residuals handling improvements project

Version 06/2004

CONTRACT DOCUMENTS FOR

RESIDUALS HANDLING IMPROVEMENTS PROJECT

VOLUME II OF II

September 2008

ITB NO. 3972

PUBLIC SERVICES AREA Wastewater Treatment Plant

CITY OF ANN ARBOR 100 North Fifth Avenue

Ann Arbor, Michigan 48104

Prepared by Greeley and Hansen

211 West Fort Street, Suite 710 Detroit, Michigan 48206

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TABLE OF CONTENTS Section Pages Table of Contents.................................................................................................... TC-1 to TC-6 Advertisement ...................................................................................................................... AD-1 Notice of Pre-Bid Conference...............................................................................................NP-1 Instructions to Bidders .................................................................................................... IB-1 to 3 Living Wage Ordinance and Compliance Form ..........................................................LW-1 to 2 Human Rights Division Contract Compliance Forms ...............................................AAF-0 to 2 Proposal ............................................................................................................................P-1 to 3 Bid Forms.................................................................................................................BF-1 to BF-8 Contract............................................................................................................................ C-1 to 4 Bond Forms...................................................................................................................... B-1 to 2 General Conditions ..................................................................................................... GC-1 to 19 Standard Specifications..........................................................................................................SS-1 Detailed Specifications Supplementary Conditions.................................................................................................. 00800 Division 1 – General Requirements Summary of Work............................................................................................................... 01110 Change Order and Work Order Procedures ........................................................................ 01250 Payments ............................................................................................................................. 01290 Contract Items..................................................................................................................... 01291 Coordination and Meetings................................................................................................. 01310 Progress Schedule ............................................................................................................... 01326 Submittals ........................................................................................................................... 01330 References........................................................................................................................... 01422 Quality Control ................................................................................................................... 01450

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Construction Facilities and Temporary Controls................................................................ 01500 Material and Equipment...................................................................................................... 01600 Lines and Grades ................................................................................................................ 01722 Cutting and Patching........................................................................................................... 01732 Cleaning .............................................................................................................................. 01740 Operation and Maintenance Manuals ................................................................................. 01783 Contract Close Out.............................................................................................................. 01789 Training............................................................................................................................... 01820

Division 2 - Sitework Hazardous Contaminated Materials.................................................................................... 02074 PCB-Contaminated Material............................................................................................... 02078 Asbestos Abatement............................................................................................................ 02081 Demolition .......................................................................................................................... 02220 Shoring, Sheeting and Bracing ........................................................................................... 02251 Excavation .......................................................................................................................... 02316 Backfilling .......................................................................................................................... 02317 Slope Protection and Erosion Control ................................................................................ 02370 Laying and Jointing Buried Pipelines................................................................................. 02500 Buried Ductile Iron Pipe and Fittings ................................................................................. 02505 Buried Steel Pipe and Fittings ............................................................................................ 02506 Sewer Manholes.................................................................................................................. 02509 Disinfection......................................................................................................................... 02512 Hydrants.............................................................................................................................. 02514 Leakage Tests ..................................................................................................................... 02516 Pavements and Walks ......................................................................................................... 02840 Landscaping ........................................................................................................................ 02900

Division 3 - Concrete Lead-Based Paint Remediation........................................................................................... 03010 Concrete Formwork ............................................................................................................ 03100 Concrete Accessories .......................................................................................................... 03150 Concrete Reinforcement ..................................................................................................... 03200 Cast-In-Place Concrete ....................................................................................................... 03310 Shotcrete ............................................................................................................................. 03361 Precast Concrete Hollow Core Slabs .................................................................................. 03415 Grout ................................................................................................................................... 03600 Concrete Cleaning............................................................................................................... 03710 Concrete Restoration........................................................................................................... 03731 Chemical Grout Injection.................................................................................................... 03733 Epoxy Grout Injection ........................................................................................................ 03734

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Division 4 - Masonry Masonry Mortar and Grout ................................................................................................. 04050 Masonry .............................................................................................................................. 04300 Masonry Restoration........................................................................................................... 04500

Division 5 - Metals Galvanizing......................................................................................................................... 05085 Structural Steel.................................................................................................................... 05120 Metal Fabrications .............................................................................................................. 05500 Metal Stairs ......................................................................................................................... 05510 Aluminum Welded Handrails and Railings ........................................................................ 05520 Metal Floor Grating and Plate ............................................................................................ 05531 Metal Castings .................................................................................................................... 05560 Expansion Joint Assemblies ............................................................................................... 05805

Division 6 - Wood and Plastics Rough Carpentry................................................................................................................. 06100 Finish Carpentry ................................................................................................................. 06200 Fiberglass Grating, Stair and Handrail ............................................................................... 06611

Division 7 - Thermal and Moisture Protection Building Insulation ............................................................................................................. 07210 Elastic Sheet Roofing.......................................................................................................... 07530 Metal Roofing System ........................................................................................................ 07610 Sheet Metal-Flashing and Trim .......................................................................................... 07620 Prefabricated Roof Specialties............................................................................................ 07710 Prefabricated Metal Coping and Edging............................................................................. 07715 Firestopping ........................................................................................................................ 07840 Joint Sealers ........................................................................................................................ 07900

Division 8 - Doors and Windows Steel Doors and Frames ...................................................................................................... 08110 Aluminum Doors ................................................................................................................ 08120 Overhead Coiling Doors ..................................................................................................... 08331 Aluminum Windows........................................................................................................... 08520 Finish Hardware.................................................................................................................. 08710 Glass and Glazing ............................................................................................................... 08800 Aluminum Window Wall System....................................................................................... 08920

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Translucent Wall System .................................................................................................... 08950

Division 9 - Finishes Gypsum Wall Board ........................................................................................................... 09260 Ceramic Tile Floor and Wall Finish ................................................................................... 09310 Epoxy Terrazzo................................................................................................................... 09445 Acoustical Ceilings ............................................................................................................. 09511 Resilient Sheet Flooring...................................................................................................... 09660 Painting ............................................................................................................................... 09900

Division 10 - Specialties Toilet Compartments .......................................................................................................... 10160 Metal Louvers ..................................................................................................................... 10210 Signage................................................................................................................................ 10420 Lockers................................................................................................................................ 10500 Fire Extinguishers ............................................................................................................... 10522 Toilet Accessories............................................................................................................... 10810

Division 11 - Equipment Chemical Feed Equipment (Polymer-Bulk)........................................................................ 11242 Lime Handling and Feed Equipment .................................................................................. 11245 Submersible Mixing Equipment ......................................................................................... 11268 Sluice Gates and Sluice Gate Operators ............................................................................. 11285 Progressing Cavity Pumps .................................................................................................. 11315 Hose Pumps ........................................................................................................................ 11318 Chemical Storage Tanks ..................................................................................................... 11345 Gravity Thickener Equipment ............................................................................................ 11350 Gravity Belt Thickeners...................................................................................................... 11352 Centrifuge Equipment......................................................................................................... 11355 Compressed Air Equipment................................................................................................ 11370 Odor Control Equipment..................................................................................................... 11395 Dewatered Cake Lime Addition Equipment....................................................................... 11750 Sludge Unloading Equipment ............................................................................................. 11850 Blend Tank Mixing and Aeration Equipment..................................................................... 11975

Division 12 - Furnishings Window Treatment ............................................................................................................. 12490 Furniture and Kitchen Appliances ...................................................................................... 12500

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Division 13 - Special Construction Aluminum Flat Covers........................................................................................................ 13232 General Instrumentation and Control ................................................................................. 13400 Field Testing ....................................................................................................................... 13402 Operational Availability Demonstration............................................................................. 13403 Field Instruments ................................................................................................................ 13420 Panels Devices and Enclosure Construction....................................................................... 13431 Programmable Logic Control (PLC) Systems .................................................................... 13451 SCADA Systems................................................................................................................. 13453 Signaling and Alarm ........................................................................................................... 13851

Division 14 - Conveying Systems Electric Traction Elevator................................................................................................... 14212 Shaftless Screw Conveyors and Cake Hoppers .................................................................. 14550 Temporary Dewatered Cake Conveyor Equipment............................................................ 14551 Monorail System................................................................................................................. 14620 Jib Cranes............................................................................................................................ 14650

