordance with ASTM D923 and test per the following standards: a) Dielectric breakdown voltage: ASTM D877 or ASTM D1816. b) Acid neutralization number: ASTM D974. c) Interfacial tension: ASTM D971. d) Color: ASTM D1500. e) Visual condition: ASTM D1524. f) Water in insulating fluids: ASTM D1533.

10) Remove a sample of insulating liquid in accordance with ASTM D924. Sample shall be tested for the following: a) Dissolved-gas analysis: IEEE C57.104 or ASTM D3612.

11) Test instrument transformers as specified in this Section: 12) Test surge arresters as specified in this Section if applicable. 13) Test transformer neutral grounding impedance device if applicable. 14) Verify operation of cubicle or air terminal compartment space

heaters. c. Test values:

1) Alarm control, and trip circuits from temperature and level indicators as well as pressure relief device and fault pressure relay shall operate within manufacturer’s recommendations for their specified settings.

2) Cooling fans and pumps shall operate. 3) Compare bolted connection resistance values to values of similar




published data.


5) Liquid levels in the transformer tanks and bushings shall be within indicated tolerances.

6) Positive pressure shall be indicated on pressure gauge for gas-blanketed transformers.

7) Minimum insulation-resistance values of transformer insulation shall be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s


8) The polarization index shall be greater than 1.0: a) Compare to any previous values.

9) Turns-ratio test result shall not deviate by more than 1/2-percent from either the adjacent coils or the calculated ratio.

10) Maximum winding insulation power-factor/dissipation-factor values shall be in accordance with the manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 11) Investigate bushing power-factor values that vary from nameplate

values by more than 150 percent. Investigate bushing capacitance values that vary from nameplate values by more than 5 percent. Investigate bushing hot-collar test values that exceed 0.1 Watts.

12) Typical excitation-current test data pattern for a 3-legged core transformer is 2 similar current readings and 1 lower current reading.

13) Sweep frequency response analysis test results shall be comparable to previously obtained results.

14) Consult the manufacturer if winding-resistance test values vary by more than 2 percent from factory test values or between adjacent phases.

15) Investigate leakage reactance per phase test results that deviate from the average of the 3 readings by more than 3 percent. The 3 phase equivalent test results serve as a benchmark for future tests.

16) Core insulation values shall be comparable to previously obtained results but not be less than 1.0 megohm at 500 VDC.

17) Investigate the presence of oxygen in the nitrogen gas blanket. 18) Insulating liquid values shall be in accordance with NETA ATS

tables. 19) Evaluate results of dissolved-gas analysis in accordance with IEEE

C57.104. 20) Results of electrical tests on instrument transformers shall be as

specified in this Section. 21) Results of surge arrester tests shall be as specified in this Section. 22) Compare grounding impedance device results to the manufacturer’s

published data. 23) Heaters shall be operational.

6. Low voltage cables, 600 volt maximum: a. Visual and mechanical inspection:

1) Compare cable data with the Drawings and Specifications. 2) Inspect exposed sections of cable for physical damage and correct

connection as indicated on the Drawings. 3) Inspect bolted electrical connections for high resistance by one of the

following methods: a) Use of low-resistance ohmmeter.


b) Verify tightness of accessible bolted electrical connections by the calibrated torque wrench method: (1) Refer to manufacturer’s instructions for proper foot-pound

levels or NETA ATS tables. 4) Inspect compression applied connectors for correct cable match and

indentation. 5) Inspect for correct identification and arrangement. 6) Inspect cable jacket insulation and condition.


low-resistance ohmmeter. 2) Perform insulation resistance test on each conductor with respect to

ground and adjacent conductors: a) Applied potential shall be 500 volts dc for 300 volt rated cable

and 1,000 volts dc for 600 volt rated cable. b) Test duration shall be 1 minute.

3) Perform continuity tests to insure correct cable connection. 4) Verify uniform resistance of parallel conductors.



connections by more than 50 percent of the lowest value. 2) Insulation-resistance values shall be in accordance with

manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. b) Investigate values of insulation-resistance less than the

allowable minimum. 3) Cable shall exhibit continuity. 4) Deviations in resistance between parallel conductors shall be

investigated. 7. Medium voltage cables:

a. Visual and mechanical inspection: 1) Compare cable data with the Contract Documents. 2) Inspect exposed sections of cables for physical damage. 3) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 4) Inspect compression-applied connectors for correct cable match and

indentation. 5) Inspect shield grounding, cable support, and terminations. 6) Verify the visible bends meet or exceed ICEA and manufacturer’s

published minimum allowable bending radius. 7) If cables are terminated through window-type current transformers,

inspect to verify that neutral and ground conductors are correctly placed and that shields are correctly terminated for operation of protective devices.


8) Inspect for correct identification and arrangements. 9) Inspect jacket insulation and condition.

b. Electrical tests: 1) Perform resistance measurements through bolted connections with

low-resistance ohmmeter. 2) Perform an insulation-resistance test individually on each conductor

with all other conductors and shields grounded: a) Apply voltage in accordance with manufacturer’s published data:


3) Perform shield-continuity test on each power cable. 4) Perform cable and time domain reflectometer (TDR) measurements

on each conductor. 5) In accordance with ICEA, IEC, IEEE, and other power cable

consensus standards, testing can be performed by means of direct current, power frequency alternating current, very low frequency alternating current, or damped alternating current. These sources may be used to perform insulation-resistance tests, and baseline diagnostic tests such as partial discharge analysis, and power factor or power dissipation factor. The selection shall be made after an evaluation of the available test methods and a review of the installed cable system. Some of available test methods are as follows: a) Dielectric withstand:

(1) Direct current dielectric withstand voltage. (2) Very low frequency dielectric withstand voltage. (3) Power frequency dielectric withstand voltage. (4) Damped alternating current voltage.

b) Baseline diagnostic tests: (1) Power factor/dissipation factor (tan delta):

(a) Power frequency. (b) Very low frequency.

(2) Direct current insulation-resistance. (3) Partial discharge:

(a) Online (50/60 hertz). (b) Offline: (c) Power frequency. (d) Very low frequency.





published data. 3) The minimum bend radius to which insulated cables may be bent for

permanent training shall be in accordance with NETA ATS tables. 4) Insulation-resistance values shall be in accordance with


published data.


b) Investigate values of insulation-resistance less than the allowable minimum.

5) Shielding shall exhibit continuity: a) Investigate resistance values in excess of 10 ohms per 1,000

feet of cable. 6) If no evidence of distress of insulation failure is observed by the end


7) Based on the test methodology chosen, refer to the applicable standards or manufacturer’s literature for acceptable values.

8. Metal enclosed bus duct: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspected physical and mechanical condition. 3) Inspect for proper bracing, suspension alignment, and grounding. 4) Verify correct connection in accordance with the one-line diagrams. 5) Inspect bolted electrical connections for high resistance using one of

the following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of bolted connections and bus joints by

calibrated torque wrench method: (1) Refer to manufacturer’s instructions for proper foot-pound

levels or NETA ATS tables. 6) Confirm physical orientation in accordance with the manufacturer’s

labels to ensure adequate cooling. b. Electrical tests:

1) Perform resistance measurements through bolted connections and bus joints with a low-resistance ohmmeter.

2) Measure insulation-resistance of each busway, phase-to-phase and phase-to-ground for 1 minute, in accordance with NETA ATS tables.

3) Perform a dielectric withstand voltage test on each busway, phase-to-ground with phases not under test grounded, in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. b) Where no dc test value is shown in the NETA ATS tables, ac

value shall be used. c) The test voltage shall be applied for 1 minute.

4) Measure resistance of assembled busway sections on insulated busway and compare values with adjacent phases: a) Compare values with adjacent phases.

5) Perform phasing test on each busway tie section energized by separate sources. Tests must be performed from their permanent sources.

6) Verify operation of busway space heaters. 7) Compare bolted connection resistance values to values of similar


connections by more than 50 percent of the lowest value.


8) Bolt-torque levels should be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. c. Test values:


connections by more than 50 percent of the lowest value. 2) Insulation-resistance test voltages and resistance values shall be in

accordance with manufacturer’s published: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. b) Minimum resistance values are for a nominal 1,000-foot busway

run. Use the following formula to convert the measured resistance value to the 1,000-foot nominal value:

Converted values of insulation-resistance less than those in NETA ATS tables or manufacturer’s minimum should be investigated. c) Dielectric withstand voltage tests shall not proceed until

insulation-resistance levels are raised above minimum values. 3) If no evidence of distress or insulation failure is observed by the end


4) Microhm or dc millivolt drop values shall not exceed the high levels of the normal range as indicated in the manufacturer’s published data: a) If manufacturer’s published data is not available, investigate

values which deviate from those of similar bus connections and sections by more than 50 percent of the lowest value.

5) Phasing test results shall indicate the phase relationships are in accordance with system design.

6) Heaters shall be operational. 9. Low voltage molded case and insulated case circuit breakers:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage and alignment. 4) Verify the unit is clean. 5) Operate the circuit breaker to ensure smooth operation. 6) Inspect bolted electrical connections for high resistance by one of the

following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 7) Perform adjustments for final protective device settings in

accordance with the coordination study.

1000

runofLength x Resistance Measured= R ft1000



low-resistance ohmmeter. 2) Perform insulation-resistance tests for 1 minute on each pole, phase-

to-phase and phase-to-ground with the circuit breaker closed and across each open pole: a) Apply voltage in accordance with manufacturer’s published data. b) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 3) Perform a contact/pole-resistance test. 4) Determine long-time pickup and delay by primary current injection. 5) Determine short-time pickup and delay by primary current injection. 6) Determine ground-fault pickup and delay by primary current injection. 7) Determine instantaneous pickup value by primary current injection. 8) Perform minimum pickup voltage tests on shunt trip and close coils in

accordance with manufacturer’s published data. 9) Verify correct operation of any auxiliary features such as trip and

pickup indicators, zone interlocking, electrical close and trip operation, trip-free, anti-pump function and trip unit battery condition: a) Reset all trip logs and indicators.

10) Verify operation of charging mechanism. c. Test values:




published data. 3) Insulation-resistance values shall be in accordance with



allowable minimum. 4) Microhm or dc millivolt drop values shall not exceed the high levels of

the normal range as indicated in the manufacturer’s published data: a) If manufacturer’s data is not available, investigate any values

which deviate from adjacent poles or similar breakers by more than 50 percent of the lowest value.

5) Long-time pickup values shall be as specified, and the trip characteristic shall not exceed manufacturer’s published time-current characteristic tolerance band including adjustment factors: a) If manufacturer’s curves are not available, trip times shall not

exceed the value shown in NETA ATS tables. 6) Short-time pickup values shall be as specified, and the trip

characteristic shall not exceed manufacturer’s published time-current tolerance band.

7) Ground fault pickup values shall be as specified, and the trip characteristic shall not exceed manufacturer’s published time-current tolerance band.


8) Instantaneous pickup values shall be as specified and within manufacturer’s published tolerances: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 9) Pickup values and trip characteristics shall be within manufacturer’s

published tolerances. 10) Breaker open, close, trip, trip-free, anti-pump, and auxiliary features

shall function as designed. 11) The charging mechanism shall operate in accordance with

manufacturer’s published data. 10. Low voltage air power circuit breakers - ANSI class breakers:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify that all maintenance devices are available for servicing and

operating the breaker. 5) Verify the unit is clean. 6) Verify the arc chutes are intact. 7) Inspect moving and stationary contacts for condition and alignment. 8) Verify that primary and secondary contact wipe and other dimensions

vital to satisfactory operation of the breaker are correct. 9) Perform all mechanical operator and contact alignment tests on both

the breaker and its operating mechanism in accordance with manufacturer's published data.

10) Inspect bolted electrical connections for high resistance by one of the following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 11) Verify cell fit and element alignment. 12) Verify racking mechanism operation. 13) Lubrication requirements:

a) Verify appropriate lubrication on moving current-carrying parts. b) Verify appropriate lubrication on moving and sliding surfaces.

14) Perform adjustments for final protective device settings in accordance with the coordination study.

15) Record as-found and as-left operation counter readings. b. Electrical tests:

1) Perform resistance measurements through bolted connections with a low-resistance ohmmeter.

2) Perform insulation-resistance tests for 1 minute on each pole, phase-to-phase and phase to ground with the circuit breaker closed, and across each open pole: a) Test voltage shall be in accordance with manufacturer’s

published data. b) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 3) Perform a contact/pole-resistance test. 4) Determine long-time pickup and delay by primary current injection.


5) Determine short-time pickup and delay by primary current injection. 6) Determine ground-fault pickup and delay by primary current injection. 7) Determine instantaneous pickup value by primary current injection. 8) Perform minimum pickup voltage tests on shunt trip and close coils in

accordance with manufacturer’s published data. 9) Verify correct operation of any auxiliary features such as trip and

pickup indicators, zone interlocking, electrical close and trip operation, trip-free, anti-pump function and trip unit battery condition: a) Reset all trip logs and indicators.

10) Verify operation of charging mechanism. c. Test values:




published data. 3) Settings shall comply with coordination study requirements. 4) Operations counter shall advance 1 digit per close-open cycle. 5) Insulation-resistance values shall be in accordance with






7) Long-time pickup values shall be as specified, and the trip characteristic shall not exceed manufacturer’s published time-current characteristic tolerance band including adjustment factors: a) If manufacturer’s curves are not available, trip times shall not

exceed the value shown in NETA ATS tables. 8) Short-time pickup values shall be as specified, and the trip

characteristic shall not exceed manufacturer’s published time-current tolerance band.

9) Ground fault pickup values shall be as specified, and the trip characteristic shall not exceed manufacturer’s published time-current tolerance band.

10) Instantaneous pickup values shall be as specified and within manufacturer’s published tolerances: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 11) Pickup values and trip characteristics shall be within manufacturer’s

published tolerances.


12) Minimum pickup voltage of the shunt trip and close coils shall conform to the manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 13) Auxiliary features shall operate in accordance with manufacturer’s

published data. 14) The charging mechanism shall operate in accordance with

manufacturer’s published data. 11. Medium voltage vacuum circuit breakers:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage and alignment and grounding. 4) Verify that all maintenance devices, such as special tools and

gauges specified by the manufacturer, are available for servicing and operating the breaker.

5) Verify the unit is clean. 6) Perform all mechanical operation tests on the operating mechanism

in accordance with manufacturer’s published data. 7) Measure critical distances such as contact gap as recommended by

the manufacturer. 8) Inspect bolted electrical connections for high resistance by one of the

following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 9) Verify cell fit and element alignment. 10) Verify racking mechanism operation. 11) Lubrication requirements:


12) Perform contact-timing test. 13) Record as-found and as-left operation counter readings.



to-phase and phase to ground with the circuit breaker closed, and across each open pole: a) Test voltage shall be in accordance with manufacturer’s


published data. 3) Perform a static contact/pole-resistance test. 4) Perform minimum pickup voltage tests on trip and close coils in

accordance with manufacturer’s published data. 5) Verify correct operation of any auxiliary features such as electrical

close and trip operation, trip-free and anti-pump function. 6) Trip circuit breaker by operation of each protective device.

a) Reset all trip logs and indicators.


7) Perform vacuum bottle integrity (dielectric withstand) test across each vacuum bottle with the breaker in the open position in strict accordance with the manufacturer’s published data. Do not exceed the maximum voltage stipulated for this test: a) Provide adequate barriers and protection against x-radiation

during this test. b) Do not perform this test unless the contact displacement of each

interrupter is within manufacturer’s published tolerance. c) Be aware that some dc high-potential test sets are half-wave

rectified and may produce peak voltages in excess of breaker manufacturer’s recommended maximum.

8) Perform a dielectric withstand voltage test in accordance with manufacturer’s published data.