Division 15 - Mechanical Supports and Anchors ......................................................................................................... 15060 Vibration Isolation .............................................................................................................. 15072 Mechanical Insulation......................................................................................................... 15080 Ductile-Iron Pipe and Fittings............................................................................................. 15106 Steel Pipe and Fittings ........................................................................................................ 15107 Miscellaneous Pipe and Fittings ......................................................................................... 15108 Erecting and Jointing Interior and Exposed Exterior Piping .............................................. 15109 Valves and Valve Operators ............................................................................................... 15110 Pressure Switches ............................................................................................................... 15122 Gauges – Pressure and Vacuum.......................................................................................... 15124 Hydronic Piping Valves and Specialties............................................................................. 15183 Refrigeration Piping and Specialties................................................................................... 15184 Chemical (water) Treatment ............................................................................................... 15187 Natural Gas System............................................................................................................. 15190 Plumbing Equipment .......................................................................................................... 15400 Plumbing Piping and Valves............................................................................................... 15405 Plumbing Specialties........................................................................................................... 15406 Plumbing Fixtures and Trim ............................................................................................... 15410 Sump Pumps ....................................................................................................................... 15446 Boiler and Boiler Room Equipment ................................................................................... 15510 Breeching Chimneys and Stacks......................................................................................... 15550 Condensing Units................................................................................................................ 15670

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Air Handling Units.............................................................................................................. 15720 Packaged Air Conditioning Units ....................................................................................... 15730 Heating, Ventilating and Air Conditioning Pumps ............................................................ 15740 Air Coils.............................................................................................................................. 15761 Terminal Heat Transfer Units ............................................................................................. 15765 Ductwork............................................................................................................................. 15810 Ductwork Accessories ........................................................................................................ 15820 Fans ..................................................................................................................................... 15830 Air Outlets and Inlets ........................................................................................................ 15850 HVAC Controls .................................................................................................................. 15900 Testing, Adjusting and Balancing....................................................................................... 15950

Division 16 - Electrical Basic Electrical Material and Methods............................................................................... 16050 Electrical Requirements for Shop-Assembled Equipment ................................................. 16055 Grounding ........................................................................................................................... 16060 Electrical Identification....................................................................................................... 16075 Electrical Testing Requirements......................................................................................... 16080 Short Circuit and Coordination Study ................................................................................ 16085 Wires and Cables - 600 Volts and Below ........................................................................... 16121 Medium Voltage Cables ..................................................................................................... 16122 Electrical Raceway Systems ............................................................................................... 16130 Underground Electrical Distribution System...................................................................... 16132 Wiring Devices ................................................................................................................... 16140 Electric Motors ................................................................................................................... 16220 Adjustable Frequency Drives.............................................................................................. 16266 Substation Transformers ..................................................................................................... 16275 Medium Voltage Fuses ....................................................................................................... 16344 Medium Voltage Interrupter Switches................................................................................ 16345 Disconnect Switches ........................................................................................................... 16411 Automatic Transfer Switches.............................................................................................. 16415 Contactors ........................................................................................................................... 16421 480 Volt Switchgears.......................................................................................................... 16430 Panelboards ......................................................................................................................... 16443 Motor Control Centers ........................................................................................................ 16445 General Purposes Dry Type Transformers ......................................................................... 16460 Control Components and Devices ...................................................................................... 16491 Lighting............................................................................................................................... 16500

AARHIP 13232-1

SECTION 13232

ALUMINUM FLAT COVERS

PART 1 GENERAL

1.1 SUMMARY

A. Section includes the requirements for design, fabrication, and furnishing a self-supporting, aluminum flat cover system at Blend Tank No. 1 and No. 2 and at the effluent weir of Gravity Thickener Tank No. 1.

B. Provide covers as shown in the Contract Drawings.

C. The CONTRACTOR must perform all necessary tank field measurements to

obtain dimensions for the proper design of the flat cover system. It is the CONTRACTOR’s responsibility to verify or determine the dimensions of the existing structures in the field and to design covers and supports to conform to field conditions. No separate or additional payment will be made for special designs of covers or supports or for any additional demolition or construction work to accommodate actual field conditions.

1.2 REFERENCES

A. Quality Standards: The following codes and standards form a part of this section to the extent specified herein:

1. ASTM C 864 - Standard Specification for Dense Elastomeric

Compression Seal Gaskets, Setting Blocks and Spacers.

2. ASTM C 1115 - Specification for Dense Elastomeric Silicone Rubber

Gaskets and Accessories. 3. Aluminum Association "Aluminum Structures: A Guide to Their

Specifications and Design". 4. Aluminum Association "Aluminum Standards and Data". 5. ASCE 8-90 - Specification for Design of Cold-Formed Stainless

Steel Structural Members. 6. ASTM F 593 - Standard Specification for Stainless Steel Bolts, Hex

Caps, Screws and Studs. 7. AASHTO - Standard Specifications for Highway Bridges.

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8. Federal Specification TT-S-00230 - Sealing Compound, Elastomeric Type, Single

Component (for Caulking, Sealing and Glazing in Buildings and Other Structures.

9. ANSI/AWS D1.2 - Structural Welding Code for Aluminum.

10. Building Officials and Code Administrations (BOCA) 1993.

1.3 DESCRIPTION

A. Provide clear span covers supported from their periphery. Provide covers consisting of a flat, self-supporting deck design. Provide a supporting system consisting of aluminum structural members. Join members by means of aluminum or stainless steel fasteners. Provide aluminum for all metal components in the covers. Do not use galvanized, painted, or plated steel. Isolate dissimilar metals in the structure that are not compatible by means of an elastomeric gasket or insulating compound.

B. System Design Concept:

1. The design concept of all the cover systems is based on flat covers.

2. Providing all support beams, trusses or spars as required for aluminum cover

support and to meet the load bearing criteria set forth in this specification. The maximum height of each truss not to exceed 7’-0”.

3. Provide all flat covers with an easily walkable (no tripping hazards) surface

on the upper or outside surface. Provide all surfaces capable of experiencing foot traffic with a permanent non-skid surface. Provide permanent raised pattern surface texturing. Non-skid surface coating systems which wear off with use will not be allowed.

4. Provide all covers with positive surface water drainage so that water is not

allowed to collect or pond on the cover. Provide covers with drainage consisting of shedding of water to the perimeter of the cover.

5. Provide covers so the deadweight of removable covers, hatches, and access

panels does not exceed 150 lbs and the lifting or opening force required shall not exceed the deadweight of the movable section. Provide lift pockets or handles that do not penetrate the cover to allow manual opening/removal and replacement of the covers and hatches.

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6. Design each cover system to maintain an air intrusion leakage not to exceed 0.2 cfm per square foot at an applied negative pressure of 0.2 inches of water column.

7. Design all covers and supports so they do not interfere with flow or

equipment in the tanks.

8. Blend Tank Covers: Provide adjustable air inlet vents as shown on the Contract Plans, to accommodate the makeup air volume required to balance the exhaust ventilation system.

9. Gravity Thickener Tank Covers: Provide covers that are attached together

to form a continuous cover over the effluent channel, weirs and scum baffle. Support the cover on the tank wall and the effluent channel wall, so that the cover is held securely in place. Do not support the cover from the scum baffle. Provide access hatches as shown to allow access to the trough and weir for inspection and maintenance.

1.4 SUBMITTALS

A. General: Submit in accordance with Division 1 and as follows:

1. Cover manufacturer's qualifications.

2. Shop Drawings describing the complete cover system and all its components, complete with materials of construction, typical details, thicknesses, gauges, and finishes. Indicate welds by symbols conforming to all standards.

a. Structural Framing: Include details showing fabrication and assembly

of the cover systems. Show anchor bolts settings. Include transverse cross sections.

b. Cover Panels: Provide drawings showing layouts of all panels, details

of edge conditions, joints, corners, custom profiles, supports, anchorages, trim, seals, gaskets, flashings, closures, and special details. Include transverse cross sections.

c. Accessory Components: Provide details of accessory components,

including access hatches and covers with their lifting handles, drains, and ventilation duct connections, and details showing slide gate covers to clearly indicate materials of construction and methods of installation. Provide the weight of all cover hatches and components to be manually lifted or the magnitude of the opening force needed.

3. Manufacturer’s specification and installation instruction for aluminum

covers, including certification of compliance.

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4. Provide accurate and fully describing product literature for all system

components and materials employed in construction of covers.

5. Complete structural design calculations sealed by a structural engineer registered in the State of Michigan, certifying that the proposed flat cover system will meet the specified design criteria.