9) Verify operation of heaters. 10) Test instrument transformers as specified in this Section.

c. Test values: 1) Critical distance measurements such as contact gap shall be in

accordance with manufacturer’s published data. 2) Compare bolted connection resistance values to values of similar




published data. 4) Contact timing values shall be in accordance with manufacturer’s

published data. 5) Trip/close coil current values shall be in accordance with

manufacturer’s published data. 6) Travel and velocity values shall be accordance with manufacturer’s

published data. 7) Operations counter shall advance 1 digit per close-open cycle. 8) Insulation-resistance values shall be in accordance with






10) Dynamic contact resistance values shall be in accordance with manufacturer’s published data.

11) Minimum pickup voltage of the trip and close coils shall conform to the manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 12) Auxiliary features shall operate in accordance with manufacturer’s

published data.


13) Protective devices shall operate the breaker per system design. 14) Power-factor or dissipation-factor values shall be compared to

manufacturer’s published data: a) In the absence manufacturer’s published data the comparison

shall be made to similar breakers. 15) Power-factor or dissipation-factor and capacitance values shall be

within 10 percent of nameplate ratings for bushings. Hot collar tests are evaluated on a milliampere/milliwatt loss basis and the results shall be compared to values of similar bushings.

16) If no evidence of distress of insulation failure is observed by the end of the total time of voltage application during the vacuum bottle integrity test, the test specimen is considered to have passed the test.

17) If no evidence of distress of insulation failure is observed by the end of the total time of voltage application during the dielectric withstand test, the test specimen is considered to have passed the test.

18) Heaters shall be operational. 19) The results of instrument transformer tests shall be as specified in

this Section. 12. Protective relays, electromechanical and solid-state:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect relays and cases for physical damage. Remove shipping

restraint material. 3) Verify the unit is clean. 4) Relay case:

a) Tighten case connections. b) Inspect cover for correct gasket seal. c) Clean cover glass. Inspect shorting hardware, connection

paddles, and knife switches. d) Remove any foreign material from the case. e) Verify target reset.

5) Relay: a) Inspect relay for foreign material, particularly in disk slots of the

damping and electromagnets. b) Verify disk clearance. Verify contact clearance and spring bias. c) Inspect spiral spring convolutions. Inspect disk and contacts for

freedom of movement and correct travel. Verify tightness of mounting hardware and connections. Burnish contacts. Inspect bearings and pivots.

6) Set relays in accordance with coordination study. b. Electrical tests:

1) Perform an insulation-resistance test on each circuit-to-frame. Procedures for performing insulation-resistance tests on solid-state relays shall be determined from the relay manufacturer’s published data.

2) Inspect targets and indicators: a) Determine pickup and dropout of electromechanical targets. b) Verify operation of all light-emitting diode indicators. c) Set contrast for liquid-crystal display readouts.


c. Control verification: 1) Functional tests:

a) Verify that each of the relay contacts performs its intended function in the control scheme including breaker trip tests, close inhibit tests, 86 lockout tests, and alarm functions.

2) In-service monitoring: a) After the equipment is initially energized, measure magnitude

and phase angle of all inputs and compare to expected value. d. Test values:

1) When not otherwise specified, use manufacturer’s recommended tolerances.

2) When critical test points are specified, the relay shall be calibrated to those points even though other test points may be out of tolerance.

13. Protective relays, microprocessor based: a. Visual and mechanical inspection:

1) Record model number, style number, serial number, firmware revision, software revision and rated control voltage.

2) Verify operation of light-emitting diodes, display, and targets. 3) Record passwords for all access levels. 4) Clean the front panel and remove foreign material from the case. 5) Check tightness of connections. 6) Verify that the frame is grounded in accordance with manufacturer’s

instructions. 7) Set the relay in accordance with the coordination study. 8) Download settings from the relay. Print a copy of the settings for the

report and compare the settings to those specified in the coordination study.

9) Connect back-up battery. 10) Set clock if not controlled externally. 11) Check with manufacturer for applicable firmware updates and

product recalls. 12) Inspect, clean and verify operation of shorting devices.

b. Electrical tests: 1) Perform insulation-resistance tests from each circuit to the grounded

frame in accordance with the manufacturer’s published data. 2) Apply voltage or current to all analog inputs and verify correct

registration of the relay meter functions. 3) Verify SCADA metering values at remote terminals. 4) Functional operation:

a) Check functional operation of each element used in the protection scheme.

b) 2/62 timing relay: (1) Determine time delay. (2) Verify operation of instantaneous contacts.

c) 21 distance relay: (1) Determine maximum reach. (2) Determine maximum torque angle. (3) Determine offset. (4) Plot impedance circle.

d) 24 volts/hertz relay: (1) Determine pickup frequency at rated voltage. (2) Determine pickup frequency at a second voltage level.


(3) Determine time delay. e) 25 sync check relay:

(1) Determine closing zone at rated voltage. (2) Determine maximum voltage differential that permits

closing at zero degrees. (3) Determine live line, live bus, dead line, and dead bus

setpoints. (4) Verify dead bus/live line, dead line/live bus and dead

bus/dead line control functions. (5) Determine time delay.

f) 27 undervoltage relay: (1) Determine dropout voltage. (2) Determine time delay. (3) Determine time delay at a second point on the timing curve

for inverse time relays. g) 32 directional power relay:

(1) Determine minimum pickup at maximum torque angle. (2) Determine closing zone. (3) Determine maximum torque angle. (4) Determine time delay. (5) Verify time delay at a second point on the timing curve for

inverse time relays. (6) Plot the operating characteristic.

h) 40 loss of field (impedance) relay: (1) Determine maximum reach. (2) Determine maximum torque angle. (3) Determine offset. (4) Plot impedance circle.

i) 46 current balance relay: (1) Determine pickup of each unit. (2) Determine percent slope. (3) Determine time delay.

j) 46N negative sequence current relay: (1) Determine negative sequence alarm level. (2) Determine negative sequence minimum trip level. (3) Determine maximum time delay. (4) Verify 2 point on the (I2)2t curve.

k) 47 phase sequence or phase balance voltage relay: (1) Determine positive sequence voltage to close the normally

open contact. (2) Determine positive sequence voltage to open the normally

closed contact (undervoltage trip). (3) Verify negative sequence trip. (4) Determine time delay to close the normally open contact

with sudden application of 120 percent of pickup. (5) Determine time delay to close the normally closed contact

upon removal of voltage when previously set to rated system voltage.

l) 49R thermal replica relay: (1) Determine time delay at 300 percent of setting. (2) Determine a second point on the operating curve. (3) Determine pickup.


m) 49T temperature (RTD) relay: (1) Determine trip resistance. (2) Determine reset resistance.

n) 50 instantaneous overcurrent relay: (1) Determine pickup. (2) Determine dropout. (3) Determine time delay.

o) 51 time overcurrent: (1) Determine minimum pickup. (2) Determine time delay at 2 points on the time current curve.

p) 55 power factor relay: (1) Determine tripping angle. (2) Determine time delay.

q) 59 overvoltage relay: (1) Determine overvoltage pickup. (2) Determine time delay to close the contact with sudden

application of 120 percent of pickup. r) 60 voltage balance relay:

(1) Determine voltage difference to close the contacts with 1 source at rated voltage.

(2) Plot the operating curve for the relay. s) 63 transformer sudden pressure relay:

(1) Determine rate-of-rise or the pickup level of suddenly applied pressure in accordance with manufacturer’s published data.

(2) Verify operation of the 63 FPX seal-in circuit. (3) Verify trip circuit to remote operating device.

t) 64 ground detector relay: (1) Determine maximum impedance to ground causing relay

pickup. u) 67 directional overcurrent relay:

(1) Determine directional unit minimum pickup at maximum torque angle.

(2) Determine closing zone. (3) Determine maximum torque angle. (4) Plot operating characteristics. (5) Determine overcurrent unit pickup. (6) Determine overcurrent unit time delay at 2 points on the

time current curve. v) 79 reclosing relay:

(1) Determine time delay for each programmed reclosing interval.

(2) Verify lockout for unsuccessful reclosing. (3) Determine reset time. (4) Determine close pulse duration. (5) Verify instantaneous overcurrent lockout.

w) 81 frequency relay: (1) Verify frequency setpoints. (2) Determine time delay. (3) Determine undervoltage cutoff.

x) 85 pilot wire monitor: (1) Determine overcurrent pickup.


(2) Determine undercurrent pickup. (3) Determine pilot wire ground pickup level.

y) 87 differential: (1) Determine operating unit pickup. (2) Determine the operation of each restraint unit. (3) Determine slope. (4) Determine harmonic restraint. (5) Determine instantaneous pickup. (6) Plot operating characteristics for each restraint.

5) Control verification: a) Functional tests:

(1) Check operation of all active digital inputs. (2) Check all output contacts or SCRs preferably by operating

the controlled device such as circuit breaker, auxiliary relay or alarm.

(3) Check all internal logic functions used in the protection scheme.

(4) For pilot schemes, perform a loop-back test to check the receive and transmit communications circuits.

(5) Upon completion of testing reset all min/max recorders, communications statistics, fault counters, sequence of events recorder and all event records.

(6) Verify trip and close coil monitoring functions. (7) Verify setting change alarm to SCADA. (8) Verify relay SCADA communication and indications such as

protection operate, protection fail, communication fail, fault recorder trigger.

(9) Verify all communication links are operational. (10) Light-emitting diodes, displays and targets should

illuminate. (11) Relay should be clean and operational. (12) Settings and logic should agree with the most recent

engineering files. (13) Verify relay displays the correct date and time.

b) Insulation-resistance values should be in accordance with manufacturer’s published data. (1) Investigate values of insulation resistance less than the

manufacturer’s recommendation. c) Voltage and current analog readings should be in accordance

with manufacturer’s published tolerances. d) SCADA readings should be in accordance with manufacturer’s

published tolerances. e) Operation of protection elements should be within the

manufacturer’s published tolerances. f) Control verification inputs, outputs, and protection schemes

should operate per the design. Results should be within manufacturer’s published tolerances.

14. Instrument transformers - current transformers: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Verify correct connection of transformers with system requirements.


4) Verify that adequate clearances exist between primary and secondary circuit wiring.

5) Verify the unit is clean. 6) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 7) Verify that all required grounding and shorting connections provide

contact. 8) Verify appropriate lubrication on moving current-carrying parts and

on moving and sliding surfaces. b. Electrical tests:


2) Perform insulation-resistance test of each current transformer and its secondary wiring with respect to ground at 1,000 VDC for 1 minute: a) For solid state devices that cannot tolerate the applied voltage,

follow the manufacturer’s recommendation. 3) Perform a polarity test of each current transformer in accordance with

IEEE C57.13.1. 4) Perform a ratio verification test using the voltage or current method in

accordance with IEEE C57.13.1. 5) Perform an excitation test on current transformers used for relaying

applications in with accordance with IEEE C57.13.1. 6) Measure current circuit burdens at transformer terminals in

accordance with IEEE C57.13.1. 7) When applicable perform insulation-resistance tests on the primary

winding with the secondary grounded: a) Test voltages shall be in accordance with NETA ATS tables.

8) Perform power-factor or dissipation-factor tests in accordance with test equipment manufacturer’s published data.

9) Verify that current transformer secondary circuits are grounded and have only 1 grounding point in accordance with IEEE C57.13.3: a) That grounding point should be located as specified by the

Engineer in the Contract Documents. c. Test values:




published data. 3) Insulation-resistance values of instrument transformers shall be in

accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 4) Polarity results shall agree with transformer markings.


5) Ratio errors shall be in accordance with IEEE C57.13. 6) Excitation results for current transformers shall match the curve

supplied by the manufacturer or be in accordance with IEEE C57.13.1.

7) Measured burdens shall be compared to instrument transformer ratings.

8) If no evidence of distress or insulation failure is observed by the end of the total time of voltage application during the dielectric withstand test, the primary winding is considered to have passed the test.

9) Power-factor or dissipation-factor values shall be compared to manufacturer’s published data: a) In the absence manufacturer’s published data, use the test

equipment manufacturer's published data. 10) Test results shall indicate that the circuits have only 1 grounding

point. 15. Instrument transformers - voltage transformers:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Verify correct connection of transformers with system requirements. 4) Verify that adequate clearances exist between primary and

secondary circuit wiring. 5) Verify the unit is clean. 6) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 7) Verify that all required grounding and connections provide contact. 8) Verify correct primary and secondary fuse sizes for voltage

transformers. 9) Verify appropriate lubrication on moving current-carrying parts and

on moving and sliding surfaces. 10) Perform as-left tests.

b. Electrical tests - voltage transformers: 1) Perform resistance measurements through bolted connections with a

low-resistance ohmmeter. 2) Perform insulation-resistance tests winding-to-winding and winding-

to-ground: a) Test voltage shall be applied for 1 minute in accordance with

NETA ATS requirements. b) For solid state devices that cannot tolerate the applied voltage,

follow the manufacturer’s recommendation. 3) Perform a polarity test on each voltage transformer to verify the

polarity marks on H1- X1 relationship as applicable. 4) Perform a turns ratio test on all tap positions. 5) Measure voltage circuit burdens at transformer terminals.


6) Perform a dielectric withstand test on the primary windings with the secondary windings grounded: a) The dielectric voltage shall be in accordance with NETA ATS

tables. b) Apply the test voltage for 1 minute.

7) Perform power-factor or dissipation-factor tests in accordance with test equipment manufacturers published data.

8) Verify that voltage transformer secondary circuits are grounded and have only 1 grounding point in accordance with IEEE C57.13.3: a) That grounding point should be located as specified by the

Engineer in the Contract Documents. c. Test values:




published data. 3) Insulation-resistance values of instrument transformers shall be in


published data. 4) Polarity results shall agree with transformer markings. 5) Ratio errors shall be in accordance with IEEE C57.13. 6) Measured burdens shall be compared to instrument transformer

ratings. 7) If no evidence of distress or insulation failure is observed by the end

of the total time of voltage application during the dielectric withstand test, the primary winding is considered to have passed the test.

8) Power-factor or dissipation-factor values shall be compared to manufacturer’s published data: a) In the absence manufacturer’s published data, use the test

equipment manufacturer's published data. 9) Test results shall indicate that the circuits have only 1 grounding

point. 16. Metering devices, microprocessor based:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect meters and cases for physical damage. 3) Clean front panel. 4) Verify tightness of electrical connections. 5) Record the following:

a) Model number. b) Serial number. c) Firmware revision. d) Software revision. e) Rated control voltage.

6) Verify operation of display and indicating devices. 7) Record passwords.


8) Verify the unit is grounded in accordance with the manufacturer's instructions.

9) Set all required parameters including instrument transformer ratios, system type, frequency, power demand methods/intervals, and communications requirements.

b. Electrical tests: 1) Apply voltage or current as appropriate to each analog input and

verify correct measurement and indication. 2) Confirm correct operation and setting of each auxiliary input/output

feature including mechanical relay, digital and analog. 3) After initial system energization, confirm measurements and

indications are consistent with loads present. c. Test values:

1) Nameplate data shall match the Contract Documents. 2) Tightness of electrical connections shall ensure a low resistance

connection. 3) Display and indicating devices shall operate per manufacturer's

published data. 4) Measurement and indication of applied voltages and currents shall

be within the manufacturer's published tolerances for accuracy. 5) All auxiliary input/output features shall operate per settings and

manufacturer's published data. 6) Measure and indications shall be consistent with energized system

loads. 17. Grounding systems:

a. Visual and mechanical inspection: 1) Inspect ground system for compliance with the Contract Documents,

and the NEC. 2) Inspect physical and mechanical condition. 3) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 4) Inspect anchorage.


low-resistance ohmmeter. 2) Perform fall of potential test or alternative test in accordance with

IEEE 81 on the main grounding electrode or system. 3) Perform point-to-point tests to determine the resistance between the

main grounding system and all major electrical equipment frames, the system neutral and any derived neutral points.

c. Test values: 1) Grounding system electrical and mechanical connections shall be

free of corrosion. 2) Compare bolted connection resistance values to values of similar




3) Bolt-torque levels shall be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 4) The resistance between the main grounding electrode and ground

shall be as specified in the Project Technical Requirements. 5) Investigate point-to-point resistance values that exceed 0.5 ohm.