NOTE:

Structural calculations will not be approved by the ENGINEER. Such calculations are required to demonstrate compliance with specified design criteria. It is and shall remain the responsibility of the structural engineer, who performs and seals the calculations, to assure the accuracy and adequacy of all such calculations.

6. Provide an erection procedures manual.

1.5 QUALITY ASSURANCE

A. Installer Qualifications: Engage experienced installers approved by the manufacturer to erect the cover system, who have specialized in the erection and installation of types of cover systems similar to that required for this project, and who are certified in writing by the manufacturer as qualified for erection of the manufacturer's products. If the field erection is undertaken by someone other than the manufacturer, provide a knowledgeable field erection supervisor to oversee the Work for the duration of the field assembly and installation of the equipment. All costs for the services of erection supervision are contract work and no separate payment will be made therefore.

1.6 DELIVERY, STORAGE, AND HANDLING

A. General: Deliver, store and handle all products and materials as specified in Division 1.

B. Deliver fabricated components, sheets, panels, and other manufactured items so

they will not be damaged or deformed. Package panels for protection against transportation damage.

C. Handling: Exercise care in unloading cover panels to prevent bending, warping,

twisting, and surface damage.

D. Stack materials on platforms or pallets covered with tarpaulins or other suitable weather tight, ventilated covering. Store panels so that water accumulations will drain freely. Do not store panels in contact with other materials that might cause staining, denting, or other surface damage.

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PART 2 PRODUCTS

2.1 MANUFACTURER

A. Acceptable manufacturers are listed below. Other Manufacturers of equivalent products may be submitted.

1. Hallsten Corporation, Sacramento, CA.

2.2 MATERIALS

A. The following is a summary of approved materials and/or material specifications. All aluminum alloys shall be as defined by the Aluminum Association and published in the Aluminum Standards and Data.

1. Bolts and Fasteners: Provide all bolts and fasteners of 6061-T6 or 7075-T73

aluminum or 316 stainless steel.

2. Plates and Sheets: Provide plate and sheet material of aluminum alloy 6061-T6, mill finish AA-M10 as fabricated. Provide formed panels in self-supporting systems with a minimum thickness of 0.09 inch.

3. Structural Shapes: Provide aluminum structural shapes of alloy 6061-T6.

4. Miscellaneous Shapes: Provide miscellaneous aluminum shapes of alloy

6061-T6, 5052-H36.

5. Gaskets: Provide gaskets of cellular neoprene or silicone conforming to ASTM C 864, or solid silicone conforming to ASTM C 1115, resistant to ozone and either immune to deterioration from ultraviolet light or shielded from exposure to ultraviolet light.

6. Sealant: Provide silicone sealants resistant to ozone and ultraviolet light,

and conforming with Federal Specification TT-S-00230. 2.3 DESIGN CRITERIA

A. Design the entire structures to sustain the loads specified herein, with stress limitations of the Aluminum Associations’ Specifications for Aluminum Structures, and in accordance with applicable local codes.

B. Utilize the load cases described below unless more severe loads are determined to

be applicable by the manufacturer.

1. Dead Load: The dead load is defined as the weight of the structure and all material permanently attached to and supported by the structure.

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2. Live Load: The uniform live load is 100 psf.

3. Snow Load: 30 psf.

4. Unbalanced Live Load: An unbalanced load of one-half of the uniform load applied to one-half of the cover with no live load on the other half.

5. Wind Load: 80 mph.

6. Load Combinations: As prescribed in BOCA.

7. Temperature: Consider the load combinations listed above for a material

temperature range of -40°F to 160°F.

8. Panel Design Load: In addition to the above-mentioned loads and load combinations, design the aluminum panels for a 400-lb load distributed over 1 sq ft at any location and a plus or minus 40-psf load distributed over the entire area of any given panel. These loads are to be taken as acting simultaneously with one another and not simultaneously with other design loads.

C. Limit deflection to L/240. Deflection limits apply to every component of the cover

system in both directions. 2.4 CONNECTIONS

A. Do not design a joint to sustain a greater total resultant shear force than that which would be allowed by summing the allowable shear force of the individual fasteners, based on their net cross section area through the shear plane and the allowable shear stress of the material. Do not use values greater than those published by the Aluminum Association and ASTM F 593 for aluminum and stainless steel fasteners, respectively.

B. Design and fabricate welded aluminum parts in accordance with Section 7 of the

Aluminum Association's Aluminum Structures Guide, and the American Welding Society D 1.2 Structural Welding Code for Aluminum. Field welding of aluminum will not be permitted.

2.5 ACCESSORIES

A. Provide accessories including hatches, makeup air inlets with dampers, hinged or removable covers, slide gate frame covers and duct penetration sleeves at the locations shown on the Drawings.

1. Access Hatches: Provide hatches at the locations, quantities and clear

opening dimensions as shown on the Drawings. Mount hatches on two (2”) inch (minimum) high extrude structural aluminum frames. Fabricate hatch

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lids of 0.090 inch minimum thickness, aluminum with a downward overlap of the hatch frame of two (2”) inches with gaskets for an airtight seal. Furnish lids with a lifting handle and positive locking device to insure air tightness in the locked position. Provide a minimum of 2 such devices per hatch. Reinforce hatch openings with aluminum channel on the underside of the surrounding panel. Provide hatches with aluminum medium duty commercial hinge assemblies and stainless steel fastening devices.

2. Blend Tank Aeration and Mixing System Enclosures: Provide a flexible

gasket seal between the aluminum cover system and Blend Tank Aeration and Mixing System openings, in order to allow a seal at all times and allow the Blend Tank Aeration and Mixing System openings to operate properly.

3. Makeup Air Inlets: Provide a flanged connection for a duct to add vacuum

relief makeup air into the enclosure. Provide one-way dampers to allow passage of air in but not out.

4. Exhaust Air Duct Connection: Provide flanged duct connection as shown on

the Drawings. Flange to be compatible to connecting flange of ventilation duct.

B. The manufacturer's standard accessories will be acceptable provided they meet the

functional requirements of the project.

PART 3 EXECUTION

3.1 INSTALLATION

A. Perform all Work by skilled mechanics experienced in the erection of aluminum covers.

B. If the field erection is undertaken by someone other than the manufacturer, provide

a knowledgeable field erection supervisor to oversee the work for the duration of the field assembly and installation of the cover(s).

C. Assemble each cover to true line and form without distortion. Field refabrication

of components of panels is not permitted. Enlargement of bolt holes and forcing or warping of assembly elements to achieve fit-up is not permitted. Replace components damaged during erection.

D. Install covers so that water drained there from does not pond on surface of existing

structures.

E. Install gasket material continuous between designed breaks in the sealing system. Splices in gaskets are not permitted.

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F. Undertake field assembly and erection so as not to interfere with normal operations of the plant or the specific structure receiving the cover(s).

G. Protect the existing structures, attached equipment, and surrounding facilities from

damage during assembly and erection at the cover systems. Restore all damaged equipment, surfaces, grounds, landscaping, and other features to their original condition.

3.2 MANUFACTURER'S FIELD SERVICES

A. Furnish the services of a qualified representative of the manufacturer to supervise the installation of the cover system, inspect the completed installation, make any necessary adjustments, and to instruct the operating personnel in its maintenance as specified in the General Requirements.

END OF SECTION

AARHIP 13400-1

SECTION 13400

GENERAL INSTRUMENTATION AND CONTROL

PART 1 GENERAL

1.1 SUMMARY

A. Section includes requirements for furnishing and installing instrumentation and control systems including all work and materials necessary to perform control and monitoring functions as illustrated on drawings, and as specified in the following sections:

1. Section 13402 - Field Testing 2. Section 13403 - Operational Availability Demonstration 3. Section 13420 - Field Instruments 4. Section 13431 - Panel Devices and Enclosure Construction 5. Section 13451 - PLC Systems 6. Section 13453 - SCADA System 7. Section 15110 - Valves and Valve Operators

1.2 REFERENCES

A. Codes and Standards referred to in this Section are:

1. IEEE 802.3 10 Mbps baseband networks 2. ISA-S5.4 Instrument Loop Diagrams. 3. NFPA 70 National Electrical Code 4. UL Underwriter’s Laboratory 5. NEMA National Electrical Manufacturers Association

1.3 DEFINITIONS

A. Terminologies

1. Systems Integrator: Firms regularly engaged in providing instrumentation, control, and Supervisory Control and Data Acquisition (SCADA) systems.