18. Rotating machinery, ac induction motors and generators: a. Visual and mechanical inspection:

1) Compare equipment nameplate information with the Contract Documents.

2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Inspect air baffles, filter media, cooling fans, slip rings, brushes, and

brush rigging 5) Inspect bolted electrical connections for high resistance using one or

more of the following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 6) Verify correct application of appropriate lubrication and lubrication

systems. 7) Verify that resistance temperature detector (RTD) circuits conform to

that indicated on the Drawings. b. Electrical tests - AC Induction:


2) Perform insulation-resistance test in accordance with IEEE 43: a) On motors 200 horsepower and smaller, test duration shall be

1 minute. Calculate dielectric absorption ratio for 60/30 second periods.

b) On motors larger than 200 horsepower, test duration shall be 10 minutes. Calculate polarization index.

3) On machines rated at 2,300 volts and greater, perform dielectric withstand voltage tests in accordance with: a) IEEE 95 for dc dielectric withstand voltage tests. b) NEMA MG1 for ac dielectric withstand voltage tests.

4) Perform phase-to-phase stator resistance test on machines rated at 2,300 volts and greater.

5) Perform insulation-resistance test on insulated bearings in accordance with manufacturer’s published data.

6) Test surge protection devices as specified in this Section. 7) Test motor starter as specified in this Section. 8) Perform resistance tests on resistance temperature detector (RTD)

circuits. 9) Verify operation of motor space heater, if applicable.

c. Test values: 1) Inspection:

a) Air baffles shall be clean and installed in accordance with the manufacturer’s published data.


b) Filter media shall be clean and installed in accordance with the manufacturer’s published data.

c) Cooling fans shall operate. d) Slip ring alignment shall be within manufacturer’s published

tolerances. e) Brush alignment shall be within manufacturer’s published

tolerances. f) Brush rigging shall be within manufacturer’s published

tolerances. 2) Compare bolted connection resistance values to values of similar




published data. 4) Air-gap spacing and machine alignment shall be in accordance with

manufacturer’s published data. 5) The recommended minimum insulation-resistance (IR1 min) test

results in megohms shall be in accordance with NETA ATS tables. a) The polarization index value shall not be less than 2.0. b) The dielectric absorption ratio shall not be less than 1.4.

6) If no evidence of distress or insulation failure is observed by the end of the total time of voltage application during the dielectric withstand test, the test specimen is considered to have passed the test.

7) Investigate phase-to-phase stator resistance values that deviate by more than 5 percent.

8) Power factor or dissipation factor values shall be compared to manufacturer’s published data: a) In the absence of manufacturer’s published data, compare

values of similar machines. 9) Tip-up values shall indicate no significant increase in power factor. 10) If no evidence of distress, insulation failure, or waveform nesting is

observed by the end of the total time of voltage application during the surge comparison test, the test specimen is considered to have passed the test.

11) Bearing insulation-resistance measurements shall be within manufacturer’s published tolerances: a) In the absence of manufacturer’s published data, compare

values of similar machines. 12) Test results of surge protection devices shall be as specified in this

Section. 13) Test results of motor starter equipment shall be as specified in this

Section. 14) RTD circuits shall conform to the design intent and machine

protection device manufacturer’s published data. 15) Heaters shall be operational. 16) Vibration amplitudes of the uncoupled and unloaded machine shall

be in accordance with manufacturer’s published data: a) In the absence of manufacturer’s published data, vibration

amplitudes shall not exceed values in NETA ATS tables.


b) If values exceed those in the NETA ATS tables, perform a complete vibration analysis.

19. Rotating machinery, synchronous motors and generators: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Inspect air baffles, filter media, cooling fans, slip rings, brushes, and

brush rigging. 5) Inspect bolted electrical connections for high resistance using one or

more of the following methods: a) Use of low-resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 6) Perform special tests such as air-gap spacing and machine

alignment. 7) Manually rotate the rotor and check for problems with the bearings or

shaft. 8) Rotate the shaft and measure and record the shaft extension runout. 9) Verify the application of appropriate lubrication and lubrication

systems. 10) Verify that resistance temperature detector (RTD) circuits conform to

that indicated on the Drawings. b. Electrical tests:


2) Perform insulation-resistance tests in accordance with IEEE 43. a) Machines larger than 200 horsepower (150 kilowatts):

(1) Test duration shall be for 10 minutes. Calculate polarization index.

b) Machines 200 horsepower (150 kilowatts) and less: (1) Test duration shall be for 1 minute. Calculate dielectric-

absorption ratio. 3) On machines rated at 2,300 volts and greater perform dielectric

withstand voltage tests in accordance with: a) IEEE 95 for dc dielectric withstand voltage tests. b) NEMA MG1 for ac dielectric withstand voltage tests.

4) Perform phase-to-phase stator resistance test on machines 2,300 volts and greater.

5) Perform insulation-resistance test on insulated bearings in accordance with manufacturer’s published data.

6) Test surge protection devices as specified in this Section. 7) Test motor starter as specified in this Section. 8) Perform resistance tests on resistance temperature detector (RTD)

circuits. 9) Verify operation of machine space heater, if applicable. 10) Perform insulation-resistance tests on the main rotating field winding,

the exciter-field winding, and the exciter-armature winding in accordance with IEEE 43.


11) Measure resistance of machine-field winding, exciter-stator winding, exciter-rotor windings, and field discharge resistors.

12) Prior to re-energizing, apply voltage to the exciter supply and adjust exciter-field current to nameplate value.

13) Verify that the field application timer and the enable timer for the power-factor relay have been tested and set to the motor drive manufacturer’s recommended values.

c. Test values: 1) Inspection:

a) Air baffles shall be clean and installed in accordance with manufacturer’s published data.

b) Filter media shall be clean and installed in accordance with manufacturer’s published data.

c) Cooling fans shall operate. d) Slip ring alignment shall be within manufacturer’s published

tolerances. e) Brush alignment shall be within manufacturer’s published

tolerances. f) Brush rigging shall be in accordance with manufacturer’s

published data. 2) Compare bolted connection resistance values to values of similar

connections: a) Investigate any values that deviate from similar bolted

connections by more than 50 percent of the lowest value. 3) Bolt-torque levels should be in accordance with manufacturer’s


published data. 4) Air-gap spacing and machine alignment shall be in accordance with

manufacturer’s published data. d. Test values - electrical:

1) Compare bolted connection resistance values to values of similar connections: a) Investigate any values that deviate from similar bolted

connections by more than 50 percent of the lowest value. 2) The recommended minimum insulation-resistance (IR 1 min) test

results in megohms shall be in accordance with NETA ATS tables. a) The polarization index value shall not be less than 2.0. b) The dielectric absorption ratio shall not be less than 1.4.


4) Investigate phase-to-phase stator resistance values that deviate by more than 5 percent.

5) Power-factor or dissipation-factor values shall be compared to manufacturer’s published data: a) In the absence of manufacturer’s published data, the

comparison shall be made to similar machines. 6) Tip-up values shall indicate no significant increase in power factor or

dissipation factor. 7) If no evidence of distress, insulation failure, or lack of waveform

nesting is observed by the end of the total time of voltage application


during the surge comparison test, the test specimen is considered to have passed the test.

8) Insulation-resistance of bearings shall be within manufacturer’s published tolerances: a) In the absence of manufacturer’s published tolerances, the

comparison shall be made to similar machines. 9) Test results of surge protection devices shall be as specified in this

Section. 10) Test results of motor starter equipment shall be as specified in this

Section. 11) RTD circuits shall be in accordance with system design intent and

machine protection device manufacturer’s published data. 12) Heaters shall be operational. 13) Vibration amplitudes of the uncoupled and unloaded machine shall

be in accordance with manufacturer’s published data: a) In the absence of manufacturer’s published data, vibration

amplitudes shall not exceed values in NETA ATS tables. b) If values exceed those in NETA ATS tables, perform complete

vibration analysis. 14) The individual pole-pole ac voltage drop shall not exceed 10 percent

variance from the average value (average value = test voltage divided by number of coils) applicable to all of the poles.

15) If no evidence of distress or insulation failure is observed by the end of the total time of voltage application during the dielectric withstand test, the winding is considered to have passed the test.

16) The measured resistance values of motor-field windings, exciter-stator windings, exciter-rotor windings, and field-discharge resistors shall be compared to manufacturer’s published data: a) In the absence of manufacturer’s published data, the

comparison shall be made to similar machines. 17) Resistance test results of diodes and gating tests of silicon-controlled

rectifiers shall be in accordance with industry standards and system design requirements.

18) Exciter power supply shall allow exciter-field current to be adjusted to nameplate value.

19) Application timer and enable timer for power-factor relay test results shall comply with manufacturer’s recommended values.

20) Recorded values shall be in accordance with system design requirements.

21) Plotted V-curve shall indicate correct exciter operation. 22) When reduced excitation falls below trip value for the power-factor

relay, the relay shall operate. 20. Motor control, motor starters, medium-voltage:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify the unit is clean. 5) Inspect bolted electrical connections for high resistance using one or

more of the following methods: a) Use of low-resistance ohmmeter.


b) Verify tightness of accessible bolted electrical connections by calibrated torque wrench method: (1) Refer to manufacturer’s instructions for proper foot-pound

levels or NETA ATS tables. 6) Test all electrical and mechanical interlock systems for correct

operation and sequencing. 7) Verify correct barrier and shutter installation and operation. 8) Exercise all active components and confirm correct operation of all

indicating devices. 9) Inspect contactors:

a) Verify mechanical operation. b) Verify contact gap, wipe, alignment, and pressure are in

accordance with manufacturer’s published data. 10) Verify overload protection rating is correct for its application. Set

adjustable or programmable devices according to the protective device coordination study.

11) Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.


low-resistance ohmmeter. 2) Perform insulation-resistance tests on contactor(s), phase-to-ground,

phase-to-phase, and across the open contacts for 1 minute in accordance with NETA ATS Tables.

3) Perform vacuum bottle integrity test (dielectric withstand voltage), if applicable, across each vacuum bottle with the contacts in the open position in strict accordance with manufacturer’s published data. Do not exceed maximum voltage stipulated for this test.

4) Perform contact resistance tests. 5) Measure blowout coil circuit resistance. 6) Measure resistance of power fuses. 7) Energize contactor using an auxiliary source. Adjust armature to

minimize operating vibration where applicable. 8) Test control power transformers as specified in this Section. 9) Test starting transformers, if applicable, as specified in accordance

with NETA ATS. 10) Test starting reactors, if applicable, in accordance with NETA ATS. 11) Test motor protection devices in accordance with manufacturer’s

published data. In the absence of manufacturer’s published data. 12) Verify operation of cubicle space heater. 13) Test instrument transformers as specified in this Section. 14) Test metering devices as specified in this Section.





published data.


3) Electrical and mechanical interlocks shall operate in accordance with system design.

4) Barrier and shutter installation and operation shall be in accordance with manufacturer’s design.

5) Indicating devices shall operate in accordance with system design. d. Test values - electrical:





3) Insulation-resistance values of control wiring shall not be less than 2 megohms.

4) Evaluate each vacuum interrupter in accordance with test equipment manufacturer’s instructions.


6) If no evidence of distress or insulation failure is observed by the end of the total time of voltage application during the vacuum bottle integrity test, the vacuum bottle is considered to have passed the test.

7) Microhm or dc millivolt drop values shall not exceed the high levels of the normal range as indicated in the manufacturer’s published data: a) If manufacturer’s published data is not available, investigate

values which deviate from those of similar connections by more than 50 percent of the lowest value.

8) Resistance values of blowout coils shall be in accordance with manufacturer’s published data.

9) Resistance values shall not deviate by more than 15 percent between identical fuses.

10) Contactor coil shall operate with minimal vibration and noise. 11) Control power transformer rest results shall be as specified in NETA

ATS. 12) Starting transformer test results shall be as specified in NETA ATS. 13) Starting reactor test results shall be as specified in NETA ATS 14) Motor protection parameters shall be as specified in manufacturer’s

published data. 15) System function test results shall be in accordance with

manufacturer’s published data and system design. 16) Heaters shall be operational. 17) Instrument transformer test results shall be as specified in this

Section. 18) Metering device test results shall be as specified in this Section.

21. Motor starters, low voltage: a. Visual and mechanical inspection:

1) Compare equipment nameplate information with the Contract Documents.


2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify the unit is clean. 5) Inspect contactors:

a) Verify mechanical operation. b) Verify contact gap, wipe, alignment, and pressure is in

accordance with manufacturer’s published data. 6) Motor-running protection:

a) Verify overload element rating/motor protection settings are correct for its application.

b) If motor running protection is provided by fuses, verify correct fuse rating.



levels or NETA ATS tables. 8) Lubrication requirements:




to-phase and phase to ground with the starter closed, and across each open pole for 1 minute: a) Test voltage shall be in accordance with manufacturer’s


published data. 3) Test motor protection devices in accordance with manufacturer’s

published data. 4) Test circuit breakers as specified in this Section. 5) Perform operational tests by initiating control devices.








allowable minimum.


4) Motor protection parameters shall be in accordance with manufacturer’s published data.

5) Circuit breaker test results shall as specified in this Section. 6) Control devices shall perform in accordance with system design

requirements. 22. Motor control centers, low voltage:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding and required clearances. 4) Verify the unit is clean and all shipping bracing, loose parts, and

documentation shipped inside cubicles have been removed. 5) Verify that circuit breaker/fuse sizes and types correspond to the

approved submittals and the coordination study. 6) Verify that current and voltage transformer ratios correspond to those

indicated on the Drawings. 7) Verify that wiring connections are tight and that wiring is secure to

prevent damage during routine operation of moving parts. 8) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 9) Verify operation and sequencing of interlocking systems:

a) Attempt closure on locked-open devices. b) Attempt to open locked-closed devices. c) Make/attempt key-exchanges in all positions.

10) Lubrication requirements: a) Verify appropriate lubrication on moving current-carrying parts. b) Verify appropriate lubrication on moving and sliding surfaces.

11) Inspect insulators for evidence of physical damage or contaminated surfaces.

12) Verify correct barrier and shutter installation and operation. 13) Exercise all active components. 14) Inspect all indicating devices for correct operation. 15) Verify that filters are in place and/or vents are clear. 16) Perform visual and mechanical inspection of instrument transformers

as specified in this Section. 17) Perform visual and mechanical inspection of surge arresters as

specified in this Section. 18) Inspect control power transformers:

a) Inspect for physical damage, cracked insulation, broken leads, and tightness of connections, defective wiring, and overall general condition.

b) Verify that primary and secondary fuse/circuit breaker ratings match the submittal drawings.

c) Verify correction functioning of grounding contacts. 19) Perform visual and mechanical inspection of all motor control center

components as specified in this Section.



low-resistance ohmmeter. 2) Perform insulation-resistance tests on each bus section, phase-to-

phase and phase-to-ground for 1 minute: a) Perform test in accordance with NETA ATS tables.

3) Perform an dielectric withstand test on each bus section, each phase to ground with phases not under test grounded, in accordance with manufacturer’s published data or NETA ATS tables. Apply the test voltage for 1 minute.

4) Perform ground-resistance tests: a) Perform point-to-point tests to determine the resistance between

the main grounding system and all major electrical equipment frames, system neutral and derived neutral points.