2. PLC: Programmable Logic Controller system, including power supply, central processing unit (CPU), communication controller, interconnect cables, and input and output interface.

3. PICS: Process and Information Control System. PICS is an integrated network of PLCs, OWSs, servers, PCs, printers and network switches and hubs. PICS serves as the computer based plant-wide monitoring and control system.

4. OIT: Graphical local Operator Interface Terminal at PLC enclosures.

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5. OWS: Operator Workstation. Personal computer (PC) based operator interface system, including hardware, operating system software, and operator interface HMI system software; generally referred to as SCADA or PICS workstation.

6. SCADA (Supervisory Control and Data Acquisition): Supervisory computer systems, which operate as primary operator interface to the entire PLC network, which include process visualization and control, data collection and storage, alarm management, and process data link to other office productivity software. This is generally synonymous with PICS for the Ann Arbor plant, however SCADA node workstations are servers, as opposed to normal view node OWS.

1.4 SYSTEM DESCRIPTION

A. Programming and Software Configuration

1. All programming and software configuration for the main PICS PLCs (PLC-BT and PLC-RS) and the PICS Operator Workstations will be performed by others (the OWNER’S Application Software Programmer) under the direction of the City of Ann Arbor.

2. All programming and software configuration of the package control system PLCs shall be included as part of this contract work

B. Provide all materials and work necessary for complete and fully functional systems.

1. Provide instrumentation and control components as well as complete system integration. Provide all mounting hardware and supports. Work shall include panel mounting and the completion of all wiring terminations within control panels.

2. Coordinate work with all electrical, mechanical, and structural work furnished in this contract.

3. Ensure proper interface between PLC, OIT and OIS systems and equipment furnished in this contract.

4. Install, make final connections, adjust, test, start-up systems per manufacturer’s instructions and recommendations.

C. Design Requirements

1. General: Provide complete instrumentation and control system for the treatment plant as indicated herein and as shown on drawings. Certain instrumentation and control components are provided as part of package control systems furnished by the various equipment manufacturers. It shall be the Contractor’s responsibility to coordinate these systems to ensure compatibility with the overall plant automation system and to ensure that all required signal interfaces are provided.

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2. Provide PICS SCADA System to monitor all PLC controlled systems, which include all work performed in this contract. PLC SCADA panel locations shall be as follows:

a. Solids Handling Building Control Room: PLC-RS (new PLC replaces the existing PLC-RS)

b. Existing Gravity Thickener Building: PLC-BT (existing PLC to remain)

c. Existing Lime Slaker Control Room: The existing lime slaker package control PLC (existing PLC to be retained)

3. The existing Gravity Thickener Building PLC-BT is being retained with its existing hardware configuration.

a. The software configuration of the existing PLC-BT will be modified by the OWNER’S Programmer to redefine some of the signals as described in Section 13451. Information available at the existing PICS system from this facility will be replicated by the OWNER’S Application Software Programmer in the new PICS SCADA node and operator workstations. All hardware and wiring modifications associated with new or redefined signals to that PLC are to be provided as part of the work under this contract.

b. OWNER’S Programmer will provide program modifications to allow the control of equipment at the Gravity Thickener Building via a link with the new PLC-RS over the PICS network segment as described in the process control descriptions included hereinafter in PART 2. The design intent is to have certain equipment in the Gravity Thickener Building interlocked with the operation of other equipment in the Solids Handling Facility. The new data link between the Gravity Thickener Building and the new PLC-RS is to be provided as part of the work under this contract.

4. Provide integration of the existing Lime Slaker PLC system into the new PLC and SCADA system. The existing Lime Slaker PLC communicates with the existing PLC-RS via DH-Plus™ data link. That link will continue to be used for communicating with the new PLC-RS. OWNER’S Application Software Programmer will reproduce the existing monitoring capabilities of the existing solids building PLC-RS in the new PLC-RS for the lime system. OWNER’S Programmer will also include this information in the configuration of the new PICS SCADA server and operator workstations. Any new hardware required to allow the continued use of the DH-Plus™ data link with the new PLC-RS is to be provided as part of the work under this contract.

5. Lift Station Server: Relocate the existing Lift Station Server (currently referred to as SCADA-6) which also acts a View client node for other process areas. The OWNER’S Programmer will be responsible to configure

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that workstation to allow it to additionally function as a View Client for the new Solids Handling SCADA Server.

a. The existing lift station SCADA server workstation is connected to a Motorola radio system by a serial link. The lift station SCADA server is responsible for communicating with the Motorola system. All other workstations get their information about the lift stations from this SCADA server.

b. Relocate the existing lift station SCADA server workstation and the corresponding Motorola MOSCAD radio equipment from the existing control room to the new Main Control Room.

c. Extend the existing MOSCAD radio system antenna cable as required to allow relocation of the hardware as shown.

d. The OWNER’S Application Software Programmer will perform all required software configuration to allow this workstation to function as both a Server for the lift station radio equipment and as a view client for the remainder of the PICS system, including the new Solids Facility SCADA Server.

e. OWNER’S Application Software Programmer will be responsible for pointing each of the new PICS workstations (SCADA node in new Control Room and View node in Centrifuge Control Room) at this Lift Station Server in order to access its data.

D. City Standards: Provide all PLC programming conforming to the following City of Ann Arbor Process and Information Control System standards documents (also available electronically):

1. Application Configuration Design Guide, dated March 20, 1998 and updated February 2007.

2. PLC Standard Modules for PLC Programming, with a print date of April 2007.

E. Network Communication Requirements

1. Provide Ethernet ready PLC systems.

2. Provide fiber optic Ethernet control system SCADA backbone as shown.

3. Configure the communications network as two separate Ethernet network segments to keep process related communications with the PLCs separate from other network traffic.

a. Provide a PLC segment which connects the individual PLCs, SCADA server nodes and development workstations.

b. Provide a PICS segment which connects the SCADA sever nodes, operator workstations (view client nodes), personal computers, printers and other PICS components.

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F. Source Code Ownership

1. Any developed ladder logic (along w/ source code) shall become property of the City. This applies to any logic associated with package control systems as well.

G. Existing Control Panels in Control Room

1. All three control panels in the existing control room are ultimately to be demolished and removed. However, the filter press panel and Panel CP-40 are to remain in service until all associated equipment has been decommissioned the gravity belt thickeners and centrifuges are in service. Panels to ultimately be removed are:

a. Passavant Filter Press Panel (north panel)

b. Panel CP-40 (center panel)

c. Incinerator Panel (south panel)

2. The incinerator panel can be removed at any time.

1.5 SUBMITTALS

A. General: Provide submittals as specified in Division 1 and as required below. Submit documents as follows:

1. Submit in three-ring binders.

2. Provide cover sheet on each binder with the following information:

a. Project Title, Location and Owner

b. Submittal Title

c. Submittal Order (First Submittal, Re-submittal Number, etc.)

3. Organize and divide documents, using tagged dividers, into logical divisions.

4. Provide index sheets.

5. Minimum drawing size: 8-1/2 by 11 inches. Put drawings, larger than 11 by 17 inches, in three-hole plastic pockets.

6. Type all text.

7. Do not submit faxed documents.

B. Action Submittals

1. Product Data: Submit manufacturer’s official and published product data, specifications, and installation recommendations for each item.

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2. Shop Drawings: Submit shop drawings as per Division 1, and as required below. Include the following information in each submittal:

a. Instrument index, including tag number, description, location, and calibrated range for each instrument.

b. Individual instrument specification sheet, including manufacturer's name and complete catalog number.

c. PLC Input and Output drawings, containing, but not limited to, the following information:

(1) Line numbers and instrument tag numbers

(2) Individual component locations

(3) Actual equipment wiring terminal designations, point to point wiring, and cable shield terminations

(4) Wire type, size and identification number

(5) Signal types (e.g., 120 Volt ac, 4-20 mAdc, pulse frequency, etc.)

(6) Contact orientations (e.g., normally open, normally closed, etc.)

(7) Equipment grounding requirements

(8) Signal boosters, interposing relays, optical isolators, and shunt resistors.

3. PICS Progress Schedule Submittal

a. Provide, in Microsoft Project format, schedule showing the proposed PICS hardware and software submittal, installation and testing schedule. Do not make any PICS related hardware and software submittals until after the PICS Progress Schedule has been submitted.

b. Include in the schedule all testing specified in Sections 13402 and 13403.

C. Information Submittals (for owner information, not for approval)

1. Test Reports: Submit all loop field calibration reports.

2. Manufacturer’s Instructions: Submit manufacturer published installation manuals for each instrument.

D. Contract Closeout Information Submittals (for owner information, not for approval): Provide submittals as required below.

1. Project Record Documents: In addition to requirements described in Division 1, provide the following:

a. PLC program documentation: Provide paper copies of all PLC software development and configuration including listing of all PLC register tables.

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b. Include functional narrative description of the developed ladder logic to describe each control system. Ladder logic is to be annotated as specified in Section 13451 to include functional alphanumeric description of logic elements to assist Owner in understanding the ladder logic for troubleshooting and future modification.

c. PLC program copies: Provide two digital copies of fully configured PLC systems. Digital copies shall be in CD-ROM format.

d. Operator interface program copies: Provide hard copy printouts and digital copies of new or modified OIT screens and SCADA operator interface screens and database listings. Digital copies shall be in CD-ROM format.

2. Operation and Maintenance Data: Provide operation and maintenance manuals as specified in Division 1. Include the following information:

a. Recommended spare parts list.

b. Manufacturer approved repair and service centers list.

c. Replacements part sources.

d. Recommended maintenance procedures and frequencies.

3. Warranty: Provide warranty certificate as described in Division 1.


A. Regulatory Requirements

1. Code Compliance: Comply with National Electrical Code (NFPA 70) and any and all local codes, applicable to construction and installation of electrical wiring, devices, material and equipment.

2. NECA Standards: Comply with applicable portions of National Electrical Contractor’s Association’s “Standard of Installation”.

3. UL Labels: Provide control panel components, power supplies, controllers, relays, etc., which have been listed and labeled by Underwriter’s Laboratories.

B. The purpose of contract drawings and specifications is to convey information required for complete and functioning systems. Systems Integrator is responsible for all details necessary to properly install, adjust, and place in operation, intended systems. “Equipment Lists” and “PLC Input and Output Lists” are provided for convenience; their accuracy is not guaranteed.


A. General: Deliver, store, and handle all products and materials as specified in Division 1.

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B. Packing and Shipping

C. Acceptance at Site: Inspect all materials and equipment against approved shop drawings at time of delivery. Immediately return for replacement or repair any equipment or materials damaged or not meeting requirements of approved shop drawings.

D. Storage and Protection: Label all equipment and materials after they have been inspected. Store all equipment and materials in dry, covered, ventilated location. Protect from harm in accordance with manufacturer’s recommendations.

1.8 PROJECT/SITE CONDITIONS

A. Environmental Requirements: Protect all equipment and instruments specified herein from moisture.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Allowable hardware and software manufacturers are listed in the respective specification sections.

2.2 SYSTEM ARCHITECTURE

A. Provide PLCs with direct 10/100 BaseT(X) Ethernet connections.

B. Provide a local Operator Interface Terminal (OIT) at each package control PLC where shown.

C. Network the PLCs and PICS operator workstations via Ethernet as shown on the drawings. Provide network switching equipment capable of 10/100Mbps Ethernet communication.

D. Valve or Gate Actuator Network

1. Provide 2-wire current loop actuator networks for valves and gates as shown. Connect the 2-wire current loop network to an actuator master control station/bridge (AMCS) as shown on drawings.

2. The valve actuator 2-wire network is specified in Section 15110.

3. Interface the actuator AMCS using a Modbus link to the Solids Handling Facility PLC-RS.

4. Provide a single actuator network for the Solids Handling Facility and Gravity Thickener Building.

E. Interface with electrical Microprocessor Metering System (MMS) network.

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1. Interface the electrical switchgear Microprocessor Metering System using a Modbus link to the Solids Handling Facility PLC-RS as shown.

2. The MMS is specified in Section 16430 and 16445. Signals to be monitored are specified hereinafter in the subpart titled CONTROL STRATEGY – ELECTRICAL METERING.

2.3 MONITORING AND CONTROL – GENERAL

A. This section contains functional descriptions of the various unit processes and equipment to be monitored and controlled by (or through) the PICS system.

B. Configure the PLC/SCADA system to meet the functional requirements specified herein.

C. Coordinate the PLC configuration programming with the configuration of the PICS computer workstations specified in Section 13453.

D. Make all register and I/O data available to the SCADA computer for display, logging and control purposes.

E. Monitoring and control requirements specified herein describe the entire addition to the SCADA system, including PLCs and PICS computer workstations.

F. Examine status of operating mode input from each equipment item/group. SCADA control logic and outputs shall only be activated if the equipment is in the proper operating mode (auto, computer or remote, as applicable). Computer Mode and Remote Mode inputs to the PLC generally refer to the same thing, i.e. that control is now handed off to the PLC.

G. In general, all PICS control discrete outputs for starting and stopping equipment are to be configured as maintained “Run” signal commands which are maintained during a power failure. This approach shall be to minimize the amount of equipment that needs to be manually restarted following a power failure. Exceptions to this approach are noted in the respective control strategy descriptions.

2.4 TYPICAL MONITORING AND CONTROL STRATEGIES

A. General

1. Provide all PICS system configuration in accordance with the City’s standards as described in the following documents:

a. Application Configuration Design Guide, dated March 20, 1998 and updated February 2007.

b. PLC Standard Modules for PLC Programming, with a print date of April 2007.

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B. Typical Valve Positioning Control

1. Configure the PICS/PLC system to be able to position each gate or valve in the actuator network at any position (from full closed to full open). Control and monitoring shall be via Modbus through the actuator network AMCS.

2. Program PLC system to scan data from the AMCS in the following order:

a. Read Alarm Status

b. Read Digital Status

c. Perform Alarm Accept

d. Read Analog Status

3. Configure the PICS workstations to annunciate AMCS alarm conditions.

4. Configure the PICS operator workstations to permit manual positioning of each gate and valve. Provide “desired position” field, which allows user to enter desired valve position in percent open. In addition, provide the following indications:

a. Valve position feedback (graphically through bargraph, and numerically in percent open).

b. Process variable feedback (graphically through bargraph and in direct engineering units).

2.5 CONTROL STRATEGY – GBT FEED PUMPS

A. WAS Tanks and Mixers

1. There are two WAS tanks. Both are normally active but can be isolated for cleaning. Provide an ultrasonic level transmitter in each tank.

2. Develop PICS screen to display the running and alarm status of the mixers, tank level and isolation sluice gate position status.

3. Allow the operator to start and stop the mixers manually from the PICS workstation.

B. GBT Feed Pumps

1. There are two feed pumps, one active and one standby. These pumps can be controlled either from a PICS workstation or from the GBT Control Panel OIT. Allow the operator to select the duty pump from either the PICS workstation or from the GBT OIT. The pumps are controlled by PICS PLC-RS.

2. Interlock the pump operation through PICS SCADA with the operation of the Gravity Belt Thickener. The GBT control system contains a dedicated package control PLC. Configure PICS PLC-RS to monitor the GBT package control PLC to determine when to start and stop the pump. The GBT PLC will issue a “run request” bit to start the duty pump. Configure

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PICS PLC-RS to run the pump as long as the “run request” bit is active. Stop the pump whenever the “run request” bit is removed. The GBT PLC also sends a percent speed command to the PICS PLC to control the speed of the pump. Configure PICS PLC-RS to control the pump speed in response to the speed command setting from the GBT PLC.

3. Allow the operator to make periodic manual adjustments to the pump speed at the PICS workstation in response to changing levels in the WAS tanks in order to avoid under-pumping or over-pumping the tanks.

4. Make the following pump status, speed and flow signals available to the GBT package control PLC in accordance with the requirements described in Section 11352.

a. Pump Running

b. Pump Failure

c. Pump Remote Mode (Auto Ready)

d. Pump Speed

e. Pump Discharge Flow

5. Develop PICS screens to display the running and alarm status of the pumps as well as the pump speed and discharge flow.

2.6 CONTROL STRATEGY – GRAVITY BELT THICKENERS

A. The GBT control system is to be a package control system with a dedicated PLC provided by the equipment manufacturer. Provide display of specific data about the status and alarm conditions for the GBT system via an Ethernet data link with the GBT master panel.