5) Control power transformers: a) Perform insulation-resistance tests, winding-to-winding and

winding-to-ground: (1) Test voltages shall be in accordance with NETA ATS tables

or as specified by the manufacturer. b) Perform secondary wiring integrity test:

(1) Disconnect transformer at secondary terminals and connect secondary wiring to a rated secondary voltage source: (a) Verify correct potential at all devices.

c) Verify correct secondary voltage by energizing primary winding with system voltage: (1) Measure secondary voltage with the secondary wiring

disconnected. 6) Verify operation of space heaters. 7) Perform electrical tests of all motor control center components as

specified in this Section. c. Test values:




published data. 3) Insulation-resistance values for bus and control power transformers

shall be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s


insulation-resistance values are above minimum values. 4) Bus insulation shall withstand the over potential test voltage applied. 5) Instrument transformer test values shall be as specified in this

Section. 6) Investigate grounding system point-to-point resistance values that

exceed 0.5 ohm.


7) Meter accuracy shall be in accordance with manufacturer’s published data.

8) Control power transformers: a) Insulation-resistance values of control power transformers shall

be in accordance with manufacturer’s published data: (1) Refer to NETA ATS tables in the absence of manufacturer’s

published data. (2) Investigate insulation values less than the allowable

minimum. (3) Do not proceed with dielectric withstand voltage tests until

insulation-resistance values are above minimum values. b) Secondary wiring shall be as indicated on the Drawings and

specified in the Specifications. c) Secondary voltage shall be as indicated on the Drawings.

9) Heaters shall be operational. 10) Test values for motor control center components shall be as

specified in this Section. 23. Variable frequency drive systems:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify the unit is clean. 5) Ensure vent path openings are free from debris and that heat transfer

surfaces are clean. 6) Verify correct connections of circuit boards, wiring, disconnects, and

ribbon cables. 7) Motor running protection:

a) Verify drive overcurrent setpoints are correct for their application.

b) If drive is used to operate multiple motors, verify individual overload element ratings are correct for their application.

c) Apply minimum and maximum speed setpoints. Verify setpoints are within limitations of the load coupled to the motor.



levels or NETA ATS tables. 9) Verify correct fuse sizing in accordance with manufacturer’s

published data. 10) Perform visual and mechanical inspection of input circuit breaker as

specified in this Section. b. Electrical tests:

1) Perform resistance measurements through bolted connections with low resistance ohmmeter.

2) Test the motor overload relay elements by injecting primary current through the overload circuit and monitoring trip time of the overload element.


3) Test for the following parameters in accordance with relay calibration procedures specified in NETA ATS or as recommended by the manufacturer: a) Input phase loss protection. b) Input overvoltage protection. c) Output phase rotation. d) Overtemperature protection. e) Direct current overvoltage protection. f) Overfrequency protection. g) Drive overload protection. h) Fault alarm outputs.

4) Perform continuity tests on bonding conductors as specified in accordance with NETA ATS.

5) Perform start-up of drive in accordance with manufacturer’s published data. Calibrate drive to the system’s minimum and maximum speed control signals.

6) Perform operational tests by initiating control devices: a) Slowly vary drive speed between minimum and maximum.

Observe motor and load for unusual noise or vibration. b) Verify operation of drive from remote start/stop and speed

control signals. 7) Perform electrical tests of input circuit breaker as specified in this

Section. 8) Measure fuse resistance.





published data. 3) Overload test trip times at 300 percent of overload element rating

shall be in accordance with manufacturer’s published time-current curve.

4) Test values for input circuit breaker shall be as specified in this Section.

5) Relay calibration results shall be as specified in this Section. 6) Continuity of bonding conductors shall be in accordance with NETA

ATS. 7) Control devices shall perform in accordance with system

requirements. 8) Operational tests shall conform to system design requirements. 9) Investigate fuse resistance values that deviate from each other by

more than 15 percent. 24. Surge arresters, low-voltage:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and clearances. 4) Verify the arresters are clean.




levels or NETA ATS tables. 6) Verify that the ground lead on each device is individually attached to

a ground bus or ground electrode. 7) Verify that stroke counter is correctly mounted and electrically

connected, if applicable. 8) Record stroke counter reading.


low-resistance ohmmeter. 2) Perform an insulation-resistance test on each arrester, phase

terminal- to- ground: a) Apply voltage in accordance with manufacturers published data. b) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 3) Test grounding connection as specified in this Section.








4) Resistance between the arrester ground terminal and the ground system shall be less than 0.5 ohm.

25. Surge arresters, medium and high voltage: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and clearances. 4) Verify the arresters are clean. 5) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 6) Verify that the ground lead on each device is individually attached to

a ground bus or ground electrode.


7) Verify that stroke counter is correctly mounted and electrically connected, if applicable.

8) Record stroke counter reading. b. Electrical tests:

1) Perform resistance measurements through bolted connections with a low resistance ohmmeter.

2) Perform an insulation-resistance test on each arrester, phase terminal-to-ground: a) Apply voltage in accordance with manufacturers published data. b) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 3) Test grounding connection as specified in this Section.








4) Resistance between the arrester ground terminal and the ground system shall be less than 0.5 ohm.

26. Outdoor bus structures: a. Visual and mechanical inspection:

1) Compare bus arrangement with that indicated on the Drawings and specified in the Specifications.

2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify the support insulators are clean. 5) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. b. Electrical tests:


2) Measure insulation-resistance of each bus, phase- to- ground with other phases grounded: a) Apply voltage in accordance with manufacturer’s published data. b) Refer to NETA ATS tables in the absence of manufacturer’s

published data.


3) Perform dielectric withstand voltage test on each bus phase, phase- to- ground with other phases grounded. Potential application shall be for 1 minute.


connections: a) Investigate values which deviate from those of similar





published data. 4) If no evidence of distress or insulation failure is observed at the end


27. Single Engine generator: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify the unit is clean.

b. Electrical and mechanical tests: 1) Perform insulation-resistance tests in accordance with IEEE 43:

a) Machines larger than 150 kilowatts: Test duration shall be 10 minutes. Calculate polarization index.

b) Machines 150 kilowatts and less: Test duration shall be 1 minute. Calculate the dielectric-absorption rate.

2) Test protective relay devices as specified in this Section. 3) Verify phase rotation, phasing, and synchronized operation as

required by the application. 4) Functionally test engine shutdown for low oil pressure,

overtemperature, overspeed, and other protection features as applicable.

5) Conduct performance test in accordance with NFPA 110. 6) Verify correct functioning of governor and regulator. 7) Load bank testing:

a) Provide a resistive load bank to test the operation of the engine generator.

b) Load bank shall be capable of loading the engine generator to its full nameplate kilowatt rating at unity power factor.

c) Load steps shall simulate the plant load steps used in sizing the engine generator.

d) Test run at full nameplate kilowatt rating for a minimum of 4 hours: (1) Record at 10 minute intervals:

(a) Voltage. (b) Frequency. (c) Current.


(d) Power factor. (e) Engine oil pressure. (f) Engine oil temperature. (g) Air inlet temperature. (h) Radiator discharge temperature. (i) Engine coolant temperature. (j) Vibration levels at each main bearing cap.

c. Test values: 1) Anchorage, alignment, and grounding should be in accordance with

manufacturer’s published data and system design. 2) The dielectric absorption ratio or polarization index shall be

compared to previously obtained results and should not be less than 1.0. The recommended minimum insulation (IR1 min) test results in megohms shall be corrected to 40 degrees Celsius and read as follows: a) IR1 min equals kilovolt + 1 for most windings made before 1970,

all field windings, and others not described below. (1) Kilovolt is the rated machine terminal-to-terminal voltage in

rms kilovolt. b) IR1 min equals 100 megohms for most dc armature and ac

windings built after 1970 (form-wound coils). c) IR1 min equals 5 megohms for most machines and random-

wound stator coils and form-wound coils rated below 1 kilovolt. (1) Dielectric withstand voltage and surge comparison tests

shall not be performed on machines having lower values than those indicated above.

3) The polarization index value shall not be less than 2.0. 4) The dielectric absorption ratio shall be greater than 1.0. 5) Protective relay device test results shall be as specified in this

Section. 6) Phase rotation, phasing, and synchronizing shall be in accordance

with system design requirements. 7) Low oil pressure, over temperature, over speed, and other protection

features shall operate in accordance with manufacturer’s published data and system design requirements.

8) Vibration levels shall be in accordance with manufacturer’s published data and shall be compared to baseline data.

9) Performance tests shall conform to manufacturer’s published data and NFPA 110.

10) Governor and voltage regulator shall operate in accordance with manufacturer’s published data and system design requirements: a) Steady state voltage regulation shall be within 0.5 percent of set

point. b) The output voltage of the generator shall not fall below

10 percent of the power system nominal rating for more than 5 seconds.

c) The output voltage of the generators shall not exceed the power system nominal rating at any time.

d) Steady state frequency regulation shall be within 59.5 hertz to 60.5 hertz.

e) Frequency variations shall not exceed 2 hertz from 60 hertz for more than 2 seconds.


28. Uninterruptible power systems: a. All testing and settings shall be conducted by the UPS manufacturer’s

field engineer: 1) Test the complete operation of the static transfer system. 2) Test the complete operation of the static bypass system. 3) Test the complete operation of the maintenance bypass system.

b. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and required clearances. 4) Verify that fuse sizes and types correspond to that indicated on the

Drawings. 5) Verify the unit is clean. 6) Test all electrical and mechanical interlock systems for correct

operation and sequencing. 7) Inspect bolted electrical connections for high resistance using one of



levels or NETA ATS tables. 8) Verify operation of forced ventilation. 9) Verify that filters are in place and/or vents are clear.

c. Electrical tests: 1) Perform resistance measurements through bolted connections with a

low-resistance ohmmeter. 2) Test static transfer from inverter to bypass and back. Use normal

load, if possible. 3) Set free running frequency of oscillator. 4) Test dc undervoltage trip level on inverter input breaker. Set

according to manufacturer’s published data. 5) Test alarm circuits. 6) Verify synchronizing indicators for static switch and bypass switches. 7) Perform electrical tests for UPS system breakers as specified in this

Section. 8) Perform electrical tests for UPS system automatic transfer switches

as specified in this Section. 9) Perform electrical tests for UPS system batteries as specified in this

Section. 10) Perform electrical tests for UPS rotating machinery as specified in

this Section. d. Test values:

1) Electrical and mechanical interlock systems shall operate in accordance with system design requirements.




3) Bolt-torque levels shall be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 4) Static transfer shall function in accordance with manufacturer’s

published data. 5) Oscillator free running frequency shall be within manufacturer’s

published tolerances. 6) Direct current undervoltage shall trip inverter input breaker. 7) Alarm circuits shall operate in accordance with design requirements. 8) Synchronizing indicators shall operate in accordance with design

requirements. 9) Breaker performance shall be as specified in this Section. 10) Automatic transfer switch performance shall be as specified in this

Section. 11) Battery test results shall be as specified in this Section. 12) Rotating machinery performance shall be as specified in this Section.

29. Automatic transfer switches: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and required clearances. 4) Verify the unit is clean. 5) Lubrication requirements:


6) Verify that manual transfer warnings are attached and visible. 7) Verify tightness of all control connections. 8) Inspect bolted electrical connections for high resistance using one of


calibrated torque wrench: (1) Refer to manufacturer’s instructions for proper foot-pound

levels or NETA ATS tables. 9) Perform manual transfer operation. 10) Verify positive mechanical interlocking between normal and alternate

sources. b. Electrical tests:


2) Perform insulation-resistance tests on all control wiring with respect to ground. Applied potential shall be 500 VDC for 300-volt rated cable and 1,000 VDC for 600-volt rated cable. Apply the test voltage for 1 minute: a) For units with solid-state components or for control devices that

cannot tolerate the applied voltage, follow manufacturer’s recommendation.

3) Perform a contact/pole-resistance test. 4) Verify settings and operation of control devices. 5) Calibrate and set all relays and timers as specified in this Section.


6) Verify phase rotation, phasing, and synchronized operation as required by the application.

7) Perform automatic transfer tests: a) Simulate loss of normal power. b) Return to normal power. c) Simulate loss of emergency power. d) Simulate all forms of single-phase conditions.

8) Verify correct operation and timing of the following functions: a) Normal source voltage-sensing and frequency-sensing relays. b) Engine start sequence. c) Time delay upon transfer. d) Alternate source voltage-sensing and frequency-sensing relays. e) Automatic transfer operation. f) Interlocks and limit switch function. g) Time delay and retransfer upon normal power restoration. h) Engine cool down and shutdown feature.




published data: 3) Refer to NETA ATS tables in the absence of manufacturer’s

published data. 4) Insulation resistance values of transfer switches shall be in


published data. b) Values of insulation resistance less than this table or

manufacturer’s recommendations shall be investigated. 5) Insulation-resistance values of control wiring shall not be less than

2 megohms. 6) Microhm or dc millivolt drop values shall not exceed the high levels of

the normal range as indicated in the manufacturer’s published data: a) If manufacturer’s published data is not available, investigate

values that deviate from adjacent poles or similar switches by more than 50 percent of the lowest value.

7) Control devices shall operate in accordance with manufacturer’s published data.

8) Relay test results shall be as specified in this Section. 9) Phase rotation, phasing, and synchronization shall be as specified in

the system design specifications. 10) Operation and timing shall be in accordance with manufacturer’s and

system design requirements. 30. Switches, air, low-voltage:

a. Visual and mechanical inspection: 1) Compare equipment nameplate data with the Contract Document. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and required clearances. 4) Verify the unit is clean.


5) Verify correct blade alignment, blade penetration, travel stops, and mechanical operation.

6) Verify that fuse sizes and types as indicated on the Drawings, short-circuit studies, and coordination study.

7) Verify that each fuse has adequate mechanical support and contact integrity.

8) Inspect bolted electrical connections for high resistance using one of the following methods: a) Use of a low resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 9) Verify operation and sequencing of interlocking systems. 10) Verify correct phase barrier installation. 11) Verify correct operation of all indicating and control devices. 12) Verify appropriate lubrication on moving current-carrying parts and



2) Measure contact resistance across each switchblade and fuseholder. 3) Perform insulation-resistance tests for 1 minute on each pole, phase-

to-phase and phase-to ground with switch closed, and across each open pole. Apply voltage in accordance with manufacturer’s published data: a) In the absence of manufacturer’s published data, use NETA

ATS requirements. 4) Measure fuse resistance. 5) Verify cubicle space heater operation. 6) Perform ground fault test as specified in this Section, if applicable. 7) Perform tests on other protective devices as specified in this Section,

if applicable. c. Test values:


connection by more than 50 percent of the lowest value. 2) Bolt-torque levels shall be in accordance with manufacturer’s


published data. d. Test values - electrical:


connections by more than 50 percent of the lowest value. 2) Microhm or dc millivolt drop values shall not exceed the high levels of

the normal range as indicated in the manufacturer’s published data: a) If manufacturer’s published data is not available, investigate



3) Insulation-resistance values shall be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s


4) Investigate fuse-resistance values that deviate from each other by more than 15 percent.

5) Heaters shall be operational. 6) Ground fault tests shall be as specified in this Section. 7) Results of protective device tests shall be as specified in this Section.

31. Switches, air, medium-voltage, metal-enclosed: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and required clearances. 4) Verify the unit is clean. 5) Verify correct blade alignment, blade penetration, travel stops, arc

interrupter operation, and mechanical operation. 6) Verify that fuse sizes and types are as indicated on the Drawings,

short-circuit study, and coordination study. 7) Verify that expulsion-limiting devices are in place on all holders

having expulsion-type elements. 8) Verify that each fuseholder has adequate mechanical support and

contact integrity. 9) Inspect bolted electrical connections for high resistance using one of

the following methods: a) Use of a low resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 10) Verify operation and sequencing of interlocking systems. 11) Verify correct phase barrier installation. 12) Verify correct operation of all indicating and control devices. 13) Verify appropriate lubrication on moving current-carrying parts and



2) Measure contact resistance across each switchblade and fuseholder. 3) Perform insulation-resistance tests for 1 minute on each pole, phase-

to-phase and phase-to ground with switch closed, and across each open pole. Apply voltage in accordance with manufacturer’s published data: a) In the absence of manufacturer’s published data, use NETA

ATS requirements. 4) Perform a dielectric withstand voltage test on each pole with switch

closed. Test each pole-to-ground with all other poles grounded. Test voltage shall be in accordance with manufacturer’s published data: a) In the absence of manufacturer’s published data, use NETA

ATS requirements. 5) Measure fuse resistance.