1. Gravity Belt Thickener (GBT) shutdown.

a. If low level is detected in the WAS sludge well, it indicates that the GBT is being fed at a rate greater than that which can be sustained by the flow of WAS into the WAS Tanks. At low level, activate an alarm shutdown bit to the GBT package control PLC logic. The GBT package control system shall shut down the operating GBT when this alarm occurs.

b. If high level is detected in the active Blend Tank, it indicates that the GBT is producing sludge at a greater rate than can be processed through the Blend Tank. At high level, activate an alarm shutdown bit to the GBT package control PLC logic. The GBT package control system shall shut down the operating GBT when this alarm occurs.

B. Develop PICS screens for the GBT system showing status and alarm data.

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C. Coordinate with the GBT manufacturer regarding data access over the Ethernet data link as described in Section 11352. Allow for a minimum of 100 status, alarm or data points to be monitored by PICS in addition to the signals described above.

2.7 CONTROL STRATEGY – THICKENED SLUDGE PUMPS

A. The thickened sludge pumps are controlled by the GBT package control system as described in Section 11352.

B. Develop PICS screens for the GBT system showing status and alarm data for the TWASP pumps. Include display of TWAS flow to the Blend Tanks.

C. Coordinate with the GBT manufacturer regarding data access over the Ethernet data link as described in Section 11352.

2.8 MECHANINCAL ROOM GAS MONITORING

A. Gas monitors are to be provided at four locations in the Mechanical Room.

B. Develop a PICS screen for the system showing alarm status and actual combustible gas concentration values for the room.

2.9 CONTROL STRATEGY – SLUDGE HOLDING TANKS

A. There are four sludge holding tanks, each to be equipped with a mixer and ultrasonic level transmitter. Each tank has two motor operated inlet valves to receive sludge from either of the following two locations:

1. Blended sludge transferred from the Gravity Thickener Building

2. Recirculated sludge from the sludge transfer pumps recirculation line.

B. Develop PICS screens for the tanks showing the flow path for each feed point and the position status of the inlet valves. Include display of tank level along with running and alarm status of the mixers.

C. Allow the operator to manually start and stop the tank mixers from the PICS workstation.

D. Allow the operator to manually open and close the tank inlet valves from the PICS workstation to set the desired flow path for sludge transfer or recirculation. Lime slurry addition to these inlet headers is described below under “Control Strategy - Lime Feed”.

2.10 CONTROL STRATEGY – SLUDGE TRANSFER PUMPS

A. There are four Sludge Transfer Pumps in the Solids Facility.

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B. Each pump’s suction line is connected to two different suction headers through two motor operated valves. In addition, each of those two suction headers is connected to each of the four Sludge Holding Tanks through motor operated valves. The design of the piping arrangement allows any pump to draw sludge from any Holding Tank while other pumps can simultaneously draw sludge from other tanks.

C. Each pump’s discharge line connects to two different discharge headers through two motor operated valves. One header is dedicated to transfer sludge to the liquid loading facility. The other header can either feed sludge to the centrifuges or can recirculate sludge back to the Sludge Holding Tanks.

D. Develop PICS screens for the pumps showing the flow path from the Holding Tanks through each pump to the appropriate discharge and the position status of the motor operated valves on the pump suction and discharge headers.

E. Allow the operator to manually open and close the pump suction and discharge header valves from the PICS workstation to set the desired flow path for sludge transfer or recirculation.

F. Allow the operator to manually start and stop the Transfer Pumps and set the pump speed from the PICS workstation. Liquid Loading transfer is a special subset of this control and is described below under “Control Strategy – Liquid Sludge Loading”.

G. Allow the operator to select the pump operating mode for each pump from the PICS workstation. Operating modes to be selected include:

1. Sludge Recirculation: under this mode, there is no interlock with other systems. Once started, the pump runs continuously until manually stopped by the operator at the PICS workstation. In this mode, display the recirculated sludge flow rate. This mode generally operates with one pump only.

2. Centrifuge Feed: under this mode, interlock the pump operation through PICS SCADA with the operation of the corresponding Centrifuge.

a. The Centrifuge control system contains a dedicated package control PLC for each Centrifuge. Configure PICS PLC-RS to monitor the Centrifuge package control PLC to determine when to start and stop the pump. The Centrifuge PLC will issue a “run request” bit to start the pump assigned to feed sludge to that centrifuge. Configure PICS PLC-RS to run the pump as long as the “run request” bit is active. Stop the pump whenever the “run request” bit is removed. The Centrifuge PLC also sends a percent speed command to the PICS PLC to control the speed of the pump. Configure PICS PLC-RS to control the pump speed in response to the speed command setting from the Centrifuge PLC.

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b. Make the following pump status and speed signals for the assigned pump available to the Centrifuge package control PLC in accordance with the requirements described in Section 11355.

(1) Pump Running

(2) Pump Failure

(3) Pump Remote Mode (Auto Ready)

(4) Pump Speed

c. Develop PICS screens to display the running and alarm status of the pumps as well as the pump speed.

d. Coordinate with the Centrifuge manufacturer regarding data access over the Ethernet data link as described in Section 11355.

3. Liquid Sludge Loading: see below under “Control Strategy – Liquid Sludge Loading”.

H. Configure the PICS screens to include running and alarm status of each of the Sludge Transfer Pumps, as well as pump speed. Include display of recirculation flow and liquid sludge loading flow.

2.11 CONTROL STRATEGY – LIQUID SLUDGE LOADING

A. Liquid loading will generally include the operation of two Sludge Transfer Pumps discharging to one of the two truck loading bays through two motor operated valves.

B. Allow the operator to manually open and close the appropriate pump discharge header isolation valves from the PICS workstation to set the desired flow path for sludge transfer to the liquid loading area. Allow the operator to select the desired one or two pumps (generally two) to be dedicated to liquid loading.

C. Once assigned to this mode, the operating speed of the pump(s) is preset by the operator at the PICS workstation.

D. There are two liquid loading stations, one in each truck bay. Each truck bay has a Red/Green truck control light box (red = Stop, green = Safe to Exit) controlled by the PICS PLC. The light box is common to both liquid and dewatered cake loading operations.

E. Each loading station is to be provided with a dedicated truck loading panel at the loading platform. Each loading panel contains a Start/Stop pushbutton and flow totalizer. Each bay also has an additional E-stop pushbutton on the lower level by the truck. Allow the pump(s) to be started and stopped by the truck driver at the liquid loading area as follows:

1. Truck control light box is illuminated green by PICS PLC as long as no liquid or solid loading is taking place.

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2. Once the truck is positioned, the platform is lowered and the discharge chute is positioned. As soon as the platform is lowered, PLC illuminates the truck light box red. The PLC input from the platform also serves as a permissive interlock for the sludge pumping. Pumps are not allowed to start and the isolation valves are not allowed to open unless the platform is lowered.

3. The truck driver presses the start pushbutton.

4. PLC is to start the pump(s) assigned to liquid loading and open the corresponding motor operated isolation valve (valve P-85-1 or P-85-2) at the loading platform, as long as the platform is down.

5. PLC monitors the totalizer input from the truck loading flow meter FIT-439. PLC repeats this totalizer pulse as an output to the truck loading panel totalizer to give the truck driver local indication of the running total of gallons delivered. Also accumulate the totalizer pulses in a PLC register to be saved at the end of the transfer event.

6. When driver presses the Stop pushbutton on the truck loading panel or the E-stop pushbutton at the lower level, stop the transfer pumps and close the corresponding motor operated isolation valve. Store the accumulated totalizer register (gallons x 100) with time and date stamp in the PICS system as a truck fill event.

7. To prevent the truck driver from trying to jog the pumps to top off the tanker, PLC is to include a time delay after the Stop pushbutton is pressed. During that time delay, system is to ignore any subsequent Start pushbutton input. Preset the time delay for 5 minutes.

8. Once the operator raises the loading platform to the up position, PLC illuminates the truck control light box green, indicating it’s safe to exit the truck bay.

F. Develop a PICS screen for the liquid loading system showing the dedicated Sludge Transfer Pump status, liquid loading transfer flow and totalizer values, loading platform position and isolation valve status.

2.12 CONTROL STRATEGY – BLEND TANKS

A. There are two blend tanks adjacent to the Gravity Thickener Building which receive thickened WAS from the gravity belt thickener. Each Blend Tank is equipped with a jet aeration mixing pump, ultrasonic level transmitter and new motor operated TWAS inlet valve. Normally, only one Blend Tank will be used at a time.

B. Allow the operator to open and close the TWAS inlet valve to each Blend Tank from the PICS workstation.

C. Jet aeration mixers are started and stopped locally at the mixer control panel. Existing PLC-BT monitors the running and alarm status of the mixers as well as

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the tank level. Whenever a mixer runs, automatically run the corresponding air blower(s) in the Solids Building via a link between existing PLC-BT and new PLC-RS. If the mixer stops, automatically stop the corresponding blower(s).

D. Develop PICS screens for the Blend Tanks showing the inlet valve position, tank level, jet aeration mixer status and alarms and corresponding assigned blower status and alarm.

2.13 CONTROL STRATEGY – BLEND TANK JET AERATION BLOWERS

A. There are three blowers. One or two blowers can be assigned to operate with a jet aeration mixing pump at the Blend Tank described above. The discharge air header has motor operated isolation valves to allow the middle blower (BTAB-2) to be piped to either blend tank.

B. Develop a PICS screen for the Blowers showing the blower running and alarm status and discharge header isolation valve position.

C. Allow the operator to assign the blowers to operate with the Blend Tank mixing pumps from the PICS workstation. Allow the operator to open and close the discharge header isolation valve to pipe the desired blower to the associated blend tank at the PICS workstation.

D. Provide a software mode selector in PICS “Computer Manual/Computer Auto” for the blowers.

1. In Computer Manual, allow the operator to manually start and stop the blowers at the PICS workstation.

2. In Computer Auto, whenever a mixing pump at the Blend Tank runs, automatically run the corresponding blower(s) assigned to that Blend Tank mixer.

2.14 CONTROL STRATEGY – GRAVITY THICKENER

A. There is one gravity thickener adjacent to the Gravity Thickener Building.

B. The thickener drive is started and stopped locally.

C. There is no PICS control of this process, only monitoring.

D. Develop a PICS screen for the Gravity Thickener showing the drive mechanism running and alarm status.

2.15 CONTROL STRATEGY – THICKENED SLUDGE TRANSFER PUMPS

A. There are three Sludge Transfer Pumps located in the Gravity Thickener Building. Each pump has a corresponding Sludge Conditioner (grinder) in series with it. The pumps and conditioners are existing, and are controlled and monitored by existing

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PLC-BT located in the Gravity Thickener Building. Each pump and conditioner is designed to run together as a pair.

B. There are nine existing pneumatically actuated isolation valves on the Sludge Transfer Pump suction header and suction lines that are controlled and monitored by existing PLC-BT. There are 13 new motor operated isolation valves provided on both the suction and discharge piping to be controlled over the actuator 2-wire network interface originating in the Solids Handling Building.

C. Develop PICS screens for the Gravity Thickener Building showing the Blend Tanks, Sludge Transfer Pumps and Conditioners, isolation valves and flow meter. Include display of pump and conditioner mode, running and alarm status, valve position and flow data.

D. Allow the operator to manually open and close the pump suction and discharge header valves from the PICS workstation to set the desired flow path for sludge transfer to the centrifuges or sludge holding tanks in the Solids Handling Building. Note that some of these valves are controlled from existing PLC-BT in the Gravity Thickener Building and some are controlled over the 2-wire actuator network link at the Solids Handling Building PLC-RS.

E. Allow the operator to assign the Transfer Pumps to either Manual duty or Centrifuge Feed duty at the PICS workstation.

1. Manual Duty: Allow the operator to manually start and stop the Transfer Pumps and set the pump speed from the PICS workstation. Starting a Transfer Pump shall automatically start the corresponding Sludge Conditioner. If a sludge conditioner fails, automatically stop the corresponding feed pump, and vice versa. Once started, the Transfer Pump is to operate continuously until manually stopped by an operator from the PICS workstation.

2. Centrifuge Duty: under this mode, interlock the Transfer Pump operation through PICS SCADA with the operation of the corresponding assigned Centrifuge. Allow the operator to assign the pump to feed a selected centrifuge at the PICS workstation

a. The Centrifuge control system contains a dedicated package control PLC for each Centrifuge. Configure PICS PLC-RS to monitor the Centrifuge package control PLC to determine when to start and stop the pump. PLC-RS shall communicate this same information to PLC-BT to control the Transfer Pump. The Centrifuge PLC will issue a “run request” bit to start the pump assigned to feed sludge to that centrifuge. Configure PICS PLC-BT to run the pump as long as the “run request” bit is active. Stop the pump whenever the “run request” bit is removed. The Centrifuge PLC also sends a percent speed command to the PICS PLC to control the speed of the pump. Configure PICS PLC-BT (via link with PLC-RS) to control the pump

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speed in response to the speed command setting from the Centrifuge PLC.

b. Make the following pump status and speed signals for the assigned pump available to the Centrifuge package control PLC in accordance with the requirements described in Section 11355.

(1) Pump Running

(2) Pump Failure

(3) Pump Remote Mode (Auto Ready)

(4) Pump Speed

c. Coordinate with the Centrifuge manufacturer regarding data access over the Ethernet data link as described in Section 11355.

2.16 CONTROL STRATEGY – CENTRIFUGE

A. There are three centrifuges, each with its own dedicated power panel and main control panel. Normally, only one or two centrifuges will operate at a time.

B. The Centrifuge control system is to be a package control system with a dedicated PLC provided by the equipment manufacturer. Provide display of specific data about the status and alarm conditions for the Centrifuge system via an Ethernet data link with each of the Centrifuge main control panels.

C. Develop PICS screens for the Centrifuge system showing status and alarm data for each of the centrifuges. Signals monitored and displayed on PICS are to be as recommended by the Centrifuge manufacturer.

D. Coordinate with the Centrifuge manufacturer regarding data access over the Ethernet data link as described in Section 11355. Allow for a minimum of 100 status, alarm or data points to be monitored by PICS for each centrifuge in addition to the interlock signals described below.

E. Interlocks with other equipment:

1. Centrifuge Feed Pump Control

a. Monitor a “run request” bit from the Centrifuge PLC to control the operation of the pump assigned to feed the centrifuge as described previously in the subparts headed “CONTROL STRATEGY – SLUDGE TRANSFER PUMPS” and “CONTROL STRATEGY – THICKENED SLUDGE TRANSFER PUMPS”

b. Make status and alarm signals available to the Centrifuge PLC regarding the pump assigned to feed the centrifuge as described in the above referenced subparts.

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c. Send the value of the centrifuge feed flow meter reading to the Centrifuge PLC to allow the centrifuge operator to visually observe the flow changes resulting from feed pump speed changes.

2. Inclined Screw Conveyor Control

a. Each centrifuge discharges to an inclined screw conveyor (take-away conveyor). The conveyor is reversible.

b. Monitor a “forward run request” and “reverse run request” bit from the Centrifuge PLC to control the operation of the screw conveyor as described below in the subpart headed “CONTROL STRATEGY – INCLINED CAKE SCREW CONVEYOR”.

c. Make status and alarm signals available to the Centrifuge PLC regarding the conveyor as described in the above referenced subpart.

3. Pug Mill Control

a. When the centrifuge shuts down for any reason, the Pug Mill is to go into a cleaning cycle.

b. Monitor a “shutdown” bit from the Centrifuge PLC to initiate a cleaning cycle for the Pug Mill as described below in the subpart headed “CONTROL STRATEGY – PUG MILL”.

2.17 CONTROL STRATEGY – INCLINED SCREW CONVEYOR

A. There is an inclined screw conveyor dedicated to receive sludge from each centrifuge. Each conveyor is reversible.

B. Develop PICS screens for the conveyors showing forward and reverse running status and alarm data for each conveyor.

C. The PICS system is to control the conveyor based on a run request bit from the Centrifuge PLC. Monitor a “forward run request” and “reverse run request” bit from the Centrifuge PLC.

1. “Forward run request”: Run the conveyor continuously in the forward direction as long as the “forward run request” bit is active. Stop the conveyor when the request bit goes inactive.

2. “Reverse Run Request”: Run the conveyor continuously in the reverse direction as long as the “reverse run request” bit is active. Stop the conveyor when the request bit goes inactive.

D. Make the following conveyor status and alarm signals available to the Centrifuge package control PLC in accordance with the requirements described in Section 11355.

1. Running Forward

2. Running Reverse

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3. Failure

4. Computer Mode (Auto Ready)

2.18 CONTROL STRATEGY – SLUDGE SCREW CONVEYORS

A. There are four sludge conveyors, normally used two at a time, which convey sludge from the centrifuge inclined screw conveyors to the Pug Mills and then from the Pug Mills to the sludge storage hoppers. Each conveyor provides a redundant path for sludge. All conveyors are one direction only and are to be controlled by PICS.