6) Verify cubicle space heater operation. c. Test values:






connections by more than 50 percent of the lowest value. 2) Microhm or dc millivolt drop values shall not exceed the high levels of

the normal range as indicated in the manufacturer’s published data. a) If manufacturer’s published data is not available, investigate


3) Insulation-resistance values shall be in accordance with manufacturer’s published data: a) Refer to NETA ATS tables in the absence of manufacturer’s


insulation-resistance values are above minimum values. 4) If no evidence of distress or insulation failure is observed by the end


5) Investigate fuse resistance values that deviate from each other by more than 15 percent.

6) Heaters shall be operational. 32. Fiber-optic cables:

a. Visual and mechanical inspection: 1) Compare cable, connector, and splice data with the Contract

Documents. 2) Inspect cable and connections for physical and mechanical damage. 3) Verify that all connectors and splices are correctly installed.

b. Optical tests: 1) Perform cable length measurement, fiber fracture inspection, and

construction defect inspection using an optical time domain reflectometer (OTDR): a) OTDR test performed on fiber cables less than 100 meters shall

be performed with the aid of a launch cable. b) Adjust OTDR pulse width settings to a maximum setting of

1/1,000th of the cable length or 10 nanoseconds. 2) Perform connector and splice integrity test using an optical time

domain reflectometer.


3) Perform cable attenuation loss measurement with an optical power loss test set: a) Perform attenuation tests with an Optical Loss Test Set capable

and calibrated to show anomalies of 0.1 dB as a minimum. b) Test multimode fibers at 850 nanometer and 1,300 nanometer. c) Test single mode fibers at 1,310 nanometer and 1,550

nanometer. 4) Perform connector and splice attenuation loss measurement from

both ends of the optical cable with an optical power loss test set: a) At the conclusion of all outdoor splices at 1 location, and before

they are enclosed and sealed, all splices shall be tested with OTDR at the optimal wavelengths (850 and 1,300 for multimode, 1,310 and 1,550 for single mode), in both directions. The splices shall be tested for integrity as well as attenuation.

5) Perform fiber links integrity and attenuation tests using each link shall be an OTDR and an Optical Loss Test Set: a) OTDR traces shall be from both directions on each fiber at the

2 optimal wavelengths, 850 nanometer, and 1,300 nanometer for multimode fibers.

b) Optical loss testing shall be done with handheld test sets in 1 direction at the 2 optimal wavelengths for the appropriate fiber type. Test equipment shall equal or exceed the accuracy and resolution of Agilent/HP 8147 high performance OTDR.

c. Test values: 1) Cable and connections shall not have been subjected to physical or

mechanical damage. 2) Connectors and splices shall be installed in accordance with industry

standards. 3) The optical time domain reflectometer signal should be analyzed for

excessive connection, splice, or cable backscatter by viewing the reflected power/distance graph.

4) Attenuation loss measurement shall be expressed in dB/km. Losses shall be within the manufacturer’s recommendations when no local site specifications are available.

5) Individual fusion splice losses shall not exceed 0.1 dB. Measurement results shall be recorded, validated by trace, and filed with the records of the respective cable runs.

33. LAN cable testing: a. Visual and mechanical inspections:

1) Compare cable type and connections with that indicated on the Drawings and specified in the Specifications.

2) Inspect cable and connectors for physical and mechanical damage. 3) Verify that all connectors are correctly installed.

b. Pre-testing: 1) Test individual cables before installation:

a) Before physical placement of the cable, test each cable while on the spool with a LAN certification test device.

b) Before the cable is installed, verify that the cable conforms to the manufacturer’s attenuation specification and that no damage has been done to the cable during shipping or handling.


c) The test shall be fully documented and the results submitted to the Engineer, including a hard copy of all traces, before placement of the cable.

d) The Engineer shall be notified if a cable fails to meet specification and the cable shall not be installed unless otherwise directed by the Engineer.

c. Electrical tests: 1) Perform cable end-to-end testing on all installed cables after

installation of connectors from both ends of the cable. 2) Test shall include cable system performance tests and confirm the

absence of wiring errors. d. Test results:

1) Cables shall meet or exceed TIA standards. e. Test equipment:

1) LAN certification equipment used for the testing shall be capable of testing Category 6 cable installation to TIA proposed Level III accuracy. Tests performed shall include: a) Near end cross talk. b) Attenuation. c) Equal level far end cross talk. d) Return loss. e) Ambient noise. f) Effective cable length. g) Propagation delay. h) Continuity/loop resistance.

2) LAN certification test equipment shall be able to store and produce plots of the test results.

3) Manufacturers: The following or equal: a) Agilent Technologies, WireScope 350.

34. Capacitors and reactors, capacitors: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect physical and mechanical condition. 3) Inspect anchorage, alignment, grounding, and clearances. 4) Verify the unit is clean. 5) Verify that capacitors are electrically connected in their specified

configuration. 6) Inspect bolted electrical connections for high resistance using one of

the following methods: a) Use of low resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels NETA ATS tables. b. Electrical tests:


2) Perform insulation-resistance tests from phase terminal(s) to case for 1 minute. a) Apply voltage in accordance with manufacturer's published data.

In the absence of manufacturer's published data, refer to NETA ATS tables.


3) Measure the capacitance of all terminal combinations. 4) Measure resistance of the internal discharge resistors.



connections by more than 50 percent of the lowest value. 2) Bolt-torque levels shall be in accordance with manufacturer's


data. d. Test values - electrical:



manufacturer's published data: a) Refer to NETA ATS tables in the absence of manufacturer's

published data. b) Values of insulation-resistance less than NETA ATS tables or

manufacturer's recommendations should be investigated. 3) Investigate capacitance values differing from manufacturer's

published data. 4) Investigate discharge resistor values differing from manufacturer's

published data. In accordance with NFPA 70 NEC, Article 460, residual voltage of a capacitor shall be reduced to 50 volts in the following time intervals after being disconnected from the source of supply:

Rated Voltage Discharge Time Less than or equal to 600 volts 1 minute

Greater than 600 volts 5 minutes

35. Direct-current systems, batteries, flooded lead-acid: a. Visual and mechanical inspection:

1) Verify that battery area ventilation system is operable. 2) Verify existence of suitable eyewash equipment. 3) Compare equipment nameplate data with the Contract Documents. 4) Inspect physical and mechanical condition. 5) Verify adequacy of battery support racks, mounting, anchorage,

alignment, grounding, and clearances. 6) Verify electrolyte level. Measure electrolyte specific gravity and

temperature levels. 7) Verify presence of flame arresters. 8) Verify the units are clean. 9) Inspect spill containment installation. 10) Verify application of an oxide inhibitor on battery terminal

connections. 11) Inspect bolted electrical connections for high resistance using one of

the following methods: a) Use of low resistance ohmmeter.


b) Verify tightness of accessible bolted electrical connections by calibrated torque wrench method: (1) Refer to manufacturer’s instructions for proper foot-pound

levels NETA ATS tables. b. Electrical tests:

1) Perform resistance measurements through all bolted connections with a low-resistance ohmmeter.

2) Measure charger float and equalizing voltage levels. Adjust to battery manufacturer's recommended settings.

3) Verify all charger functions and alarms. 4) Measure each cell voltage and total battery voltage with charger

energized and in float mode of operation. 5) Measure intercell connection resistances. 6) Perform internal ohmic measurement tests. 7) Perform a load test in accordance with manufacturer's published data

or IEEE 450. 8) Measure the battery system voltage from positive-to-ground and

negative-to-ground. c. Test values: d. Electrolyte level and specific gravity shall be within normal limits.


connections by more than 50 percent of the lowest value. 2) Bolt-torque levels shall be in accordance with manufacturer's

published data: a) Refer to NETA ATS tables in the absence of manufacturer's

published data. e. Test values - electrical:


connections by more than 50 percent of the lowest value. 2) Charger float and equalize voltage levels shall be in accordance with

battery manufacturer's published data. 3) The results of charger functions and alarms shall be in accordance

with manufacturer's published data. 4) Cell voltages shall be within 0.05 volt of each other or in accordance

with manufacturer's published data. 5) Cell internal ohmic values (resistance, impedance, or conductance)

shall not vary by more than 25 percent between identical cells in a fully charged state.

6) Results of load tests shall be in accordance with manufacturer's published data or IEEE 450.

7) Voltage measured from positive to ground shall be equal in magnitude to the voltage measured from negative to ground.

36. Direct-current systems, batteries, vented nickel-cadmium: a. Visual and mechanical inspection:

1) Verify that batteries are adequately located. 2) Verify that battery area ventilation system is operable. 3) Verify existence of suitable eyewash equipment. 4) Compare equipment nameplate data with the Contract Documents.


5) Inspect physical and mechanical condition. 6) Verify adequacy of battery support racks or cabinets, mounting,

battery spill containment system, anchorage, alignment, grounding, and clearances.

7) Verify electrolyte level. Measure pilot-cell electrolyte temperature. 8) Verify the units are clean. 9) Verify application of an oxide inhibitor on battery terminal


the following methods: a) Use of a low resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by



1) Perform resistance measurements through all bolted connections with a low-resistance ohmmeter.

2) Measure charger float and equalizing voltage levels. Adjust to battery manufacturer’s recommended settings.

3) Verify all charger functions and alarms. 4) Measure each cell voltage and total battery voltage with charger

energized and in float mode of operation. 5) Measure intercell connection resistances. 6) Perform internal ohmic measurement tests. 7) Perform a load test in accordance with manufacturer’s published data

or IEEE 1106. 8) Measure the battery system voltage from positive-to-ground and

negative-to-ground. c. Test values:

1) Electrolyte level shall be within normal limits. 2) Compare bolted connection resistance values to values of similar






connections by more than 50 percent of the lowest value. 2) Charger float and equalize voltage levels shall be in accordance with

battery manufacturer’s published data. 3) The results of charger functions and alarms shall be in accordance

with manufacturer’s published data. 4) Cell voltages shall be within 0.05 volt of each other or in accordance

with manufacturer’s published data.


5) Cell internal ohmic values (resistance, impedance, or conductance) shall not vary by more than 25 percent between identical cells that are in a fully charged state, or shall be in accordance with manufacturer’s published data.

6) Results of load tests shall be in accordance with manufacturer’s published data.

7) Voltage measured from positive to ground shall be equal in magnitude to the voltage measured from negative to ground.

37. Direct-current systems, batteries, valve-regulated lead-acid: a. Visual and mechanical inspection:

1) Verify that batteries are adequately located. 2) Verify that battery area ventilation system is operable. 3) Verify existence of suitable eyewash equipment. 4) Compare equipment nameplate data with the Contract Documents. 5) Inspect physical and mechanical condition. 6) Verify adequacy of battery support racks or cabinets, mounting,

anchorage, alignment, grounding, and clearances. 7) Verify the units are clean. 8) Verify the application of an oxide inhibitor on battery terminal


the following methods: a) Use of low resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by




2) Measure negative post temperature. 3) Measure charger float and equalizing voltage levels. 4) Verify all charger functions and alarms. 5) Measure each monoblock/cell voltage and total battery voltage with

charger energized and in float mode of operation. 6) Measure intercell connection resistances. 7) Perform internal ohmic measurement tests. 8) Perform a load test in accordance with manufacturer’s published data

or IEEE 1188. 9) Measure the battery system voltage from positive to ground and

negative to ground. c. Test values:

1) Compare bolted connection resistance values to values of similar connections: a) Investigate values that deviate from those of similar bolted



published data.


d. Test values - electrical: 1) Compare bolted connection resistance values to values of similar

connections: a) Investigate values that deviate from those of similar bolted

connections by more than 50 percent of the lowest value. 2) Negative post temperature shall be within manufacturer’s published

data or IEEE 1188. 3) Charger float and equalize voltage levels shall be in accordance with

the battery manufacturer’s published data. 4) Results of charger functions and alarms shall be in accordance with

manufacturer’s published data. 5) Monoblock/cell voltages shall be in accordance with manufacturer’s

published data. 6) Monoblock/cell internal ohmic values (resistance, impedance, or

conductance) shall not vary by more than 25 percent between identical monoblocks/cells in a fully charged state.

7) Results of load tests shall be in accordance with manufacturer’s published data or IEEE 1188.

8) Voltage measured from positive to ground shall be similar in magnitude to the voltage measured from negative to ground.

38. Direct-current systems, chargers: a. Visual and mechanical inspection:

1) Compare equipment nameplate data with the Contract Documents. 2) Inspect for physical and mechanical condition. 3) Inspect anchorage, alignment, and grounding. 4) Verify the unit is clean. 5) Inspect all bolted electrical connections for high resistance using one

of the following methods: a) Use of low resistance ohmmeter. b) Verify tightness of accessible bolted electrical connections by


levels or NETA ATS tables. 6) Inspect filter and tank capacitors. 7) Verify operation of cooling fans and presence of filters.


low-resistance ohmmeter. 2) Verify float voltage, equalize voltage, and high voltage shutdown

settings. 3) Verify current limit. 4) Verify correct load sharing (parallel chargers). 5) Verify calibration of meters as specified in this Section. 6) Verify operation of alarms. 7) Measure and record input and output voltage and current. 8) Measure and record ac ripple current and voltage imposed on the

battery. 9) Perform full-load testing of charger.



connections: a) Investigate values that deviate from those of similar bolted




1) Compare bolted connection resistance values to values of similar connections: a) Investigate values that deviate from those of similar bolted

connections by more than 50 percent of the lowest value. 2) Float and equalize voltage settings shall be in accordance with the

battery manufacturer’s published data. 3) Current limit shall be within manufacturer’s recommended maximum. 4) Results of load sharing between parallel chargers shall be in

accordance with system design specifications. 5) Results of meter calibration shall be as specified in this Section. 6) Results of alarm operation shall be in accordance with

manufacturer’s published data and system design. 7) Input and output voltage shall be in accordance with manufacturer’s

published data. 8) AC ripple current and voltage imposed on the battery shall be in

accordance with manufacturer’s published data. 9) Charger shall be capable of manufacturer’s specified full load.

END OF SECTION


SECTION 17950

SCADA SYSTEM CALIBRATION, TESTING, TRAINING AND COMMISSIONING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Calibration, testing, training, and commissioning requirements that apply to the

Supervisory Control and Data Acquisition (SCADA) System. SCADA system includes field instruments and devices, control panels, Programmable Logic Controllers (PLC), Human Machine Interface (HMI), Operator Interface Terminals (OIT), networking hardware, and fiber and copper communication cables and associated hardware.

B. The Design-Builder is responsible for scheduling, coordinating, and conducting all calibration, testing, training, and commissioning for the SCADA system as required by this Section and Section OR-01757 - Commissioning.

1.02 REFERENCES

A. American National Standards Institute (ANSI).

B. Electronics Industries Alliance (EIA).

C. Telecommunications Industry Association (TIA).

D. International Society of Automation (ISA).

1.03 DEFINITIONS

A. As specified in Sections OR-01757 – Commissioning.

B. OLTS: Optical Loss Test Set.

C. OTDR: Optical Time Domain Reflectometry.

D. LIA: Laser Institute of America.

1.04 SUBMITTALS

A. Furnish submittals as specified in Section OR-01300 - Submittal Procedures.

B. Pre-Submittal Conference: 1. Before producing any submittals, Design-Builder shall schedule a pre-

submittal conference for the purposes of reviewing the entire project, equipment, HMI philosophy, control philosophy, schedules, and submittal requirements.

2. The Design-Builder, planned I&C Engineer-of-Record, electrical subcontractor, instrumentation and control subcontractor, City’s approved system integrator,


and all manufacturers furnishing major pieces of equipment must attend, including but not limited to: a. PLC. b. HMI/OIT. c. Field instruments and devices. d. Fiber and copper networking hardware. e. Control panels. f. Motor control centers. g. Switchgear. h. Variable frequency drives.

3. Bring to this meeting, a listing of the submittals that will be provided for the SCADA system and a schedule for when each submittal will be provided.

C. Test procedures: 1. Develop and submit detailed test procedures to show that the integrated

SCADA system hardware and software is in compliance with the requirements specified in the Contract Documents.

2. Provide a statement of test objectives for each test. 3. Prepare specific procedures for each process system. 4. Describe the steps to be followed in verifying the correct installation of each

process system. 5. Describe sequentially the steps to be followed in verifying the correct operation

of each process system, including all features described in the loop descriptions, control strategies, and shown in the P&IDs. Implied or generic test procedures are not acceptable.

6. Specify who will perform the tests, specifically what testing equipment will be used (including serial numbers and NIST-traceable calibration), and how the testing equipment will be used.

7. Describe the expected role of the Owner and the Engineer-of-Record, as well as any requirements for assistance from Owner’s staff.

8. Provide the forms and checklists to be used.

D. Test forms: 1. Provide test procedures, calibration forms and checklists for each of the

following: a. Source tests. b. Installation tests. c. Functional tests. d. Instrumentation and Controls Fine-Tuning. e. Communication tests, including all digital communications and all forms of

Ethernet. 2. Test forms shall include the detailed test procedures or shall include clear

references to separate pages containing the complete test procedure applicable to each form. If references to procedures are used, the complete procedure shall be included with each test binder.

3. Every page of each test form shall include project name, date, time, name of person conducting the test, signature of person conducting the test, and for witnessed tests, place for signature of person (Engineer-of-Record and Owner) witnessing the test.

4. Some sample test forms are included at the end of this Section. These test forms show the minimum required test form content. They are not complete and have not been customized for this Project. The Design-Builder shall


develop and submit test forms customized for the Project and meeting all the specified test and submittal requirements.

E. Testing binders: 1. For each sub-system to be tested, provide and submit a test binder containing

all test procedures and individual test forms for the test. References to other documents for test procedures and requirements are not acceptable.

2. Fill out in advance, headings and all other information known before the test. 3. Include applicable test plan information, as well as a list of all test

prerequisites, test personnel, and equipment. 4. Include or list reference material and provide separately at the time of the test. 5. Record test results and verify that all test requirements and conditions have

been met.

F. Test reports: 1. At the conclusion of each test, submit a complete test report, including all test

results and certifications. 2. Include all completed test binders, forms, and checklists.

1.05 MEETINGS

A. Pre-submittal conferences as described in this Section (Paragraph 1.05 Submittals).

B. Initial Package Control System Meetings: Facilitate a meeting with each equipment supplier (including HVAC) who is providing equipment with a PLC and/or OIT/HMI. Individuals responsible for programming PLCs, OIT, and other programmable devices supplied by Design-Builder shall attend this meeting in person or by telephone conference call. Meeting discussion point will include the following at a minimum: 1. Tag Naming conventions. 2. PLC to PLC global data mapping. 3. All PLCs to HMI tags mapping. 4. OIT screen colors and navigation. 5. Interlock and Permissive definitions. 6. Communication methods. 7. Standard code blocks for common control functionality. 8. Alarms: Clearing, formats, colors, and status.

C. HMI/OIT Configuration Meetings: For each system being furnished with an HMI/OIT, review the system configuration, system databases, display graphics, report formats, historical data collection needs, etc., with the Engineer-of-Record and Owner on at least 3 occasions during development. This includes the thin client HMI workstation as well the OITs being furnished with package control systems. Individuals responsible for programming HMI/OIT and other programmable devices supplied by Design-Builder shall attend this meeting in person or by telephone conference call.

a. Preliminary meeting: Conduct meeting before commencing system configuration work. Bring to this meeting, example of displays, display symbols, reports, etc. to demonstrate the intended implementation.

b. Intermediate review meeting: Held after the initial database is entered and typical screens and reports have been generated. Submit an informal


hardcopy of developed HMI/OIT screens for review by the Owner and Engineer-of-Record to determine that requirements are being met.

c. Final review meeting: Held after initial completion of all configuration work. This final meeting may not be held in conjunction with the testing. Make final format revisions after this review.

d. Design-builder shall follow requirements for a High Performance (Controlled color usage) HMI to the extent possible.

D. Control Logic Meetings: 1. For each system being furnished with a PLC, review the PLC programming

with the Engineer-of-Record, and Owner on at least 3 occasions during development. This includes the main PLC and the individual equipment PLCs being provided with the package control systems. Individuals responsible for programming PLCs and other programmable devices supplied by Design-Builder shall attend this meeting in person or by telephone conference call. a. Preliminary meeting: Conduct meeting before commencing configuration

work on any PLCs programmed by the Design-Builder. 1) Design-Builder shall provide a list of each PLC and other

programmable devices that will interface to the rest of the control system, including make, model, and a description of the interface; provide contact information for each individual responsible for programming each said PLC and device.

b. Intermediate review meeting: Held after approximately one-half of the submittals identified in the Pre-Submittal Conference have been submitted. 1) Meet to discuss all control system interface requirements. 2) Programmers to provide list of setpoint clamping values, watchdog

timers, proving timers, etc. needed for programming. Owner and Engineer-of-Record to furnish values.

c. Final review meeting: Held after initial completion of all configuration work. This final meeting may not be held in conjunction with testing. Make final control logic adjustments after this meeting.

1.06 SEQUENCING

A. Source Testing: 1. Schedule the source testing after receiving approval of the test procedures

submittal. 2. Submit a copy of the test procedures including all forms at least 21 days

before any scheduled test date. 3. Notify the Owner of scheduled tests a minimum of 15 days before the date of

the test.

B. General Field Start-up and testing procedures: As specified herein and in Section OR-01757 - Commissioning.

C. Installation Testing: 1. As specified in Section OR-01757 - Commissioning. 2. Acceptance of the SCADA Installation testing must be provided in writing by

the Owner before the functional testing may begin.

D. Training: As specified herein and in Section OR-01757 - Commissioning.


E. Functional Testing: 1. Commence after source tests, installation tests, inspections and training have

been completed. 2. Submit a copy of the test procedures including all forms at least 21 days


the test.

F. Provide all special tools and spare parts before performance testing, suitably wrapped, and identified.

G. SCADA Acceptance Testing: 1. Commence following Mechanical Completion and after functional testing has

been completed. 2. Submit a copy of the test procedures including all forms at least 21 days


the test.


A. Test personnel: 1. Furnish qualified technical personnel to perform all calibration, testing, and

verification. The test personnel are required to be familiar with this Project and the equipment, software, and systems before being assigned to the test program.

PART 2 PRODUCTS


A. Source Tests: 1. Before the delivery and installation of control panels, PLCs, control system

equipment, and other control system components at the job site, but after the procurement and assembly of components, perform Source Tests for each system.

2. Perform tests to show that the system hardware and software is fully operational and in compliance with the requirements specified in the Contract Documents. A sample source test form has been provided at the end of this Section.

3. The source tests shall be witnessed by the Design-Builder and the Owner. a. The Owner retains the right to observe all source tests activities including

any and all subsystem preparation, pretests, troubleshooting, retests, warm-up, and software modification and/or update.

b. The Owner reserves the right to test any specified function, whether or not explicitly stated in the test submittal.

4. Correction of deficiencies: Any deficiencies observed during the source test shall be corrected and retested before completion of the test. a. Any changes and/or corrections shall be noted on the test forms. Owner

shall witness the revisions and/or corrections prior to leaving the test site.


b. If the corrections and/or revisions are too extensive to be made while the Owner is scheduled to be at the source test site, the source test shall be, at the Owner or Engineer-of-Record’s sole discretion, considered failed, and the test shall be restarted at a later date. All costs for the re-test shall be borne by the Design-Builder, including Owner’s travel expenses per Section OR-01757 – Commissioning.

5. Testing simulation: a. The source tests shall make use of hardware simulators that contain

switches, pilot lights, variable analog signal generators, and analog signal level displays, which shall be connected to the I/O points within the SCADA system. All inputs and outputs shall be simulated, and proper control and system operation shall be validated.

b. The use of jumper wires, terminal block mounted pilot lights, and loose meters to act as or supply the functionality of a simulator shall not be allowed.

c. The hardware simulator may consist of a PLC, operating under a SCADA software package, or other approved software that has its I/O points wired to PLC’s I/O points. Software operating on an HMI/OIT may then act as the switches, pilot lights, variable analog signal generators, and analog signal level displays.

6. The source test results submittal shall include a letter, signed by the Design-Builder’s project managers or company officers, certifying that the system is complete, has been tested successfully, and is fully ready for shipment. The submittal shall include completed source test forms, signed by the Design-Builder’s staff and reviewed by the Engineer-of-Record.

7. Panel inspections: a. The Owner will inspect each control panel for completeness,

workmanship, fit and finish, and compliance with the Contract Documents and the accepted shop drawings.

b. Provide panel inspection forms as part of the source test procedure submittal.

c. Inspection to include, as a minimum: Layout, mounting, wire and data cable routing, wire tags, power supply, components and wiring, I/O components layout (including terminals, wiring and relays), device layout on doors and front panels, and proper ventilation operation.

8. I/O test: a. Verify that I/O is properly wired to field terminals and is properly mapped

into the PLC and the rest of the SCADA system, including all operator interface devices.

b. Test methodology: 1) Discrete inputs: Apply appropriate input at panel terminal, observe

input card indicator, observe data value at each indicated data address, observe data received on all operator interface displays.

2) Discrete outputs: Issue commands from operator interface screen, verify output card indicator light and measure response at field wiring terminals. Repeat for each operator interface screen.

3) Analog inputs: Apply appropriate analog input signal at panel terminals, observe data value at each indicated data address, and observe data properly received at each operator screen. Check each point at 0 percent, 50 percent, and 100 percent of scale.


4) Analog outputs: Enter scaled values in the output buffer file, observe the output data file value, and measure appropriate response at panel wiring terminals.

c. Test forms to include, but not be limited to: 1) PLC and panel number. 2) I/O type. 3) I/O tag name. 4) Panel terminal block numbers. 5) Rack/slot/number of I/O point. 6) Check-off for correct response for each I/O point. 7) Space for comments. 8) Initials of individual performing test. 9) Date test was performed. 10) Witness’ signature lines.

9. System configuration test: a. Demonstrate and test the setup and configuration of all operator interface

devices. The test shall be performed using simulated I/O. b. Demonstrate all utility software and functions, such as virus protection,

backup, optical drive burning, remote updates, network monitoring, etc. c. Demonstrate the proper operation of all peripheral hardware. d. Demonstrate all general functions. e. Demonstrate proper operation of log-on and other access security

functions. f. Perform network performance testing to prove it is operating at stated

speeds (e.g. gigabit fiber loop). g. Demonstrate the proper operation of all historical data storage, trend,

display, backup, and report functions. h. Test automatic fail over of redundant equipment. i. Demonstrate the proper operation of the alarm display and

acknowledgement functions. j. Test forms:

1) For each test, list the specification page and paragraph of the function demonstrated, and provide a description of the function.

2) List the specific tests and steps to be conducted. For each function, list all of the different sub-functions or ways the function can be used and provide a test check-off for each. Include signature and date lines.

10. Control logic test: a. The purpose of this test is to verify that all software functions and logic

work as specified, along with any hardwired logic or functions in the tested control panels. The test shall be performed using simulated I/O.

b. Testing requirements: 1) Demonstrate each function in Control Strategies. Demonstrate in

detail how each function operates under all design conditions and variety of operating scenarios. Test to verify the application of each general control strategy function to each specific control strategy or loop description.

2) Demonstrate the proper operation of the programming and configuration for each control strategy or loop description. Test each strategy or loop description on a sentence by sentence and function by function basis. Loops with similar or identical logic must each be tested individually.


3) Demonstrate the proper operation of all digital communication links and networks. Verify each digital communication I/O point.

4) Failure testing: In addition to demonstrating correct operation of all specified features, special effort shall be made to demonstrate how the system responds to and recovers from abnormal conditions including, but not limited to: equipment failure, operator error, communications subsystem error, communications failures, simulated/forced software lockups, power failure (both utility power and power to SCADA hardware), process equipment failure, and high system loading conditions, as well as concurrent instances of failures.

c. Test forms: 1) Include the fully revised and approved control strategy for the loop

being tested. 2) Identify the cause and effect as each I/O point is toggled through the

simulator. Check boxes shall be provided to track proper and/or improper operation of the loop.

3) Any deficiencies or operational changes shall be noted on the forms for correction and documentation. Include signature and date lines.

PART 3 EXECUTION

3.01 COMMISSIONING

A. Owner training: 1. Complete Owner training in accordance with Section OR- 01757 –

Commissioning. 2. Maintenance Training:

a. Course Objective: For Owner’s maintenance personnel to develop skills needed for routine maintenance of Process Control and Instrumentation System (PCIS).

b. Content: Provide training for each type of component and function provided, including each type of instrument.

c. Component calibration. d. Adjustments: For example, controller tuning constants, current switch trip

points, and similar items. e. Troubleshooting and diagnostics for equipment and software. f. Replacing lamps and fuses. g. I&C and PLC components removal and replacement. h. Periodic preventive maintenance.

3. Operations Training: a. Course Objective: Develop skills needed to use SCADA system

components and functions to monitor and control the plant on a day-to-day basis.

b. Primary Topics: 1) PCIS Overview: How hardware and software are used for operation

and control of facilities. 2) Block Diagram Presentation of PCIS: How and what information

flows within system and what is done by each functional unit. 3) Process/Operator Interface: Explanation and demonstration of how to

use HMI/OIT to access displays, reports, and controls.


c. Training on loop-by-loop basis. 1) Loop Functions: Understanding of loop functions, including interlocks

for each loop. 2) Loop Operation: For example, adjusting process variable setpoints,

AUTO/MANUAL control transfer, AUTO and MANUAL control, annunciator acknowledgement and resetting. Description of which functions are available to operators versus senior plant operation versus chief plant operations/superintendents.

d. Walk-through of installed systems.

B. Installation Tests: 1. General:

a. The Owner reserves the right to test any specified function, whether or not explicitly stated in the test submittals.

b. Failure testing: 1) In addition to demonstrating correct operation of all specified

features, demonstrate how the system reacts and recovers from abnormal conditions including, but not limited to: a) Equipment failure. b) Operator error. c) Communications sub-system error. d) Power failure. e) Process equipment failure. f) High system loading conditions.

c. Conduct testing Monday through Friday during first shift no more than 8 hours per day. 1) Testing at other times requires approval of the Owner.

2. Calibration: a. After installation but before starting other tests, calibrate and adjust all

instruments, devices, valves, and systems, in conformance with the component manufacturer's instructions and as specified in these Contract Documents.

b. Components having adjustable features are to be set carefully for the specific conditions and applications of this installation. Test and verify that components and/or systems are within the specified limits of accuracy.

c. Replace either individually or within a system, defective elements that cannot achieve proper calibration or accuracy.

d. Calibration points: 1) Calibrate each analog instrument at 0 percent, 25 percent,

50 percent, 75 percent, and 100 percent of span, using test instruments with accuracies traceable to NIST.

e. Field verify calibration of instruments that have been factory-calibrated to determine whether any of the calibrations are in need of adjustment.

f. Analyzer calibration: 1) Calibrate and test each analyzer system as a workable system after

installation. Follow the testing procedures directed by the manufacturers' technical representatives.

g. Complete instrument calibration sheets for every field instrument and analyzer.

h. Calibration tags: 1) Attach a calibration and testing tag to each instrument, piece of

equipment, or system.


2) Sign the tag when calibration is complete. 3. LAN Cable Tests:

a. After installing the cable and connectors, test all cables using the LAN certification to confirm the installation meets the requirements of the specification.

b. Provide test documentation that includes the cable number, total length of cable, a permanent hard copy, as well as a USB or CD copy of all traces. 1) After installing connectors:

a) Perform cable end-to-end testing on all installed cables from both ends of the cable. Test shall include cable system performance tests and confirm the absence of wiring errors.

b) Submit a signed test report presenting the results of the cable testing.

c) Repair or replace any portions of the system not meeting ANSI/TIA/EIA standards for a Category 6 installation. Repaired sections shall be retested.

c. Submit 3 copies of all final documentation (including traces), using the approved test form, to the Owner upon successful completion of the testing.

4. Fiber Optic Cable Tests: a. Test procedures and field test instruments shall comply with applicable

requirements of TIA: 1) LIA Z136.2. 2) TIA 455 78. 3) TIA 455 133. 4) TIA 526 7. 5) TIA 526 14. 6) TIA 586-C.0. 7) TIA 568-C.1. 8) TIA 568 C.3.

b. Test attenuation and polarity of installed cable with OLTS and installed condition of cabling system and its components with OTDR.

c. Verify condition of fiber end face. d. Perform on each cabling link (connector to connector). e. Perform on each cabling channel (equipment to equipment). f. Do not include active devices or passive devices within link or channel

other than cable, connectors, and splices. For example, link attenuation does not include such devices as optical bypass switches, couplers, repeaters, or optical amplifiers.

g. Document Tests: 1) OLTS dual wavelength attenuation measurements for single mode

and multimode links and channels. 2) OTDR traces and event tables for single mode and multimode links

and channels. h. Submit 3 copies of all final documentation (including traces), using the

approved test form, to the Owner upon successful completion of the testing.

5. Ultrasonic and radar check out: a. Check response under all operating conditions. b. Track all responses through trend charts in the SCADA system. c. Check for ground or current leaking from grounding.


d. Provide Echo Transmission and signal quality on all level transmitters including guided and unguided units. 1) Provide printout of the actual transmission and all parameters.

Printout shall list any suppression used due to interferences. 6. Loop Validation Test:

a. Check all control loops under simulated operating conditions by causing a range of input signals at the primary control elements and observing appropriate responses of the respective control and monitoring elements, final control elements, and the graphic displays associated with the SCADA system. Issue commands from the SCADA system and verify proper responses of field devices. Use actual process inputs wherever available.

b. Provide “end-to-end” tests: 1) Test SCADA system inputs from field device to SCADA system

operator workstations. 2) Test SCADA system outputs from SCADA operator workstations to

field devices and equipment. 3) Observe and record responses at all intermediate devices. 4) Test and record operator commands and signal readouts to each

operator device where there is more than one operator interface point.

5) For each signal, perform separate tests for HMI computer screens, operator interface terminal (OIT) screens, and local control panels.

c. Retest any loop following any necessary corrections. d. Specified accuracy tolerances for each analog network are defined as the

square-root of the sum of the squares of individual component accuracy. e. Apply simulated sensor inputs corresponding to 0 percent, 25 percent,

50 percent, 75 percent, and 100 percent of span for networks that incorporate analog elements and monitor the resulting outputs to verify compliance to accuracy tolerance requirements.

f. Apply continuously variable up and down analog inputs to verify the proper operation and setting of discrete devices (signal trips, etc.).

g. Apply provisional settings on controllers and alarm setpoints. h. Record all analog loop test data on test forms. i. Exercise each field device requiring an analog command signal, through

the SCADA system. Vary, during the validation process, the output from the PLC SCADA system and measure the end device position, speed, etc. to confirm the proper operation of the device for the supplied analog signal. Manually set the output from the SCADA screen at 0 percent, 25 percent, 50 percent, 75 percent, and 100 percent and measure the response at the final device and at any intermediate devices.

j. Exercise each field device providing a discrete input to the SCADA system in the field and observe the proper operation at the operator workstation: 1) Test limit switches. Set limits mechanically and observe proper

operation at the operator workstation. 2) Exercise starters, relay contacts, switch contacts, and observe

proper operation. 3) Calibrate and test instruments supplying discrete inputs and observe

proper operation.


k. Test each device accepting a discrete output signal from the SCADA. Perform the appropriate operator action at the HMI computer screens, operator interface terminal (OIT) screens, and local control panels and confirm the proper operation of the field device: 1) Stroke valves through outputs from the SCADA system, and confirm

proper directional operation. Confirm travel limits and any feedback signals to the SCADA system.

2) Exercise motors starters from the SCADA system and verify proper operation through direct field observation.

3) Exercise solenoids and other field devices from the SCADA system and verify proper operation through direct field observation.

l. Include in the test forms: 1) Analog input devices:

a) Calibration range. b) Calibration data: Input, output, and error at each test value. c) Analog input associated PLC register address. d) Value in PLC register at each test point. e) Value displayed at each operator interface station (local

operator interface displays and SCADA workstations). 2) Analog output devices:

a) Calibration range. b) Test value at each test point. c) Analog output associated PLC register address. d) Control variable value at field device at each test point. e) Physical device response at each test point:

(1) Response to be actual valve position, or motor speed, etc. 3) Discrete instrument input devices:

a) Switch setting, contact action, and dead band. b) Valve position switches:

(1) Response in the PLC as the valve is stroked from the PLC. (2) Field observed actual valve position, and valve indicator

position as the valve is stroked from the PLC. c) Operator interface switches (control stations and other pilot

devices) and associated response. d) Starter and drive auxiliary device contact response. e) Response of all other discrete inputs to the PLC.

4) Discrete output devices: a) Observed response of field device to the discrete output from

the PLC. b) Observe the proper operation of Open, Close, Start, Stop, On,

Off, etc. 5) Test equipment used and associated serial numbers.

m. Loop validation certifications: 1) After the field device loop tests have been successfully completed,

submit a certified copy of all test forms signed by the Design-Builder, Vendor, and the Owner’s representative with test data entered, together with a clear and unequivocal statement that all instrumentation, including all control and signal wiring, has been successfully calibrated, inspected, and tested.

C. Functional Testing: 1. General:


a. Commence Functional tests after completion of all installation tests. b. Purpose: Demonstrate proper operation of all systems with process

equipment operating over full operating ranges under conditions as closely resembling actual operating conditions as possible.

c. Follow approved detailed test procedures and check lists for Functional Test activities.

2. Control Logic Operational Validation: a. The purpose of control logic validation is to field test the operation of the

complete control system, including all parts of the SCADA system, all control panels (including vendor control panels), all control circuits, all control stations, all monitored/controlled equipment, and final control elements.

b. Demonstrate all control functionality shown on the P&IDs, control schematics, and other drawings, and specified in the loop descriptions, control strategies, Electrical Specifications, and Mechanical Equipment Specifications.

c. Test in detail on a function-by-function and sentence-by-sentence basis. d. Thoroughly test all hardware and software functions:

1) Including all hardwired and software control circuit interlocks and alarms.

e. Test final control elements, controlled equipment, control panels, and ancillary equipment under startup, shut down, and steady-state operating conditions to verify all logic and control is achieved.

f. Control logic validation tests to include, but not limited to: a repeat of all control logic tests from the source test, modified and expanded to include all field instruments, control panels, circuits, and equipment.

3. Loop Tuning: a. Optimally tune all electronic control stations and software control logic

incorporating proportional, integral, or derivative control. Apply control signal disturbances at various process variable levels and adjusting the gain, reset, or rate settings as required to achieve proper response.

b. Verify the transient stability of final control elements operating over the full range of operating conditions, by applying control signal disturbances, monitoring the amplitude and decay rate of control parameter oscillations and making necessary controller adjustments as required to eliminate excessive oscillatory amplitudes and decay rates. As a minimum, achieve 1/4-wave amplitude decay ratio damping (subsidence ratio of 4) under the full range of operating conditions.

c. If excessive oscillations or system instability occur, as determined by the Owner, continue tuning and parameter adjustments, or develop and implement any additional control algorithms needed to achieve satisfactory control loop operation.

4. Functional Validation Sheets: a. Document each functional test on an approved test form. b. Document loop tuning with a report for each loop, including two-pen chart

recordings showing the responses to step disturbance at a minimum of 3 setpoints or process rates approved by the Owner. Show tuning parameters on the charts, along with time, date, and sign-off by Design-Builder and Owner.

c. Include on the form, functions which can be demonstrated on a loop-by-loop basis: 1) Loop number and P&ID number.


2) Control strategy, or reference to specification tested. 3) Test procedures: Where applicable, use the Source Test function-by-

function, sentence-by-sentence loop test checklist forms modified to meet the requirements of the Functional test. Otherwise, create new forms.

d. For functions that cannot be demonstrated on a loop-by-loop basis (such as overall plant power failure), include on the test form a listing of the specific steps and tests to be conducted. Include with each test description the following information: 1) Specification page and paragraph of function demonstrated. 2) Description of function and/or text from specification. 3) Test procedures: Use the source loop test checklist forms modified to

meet the specific testing conditions of the functional test. 5. Functional certification:

a. Provide Manufacturer’s Certificate of Installation and Functionality Compliance as specified in Section OR-01757 - Commissioning. 1) Including all test forms with test data entered, submitted to the Owner

with a clear and unequivocal statement that all Functional test requirements have been satisfied.

D. Process Start-Up Phase: Refer to Section OR-01757 – Commissioning.

E. Instrumentation and Controls Fine-Tuning: 1. After the Acceptance Testing, test PCIS system for additional 30 days as

specified in this Section to identify issues and make corrections, as needed. 2. General:

a. The performance test is part of the Work that must be completed as a condition of Acceptance and Final Completion for the entire Project.

b. The complete PLC control and SCADA system must run continuously for the duration of Acceptance Testing.

c. Test and use the entire process control system under standard operating conditions.

d. Exercise all system functions. e. Log failure, any system interruption and accompanying component,

subsystem, or program failure including time of occurrence, duration of each failure, failure classification, and cause: 1) Provide a competently trained technician or programmer on call for

the Project Site during all normal working days and hours from the start of the performance test until final acceptance of the system. a) Response time to the Project Site: 4 hours or less, for a major

failure. 3. SCADA system testing:

a. Exercise each system function, e.g., status report, alarms, logs, and displays several times at a minimum, and in a manner that approximates "normal" system operation.

b. Failure of the SCADA system during Acceptance Testing shall be considered as indicating that the programs and operating system do not meet the requirements of the specifications. 1) Corrective action is required before restarting the performance test.

c. Only those components, sub-systems, and systems covered in this Section and supplied under this Contract shall be considered for this acceptance test. Problems and failures of other systems shall not be


considered as part of this test, except as they display the capabilities of this system to detect failures.

4. Failures: a. Classify failures as either major or minor:

1) Minor failure: a) A small and non-critical component failure or software problem

that can be corrected by the Owner's electronic technicians. b) Log this occurrence but this is not a reason for stopping the test

and is not grounds for non-acceptance. c) Should the same or similar component failure occur repeatedly,

this may be considered as grounds for non-acceptance. d) Failure of one printer or operator station is considered a minor

failure providing all functions can be provided by backup equipment, i.e., alternate printers and operator station, and repairs can be made and equipment returned to service within 3 working days.

2) Major failure: a) Considered to have occurred when a component, subsystem,

software control, or program fault causes a halt in or improper operation of the system and/or when a technician's work is required to make a repair or to re-initiate operation of the system.

b) Cause termination of the performance test. c) Start a new acceptance test when the causes of a major failure

have been corrected. d) A failure is also considered major when failure of any control

system that results in an overflow, underflow, overdose, or underdose condition, or permit violation, occurs.

5. Technician report: a. Each time a technician is required to respond to a system malfunction,

they must complete a report, which includes details concerning the nature of the complaint or malfunction and the resulting repair action required and taken.

b. If a malfunction occurs which clears itself or which the operator on duty is able to correct, no report is required or logged as specified above.

c. If a technician has performed work but no report is written, then a major failure is considered to have occurred.

d. Each report shall be submitted within 24 hours to the Owner, or its representative.

3.02 SCHEDULES

A. Example test forms: 1. Example test forms are attached at the end of this Section. They may be used

as a starting point for the development of Project-specific test forms for this Project.

2. The example test forms are not intended to be complete or comprehensive. Edit and supplement the forms to meet the requirements for testing and test forms specified in this Section and other Contract Documents.

END OF SECTION


SOURCE TEST - CONTROL PANELS

1. GENERAL INSPECTION A. Structural Inspection

Verify Lifting Lugs Installed Verity enclosure has lock and lock is functional Confirm that seismic bracing components are provided per manufacturer’s installation instructions

B. Exterior Inspection Cabinet exterior is clean, scratch, and dent free Inspect externally for corrosion and damage Verify enclosure door opens and closes easily Verify enclosure has a 3-point latch Verify enclosure has a flange mounted disconnect (where voltages greater than 120 VAC enter the cabinet) Verify enclosure has the appropriate NEMA rating (1, 1G, 12, 3R, 4, 4X, etc.) Verify enclosure is the appropriate size (not grossly larger than design, and will still fit in the plant)

Nameplates Cabinet has identification nameplate

All door labels are straight, spelled correctly, and match the tagging defined in the Contract

Cabinet has a nameplate that includes the following:

Power source(s) Integrator’s Logo Circuit ID(s) Short Circuit KAIC ratings If labels are screwed to door, silicone was utilized to cover screw holes (Labels screwed to the door of a

NEMA 4/4X panel technically violates the NEMA rating.) Door Devices All devices penetrating the outside of panel have gaskets, silicone or both All door devices are installed (HMIs, Pilot Devices, etc.) Door mounted equipment is mounted straight and square All exterior or door mounted equipment present and accounted for, installed and securely fastened NEMA classification has not been violated due to penetrations Door mounted equipment has the same NEMA rating as the panel All door mounted equipment installed at the correct height All door mounted equipment installed in the correct positions and order (layout of door mounted equipment

is grouped properly and in a logical manner) Doors with multiple penetrations have adequate bracing (if needed) Visually check condition of indicators , controllers and annunciators Check that pilot lights illuminate correctly Check the Push-To-Test function Ensure correct pilot light color Peripheral Devices Horn / Beacon is installed (where required) Silence and Reset pushbutton PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



1. GENERAL INSPECTION (continued) C. Interior Inspection

Cabinet is cleaned of marks and dirt. Inspect internally for corrosion and damage. Back panel is clean of marks and dirt. Interior of panel vacuumed and shall be free of all debris. Check that the panel roof is clean and clear of foreign materials. Bottom of panel has been cut out (where bottom entry is required), with angle iron welded around the bottom

perimeter. Re-painting has been performed. If internal light door limit switch is provided, ensure the light automatically turns "on" when the doors are open. Intrusion alarms (where required).

Interior Labeling All panel mounted equipment has identification labeling, by using either a Brothers or Phenolic type tags. Verify that door mounted components are mounted square and symmetrical. Verify that nameplates are straight, legible, and spelled correctly. All terminal blocks are identified/labeled with permanent labels including tight end blocks and caps. All wiring shrink labeled and or phased correctly to the specifications. All wire labels shrunk completely rotated and aligned alike for easy identification. All fuses and circuit breakers are labeled with ID and current rating. System Integrator’s label or labels installed on door. Panel manufacturer model/serial number tag is present. All required safety/warning tags installed and straight. Correct UL (typically UL 508) or cUL tag installed and registered and all other associated tags installed and

straight (the UL tag might not be installed in the panel at the factory test. If the panel is modified due to changes during the factory test or a punch list generated from the factory test, the UL labeling would need to be re-applied. Some UL shops do not apply the UL label until the panel is released to be shipped.).

Wireways Plastic wire way covers installed properly. Plastic wireways have no sharp edges. No wire Ties inside the wireways. No sharp edges on wire ties. Separation: White duct is used for DC voltages, Gray duct is used for AC voltages. Ensure wiring duct is not over-full, includes provision for 20% more wiring and the cover may easily be

installed. Panduit recommends 50% duct fill, but 40% is a better practice. PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



1. GENERAL INSPECTION (continued) C. Interior Inspection (continued) Wiring Visually check terminals and condition of internal wirings Verify that the control panel has been assembled and wired as designed Verify that all components are operational and perform the functions intended Verify that all components are sized appropriately for the application Verify that equipment control circuits function as intended Back of door wiring is labeled and neatly formed Back panel to door wiring has sufficient bending radius with spiral wrap Wire connection has been verified wired to correct points within the panel Individual wires have been given a pull test to verify a good terminal connection Wire and cable minimum bending radius have not been violated All equipment installed straight and square to back panel Wire colors are correct: Black and White > AC hot and neutral, respectively Red > AC control signals Blue > DC power and control (Blue w/White stripe for DC ground) Yellow > Foreign voltages (those still present when panel power is disconnected) Green > AC equipment ground Black > TSP (+) White> TSP(-) Analog wiring shields are continuous (connected by a dedicated terminal block for such shields) Analog shield wires are grounded within the panel, where not otherwise grounded at the transmitter itself Discrete inputs are separately fused or protected by a circuit breaker on a “per loop” basis Intrinsic Safety Wiring Ensure wiring associated with intrinsic safety circuits or intrinsic safety barriers is kept away from all

other wiring by UL minimum distances or by a physical (grounded metal) barrier preventing non-intrinsically safe wiring from coming in contact with intrinsically safe circuits or wiring

Verify all spare terminals are installed according to the percentage listed in the specifications Grounding Equipped with “Blackburn” or other grounding type lug Lug is securely fastened to the panel structure Verify Grounding bar is installed Verify Isolated ground bar is installed PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



2. POWER TEST A. AC Power

AC Power is routed correctly within the panel, and is isolated from DC and network wiring. All fuses are installed and sized properly. All breakers are installed and sized properly. 24 VDC Power Supplies are functional. 24 VDC Power fail contacts are functional. 24 VDC power supplies are redundant, and have diode modules enabling the hot swap-over between supplies.

24 VDC supplies are equipped with dry contact failure alarms, wired as PLC inputs to signal failure of any DC power supply. Such alarm inputs to the PLC have been tested as being functional.

Dedicated receptacle is wired to receive a dedicated AC supply. Verify continuity for all DC commons, ground and AC neutrals. Verify that the CP temporary input power is connected correctly and is the correct voltage. Close the CP main circuit breaker(s). Verify that voltages at subsequent circuit breakers are correct. Close circuit breakers. Verify that power feeding interruptible and uninterruptible power supplies is correct. Turn on power supplies if they are not already on. Verify that voltages at distribution terminals are correct. Energize any remaining hardware such as the PLC.

B. Uninterruptible Power Supply (UPS) Mounted appropriately within the cabinet, on a dedicated shelf, or rear of a swing-out sub panel. Is equipped with maintenance bypass switch (or at least plug/receptacle means for bypassing the unit). Test all UPS alarms (on inverter, failure, battery failure etc.) Turn off the AC power supply and verify that the UPS will be switched on to supply the designated vital loads in

the control panel. 3. CONTROLS & AUXILIARY DEVICES TEST

Verify all interposing and auxiliary relays are functioning.

Verify panel lights are functioning. Ventilation and Heating

If ventilation fans are fitted, check the fans operate correctly any associated air filters are clean and not blocked. Verify components are installed in the correct orientation for proper air flow.

4. HARDWIRED INTERLOCK AND SAFETY TEST Verify that hardwired interlocks through the control panel as shown on schematic drawings are functioning. For

example, outlet high pressure switch interlock to a pump. Verify that all hardwired safety devices through the control panel is functioning. For example, the pull cord

emergency stops of conveyors. PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



5. PLC TEST A. Components

PLC interior High Temperature alarm is installed, wired to the PLC, and is shown to be functional. Relays have transient suppression across their coils. This is particularly important for DC coil relays, where

diodes in reverse polarity are often used. TVSS is installed across the main incoming 120 VAC.

PLC and PLC Rack Verify all cards are securely seated. Ensure clearance around PLC rack has been met, such that convective heat transfer is not impeded by

devices erroneously mounted in the “no encroachment” area. Confirm with manufacturer clearance recommendations.

B. PLC I/O Test Furnish I/O test forms and test all the listed input and output points as follows:

Discrete Inputs: Simulate a field contact closure by “shorting” across the appropriate terminal blocks. Observe the transition between a logical “0” and “1” in the PLC software.

Discrete Outputs: Force the output bit to toggle between logical “0” and logical “1” using the PLC software. Measure contact resistance at the wired terminal blocks using a digital meter selected for the “ohms” setting.

Analog Inputs: Connect a signal generator to the appropriate terminal blocks. Tailor the connection depending on whether a 2-wire or 4-wire simulation is required. Modulate the 4-20mA signal. Observe the associated PLC internal memory register to transition between 0-65535 or if scaled in engineering units, between 0 and the maximum scaled engineering unit. The latter method is preferred.

Analog Outputs: Force the output register to a value between 0-65535 or 0-100%, if the scaling block can be manipulated. Observe the measured 4-20mA value increment and decrement using a digital ammeter.

C. Redundant Controllers (where required) Test Remove Communication cable from PLC-1 to verify switching to PLC-1A Remove Communication cable from PLC-1A to verify switching back to PLC-1 Remove Power from PLC-1 to verify switching to PLC-1A Remove Power from PLC-1A to verify switching to PLC-1 Remove Communication cable from PLC-1 to I/O rack and verify switching to PLC-1A Remove Communication cable from PLC -1A to I/O rack and verify switching to PLC-1

D. PLC Control Logic Verification The PLC control strategy is verified by following the Control Logic Verification Form based on the specifications.

Each control strategy will be verified by simulating the process and checking the state or value of PLC outputs. The results of equipment status and alarms and process instrument values and trends shall also be verified on the Plant SCADA graphic screens stored in a temporary SCADA computer. Since all PLC input and output wiring has been verified and some field devices are not available during Factory Acceptance Testing, certain inputs will be simulated either by means of additional hardware and/or software as described below.

DI states are either simulated by hardwired switches or forced inputs using a programming terminal. For example, when starters and drives are not provided as part of the contract, jumpers may be installed

from the output call relays to the running confirmation inputs to simulate the running state of the motors. AI values are either simulated by an external source or within software using a programming terminal. For example, when a level transducer is not provided as part of the contract the level transducer loop

current may be simulated with a loop powered potentiometer and adjusted manually for the level input. PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



5. PLC TEST (continued) D. PLC Control Logic Verification (continued) Typical Fault Logic If the fault input is high and the disable (if applicable) for the fault is not high and the common disable (if

applicable) is not high begin timing. If any of these conditions changes, stop timing and reset the timer. If the timer reaches its preset, activate the alarm output. If the fault alarm is a shutdown alarm stop the associated motor and latch the alarm so that it remains present even if the condition clears.

The fault condition must return to normal and the alarm must be reset for a latched alarm to clear. Typical Fail to Start Logic If the motor is called to run (call output high) and no running feedback is received (running input is low) and

the fail to start and common alarm disables (if applicable) are not high start timing. If any of these conditions changes, stop timing and reset the timer. If the timer reaches its preset, activate the alarm output, stop calling the motor and latch the alarm.

6. HMI OR OIT TEST HMI / OIT Functionality Communication with PLC Screen Layouts Screen Navigation Set Point Entry Animation Color Correctness (Green=Run, Red=Off, Amber=Alarm, or the agreed upon convention) Alarms Acknowledge and Reset Security / Access Levels / Passwords 7. NETWORK COMMUNICATION TEST A. Network Components Fiber optic cabling terminates in a patch panel Media converters are installed and functional Terminating resistors have been installed for trunk/tap topologies or where required Wire and cable bending limitations have not been violated B. Networking Functions Verify data transfer via the network to different PLCs as shown on the Network Block Diagrams Verify network traffic rate and error margin is acceptable PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



8. SOURCE TEST DOCUMENTATION AND RECORD Panel Documentation As-built panel drawings showing actual panel construction and devices arrangement and c/w Bill of

Material. Panel schematic and interconnection drawings. P&ID drawings and schematic drawings for the process area controlled by the panel that is to be tested. I/O list test forms of the process area to be tested. Source test procedure of the process area to be tested. Test record forms of the process area to be tested. Forms shall include area for signature of responsible

test personnel. Hard copy of the PLC application program of the process area to be tested. Hard copy of the HMI/OIT graphic screens of the process area to be tested. 9. SOURCE TEST TOOLS AND SOFTWARE

Simulation software if required Digital volt meter Fluke 87 Process meter Fluke 787 Laptop computer with PLC application program Temporary SCADA computer with HMI software and applicable graphic screens Jumper wires

PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:


INSTALLATION AND CERTIFICATION CHECKLIST DOCUMENTATION

INSTRUMENT LOOP NO.

SERVICE DESCRIPTION

A COPY OF LATEST ISSUE OF THE FOLLOWING DOCUMENTS ARE INCLUDED IN THIS INSTRUMENT INSTALLATION CERTIFICATION FILE:

INSTRUMENT SPECIFICATION SHEETS (FOR ALL INSTRUMENTS IN THE LOOP)

INSTRUMENT INSTALLATION DETAILS (FOR ALL INSTRUMENTS IN THE LOOP)

INSTRUMENT LOOP WIRING DIAGRAMS

INSTRUMENT INSTALLATION CERTIFICATION CHECKLIST

SIZING CALCULATIONS

INSTRUMENT INSTALLATION SCHEDULE (APPLICABLE PART)

NAMEPLATE SCHEDULE (APPLICABLE PART)

VENDOR LITERATURE CALIBRATION INFORMATION

INSTRUMENT LOOP IS PART OF EQUIPMENT START-UP/SHUTDOWN INTERLOCKS? No Yes

REMARKS:

CHECKED BY (COMPANY) ACCEPTED BY (COMPANY)

SIGNATURE SIGNATURE

DATE DATE


SWITCHES INSTALLATION AND CALIBRATION CHECKLIST

INSTRUMENT LOOP NO.

SERVICE DESCRIPTION

CHECK BELOW, WHEN COMPLETED:

BENCH CALIBRATED PER SPECIFICATION SHEET NO.

VERIFIED PER P&ID NO.

CORRESPONDS TO SPECIFICATION SHEET NO.

WIRING CORRECT PER INSTRUMENT LOOP DRAWING NO.

INSTALLATION CORRECT PER DETAIL NO.

ACCESSORIES ARE PRESENT AND PROPERLY INSTALLED

INSTRUMENT IS ACCESSIBLE FOR MAINTENANCE OR REMOVAL

ENGRAVED LAMINATED NAMEPLATE (NO SPELLING ERRORS) PERMANENTLY INSTALLED


FIELD CALIBRATION CHECK

CONTACT NO. FUNCTION

FOR SIGNAL

CONTACT IS TO AT SPECIFIED VALUE FOR ACTUAL TRIP POINT WAS

1 ALARM INCR OPEN SET PT = SET PT =

S/D PERM DECR CLOSE RESET = RESET =







NOTE: PERM IS ABBREVIATION FOR PERMISSIVE


SWITCHES INSTALLATION AND CALIBRATION CHECKLIST

REMARKS:


SIGNATURE SIGNATURE

DATE DATE


TRANSMITTER/CONTROLLER/INDICATOR INSTALLATION AND CALIBRATION CHECKLIST


INSTRUMENT TYPE INDICATOR TRANSMITTER CONTROLLER

OTHER DESCRIPTION

INSTRUMENT TAG NO. SERIAL NO.

SERVICE DESCRIPTION

BENCH CALIBRATION CHECK

INPUT RANGE = OUTPUT RANGE =

HEAD CORRECTION = LINEAR

CALIBRATED SPAN = SQUARE ROOT

% CALIB SPAN DESIRED VALUE ACTUAL VALUE EXPECTED VALUE ACTUAL VALUE

0

50

100

CHECK BELOW, WHEN COMPLETED:









FIELD CALIBRATION CHECK


% CALIB SPAN DESIRED VALUE ACTUAL VALUE EXPECTED VALUE ACTUAL VALUE

0

50

100


TRANSMITTER/CONTROLLER/INDICATOR INSTALLATION AND CALIBRATION CHECKLIST

DIRECT REVERSE

ACTION VERIFIED AT 50% SPAN

ACTION VERIFIED AT SPAN

CONTROLLER SETTINGS

SETTING GAIN PB RESET

(INTEGRAL) DERIV. (RATE)

HIGH LIMIT

LOW LIMIT

ELEV. ZERO

ZERO SUPP

PRE-TUNE

POST-TUNE

PRE-TUNE SETTINGS

GAIN PB RESET (REPEAT/MIN) RESET (MIN/REPEAT) DERIVATION (MINUTES)

FLOW 1.0 100 10 0.1 N/A

LEVEL 1.0 100 MIN. MAX. N/A

PRESSURE 2.0 50 2.0 0.5 N/A

TEMP. 4.0 25 0.1 10 OFF

REMARKS


SIGNATURE SIGNATURE

DATE DATE


ANALYZERS INSTALLATION AND CALIBRATION CHECKLIST


TYPE OF INSTRUMENT

INSTRUMENT TAG NO. SERIAL NO.

SERVICE DESCRIPTION

CHECK BELOW, IF TRUE









REMARKS


SIGNATURE SIGNATURE

DATE DATE


CONTROL VALVES INSTALLATION AND CALIBRATION CHECKLIST


VALVE TAG NO. SERIAL NO.

TRANSDUCER TAG NO. SERIAL NO.

SOLENOID TAG NO. SERIAL NO.

VOLUME BOOSTER TAG NO. SERIAL NO.

POSITIONER SERIAL NO.

SERVICE DESCRIPTION

TRANSDUCER CHECK


CALIBRATED SPAN = CALIBRATED SPAN =

BENCH

SPAN DESIRED ACTUAL SPAN EXPECTED ACTUAL

0% 0%

50% 50%

100% 100%

FIELD

SPAN DESIRED ACTUAL SPAN EXPECTED ACTUAL

0% 0%

50% 50%

100% 100%

CHECK BELOW, IF TRUE:

BENCH CALIBRATED PER ABOVE



VALVE SPECIFICATION NO.

TRANSDUCER SPECIFICATION NO.

SOLENOID SPECIFICATION NO.


INSTALLATION CORRECT PER INSTRUMENT INSTALLATION DETAILS

VALVE DETAIL NO.

TRANSDUCER DETAIL NO.

SOLENOID DETAIL NO.


CONTROL VALVES INSTALLATION AND CALIBRATION CHECKLIST




VALVE CHECK

FLOW CHECK PROCESS FLOW DIRECTION THROUGH THE VALVE IS CORRECT

SAFETY CHECK

ON LOSS OF AIR VALVE FAILS ON LOSS OF POWER SOLENOID FAILS OPEN CLOSE TO VENT TO VALVE

TRAVEL CHECK

FULL OPEN AT FULL CLOSED AT MEASURED TRAVEL

PSI PSI INCHES

SEATING CHECK

ON BENCH RESULTS ACTUATOR BENCH SET

IN-LINE

POSITIONER CHECK

VALVE FULL OPEN AT PSI TO POSITIONER

VALVE FULL CLOSED AT PSI TO POSITIONER

VOLUME BOOSTER CHECK

BYPASS VALVE (GAIN) ADJUSTING SCREW BACKED OUT TURNS FROM CLOSED TO ENSURE QUICK BUT

STABLE OPERATION (TYPICALLY 1-1/2 TO 2 TURNS)

REMARKS


SIGNATURE SIGNATURE

DATE DATE