B. There are five motor operated slide gates which control the diversion of sludge from the inclined screw conveyors to the first two sludge screw conveyors, and then from those two sludge screw conveyors to the pug mills. The valves are to be controlled by PICS over the actuator network link based on the preset sludge path.

C. Develop PICS screens for the conveyors showing mode status, running status and alarm data for each conveyor. Allow the operator to assign the sludge path from each centrifuge to the pug mills and then on to the sludge storage hoppers.

D. Configure two operating modes in PICS for each conveyor, Computer Manual and Computer Auto.

1. Computer Manual: Allow the operator to start and stop the conveyor manually from the PICS workstation. There are no interlocks with other equipment in this mode. The conveyor simply runs until stopped by the operator (or by E-stop locally).

2. Computer Auto: PICS automatically runs the conveyor based on the assigned sludge path.

2.19 CONTROL STRATEGY – PUG MILL

A. There are two Pug Mills (Dewatered Cake Lime Addition Equipment). Normally, only one pug mill operates at a time, but simultaneous operation is possible.

B. The Pug Mill control system is to be a package control system with a dedicated PLC provided by the equipment manufacturer for each Pug Mill. Provide display of specific data about the status and alarm conditions for the Pug Mill system via an Ethernet data link with each of the Pug Mill operator interface panels.

C. Develop PICS screens for the Pug Mill system showing status and alarm data for each of the pug mills. Signals monitored and displayed on PICS are to be as specified in Section 11750 and as recommended by the pug mill manufacturer.

D. Coordinate with the pug mill manufacturer regarding data access over the Ethernet data link as described in Section 11750. Allow for a minimum of 100 status, alarm

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or data points to be monitored by PICS for each pug mill in addition to the interlock signals described below.

E. Interlocks with other equipment:

1. In-feed Sludge Screw Conveyor Control

a. Pug Mill will issue a “feed permissive” bit to PICS when the Pug Mill is ready to accept sludge. The in-feed sludge screw conveyor and corresponding centrifuge and inclined screw conveyor may only operate as long as this permissive signal is active. If the permissive signal terminates, all equipment upstream of the pug mill shall stop.

b. Monitor the “feed permissive” bit from the Pug Mill PLC to control the in-feed Sludge Screw Conveyor to the Pug Mill as described previously in the subpart headed “CONTROL STRATEGY – SLUDGE SCREW CONVEYORS”.

2. Out-feed Sludge Screw Conveyor Control

a. Monitor a “run request” bit from the Pug Mill PLC to control the operation of the out-feed conveyor as described previously in the subpart headed “CONTROL STRATEGY – SLUDGE SCREW CONVEYORS”.

b. Make status and alarm signals available to the Pug Mill PLC for conveyor status as described in the above referenced subpart.

3. Centrifuge Control

a. When the centrifuge shuts down for any reason, the Pug Mill is to go into a cleaning cycle.

b. Monitor a “shutdown” bit from the Centrifuge PLC. Send this signal via Ethernet data link to the Pug Mill PLC to initiate a cleaning cycle for the Pug Mill.

2.20 CONTROL STRATEGY – SLUDGE CAKE HOPPERS

A. There are two sludge cake hopper systems (one for each of the two truck bays) which receive sludge from the pug mill and dispense sludge to the trucks for land disposal. Both can be operating simultaneously.

B. The Sludge Cake Hopper control system is to be a package control system with a dedicated PLC provided by the equipment manufacturer for each hopper system. Provide display of specific data about the status and alarm conditions for the hopper system via an Ethernet data link with each of the Sludge Cake Hopper master control panels.

C. Each truck bay has a wall-mounted Red/Green truck control light box (red = Stop, green = Safe to Exit) controlled by the PICS PLC. The light box is common to both liquid and dewatered cake loading operations. Configure the PICS PLC to

AARHIP 13400-22

activate the light box in response to a “truck warning” bit issued by the Sludge Cake Hopper package control PLC. Whenever the “truck warning” bit is active, PICS PLC is to illuminate the truck control light box Red, indicating Stop. When the “truck warning” bit is not active, PICS PLC is to illuminate the light box Green, indicating Safe-to-Exit.

D. The hopper system includes a number of motor operated valves that are controlled directly by the Sludge Cake Hopper PLC. These valves are also connected to the two-wire actuator network for PICS monitoring only.

E. Develop PICS screens for the hopper system showing status and alarm data for each of the hopper systems. Signals monitored and displayed on PICS are to be as specified in Section 14550 and as recommended by the sludge cake hopper manufacturer.

F. Coordinate with the hopper system manufacturer regarding data access over the Ethernet data link as described in Section 14550. Allow for a minimum of 100 status, alarm or data points to be monitored by PICS for each hopper system in addition to the interlock signals described below.

G. Store each truck loading batch (tons loaded) with time and date stamp in the PICS historian. The truck loading batch is calculated in the sludge hopper package control PLC as described in Section 14550.

1. Sludge Cake Hopper PLC will issue a “truck load completion” bit to PICS to indicate that a new truck loading cycle has been completed.

2. PICS should then read the “net truck fill weight” along with date and time stamp and store the value.

3. PICS should then issue a “truck load acknowledge” bit to the Sludge Cake Hopper PLC to reset the “truck load completion” bit.

H. Interlocks with other equipment:

1. In-feed Sludge Screw Conveyor Control

a. The in-feed conveyor to the hopper is the Pug Mill out-feed conveyor. This conveyor operates on a batch schedule controlled by the Pug Mill PLC via Ethernet link through the PICS PLC-RS. The Sludge Cake Hopper PLC will issue a “hopper permissive” bit to PICS when the hopper system is ready (available) to accept sludge. The in-feed sludge screw conveyor may only operate as long as this permissive signal is active. If the permissive signal terminates, the in-feed conveyor (and thus all equipment upstream of the hopper) shall not run.

b. Monitor the “hopper permissive” bit from the Sludge Cake Hopper PLC to enable control of the in-feed Sludge Screw Conveyor to the Sludge Hopper and as a permissive interlock to also feed the Pug Mill

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as described previously in the subparts headed “CONTROL STRATEGY – SLUDGE SCREW CONVEYORS” and “CONTROL STRATEGY – PUG MILL”.

2. Truck Control Light Box

a. Monitor the “truck warning” bit from the Sludge Cake Hopper PLC to control the active color of the truck control light box as described above.

2.21 CONTROL STRATEGY – LIME FEED

A. The lime system includes an existing lime slaker system and three new lime slurry feed pumps. One pump is provided for each of two application points plus one standby. Pumps are to be controlled manually through PICS.

B. Develop PICS screens for the pumps showing the application point for each feed point, pump running and alarm status, pump speed and pump discharge flow rate to each application point.

C. Allow the operator to manually start and stop the feed pumps and set their speed from the PICS workstation.

D. Develop PICS screens for the existing lime slaker system using existing PICS screens as a pattern. The new PICS screens are to be a functional equivalent of the existing PICS monitoring system.

2.22 CONTROL STRATEGY – THICKENING POLYMER SYSTEM

A. There are two thickening polymer dilution units. These polymer dilution and feed units are controlled directly by the Gravity Belt Thickener package control system.

B. The remainder of the thickening polymer system includes one bulk storage tank, two transfer/recirculation pumps, two motor operated ball valves and one day tank.

C. Two transfer and recirculation pumps are provided, one duty and one standby. Allow the operator to select the duty pump at the PICS workstation.

D. Develop PICS screens for the pumps showing the transfer/recirc pump running and alarm status, motor operated valve position, day tank level and bulk tank level.

E. Set day tank level alarm points as follows:

1. Low level = 3-inches above tank bottom

2. High level = 8-inches below tank rim

F. There are also day tank level control points (high and low level) to be monitored by PICS for control of the transfer/recirc pumps.

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G. Allow the operator to select the mode of operation for the transfer/recirc pumps as follows:

1. Manual: Operator starts and stops the pump manually from the PICS workstation.

2. Transfer Automatic: Under this mode, pump starts and stops in repeating fashion based on day tank level.

a. When day tank reaches low level control point, automatically open the day tank feed valve BA-84-24, verify recirc valve BA-84-23 is closed, and start the selected duty pump.

b. When the day tank level rises to the high level control point, stop the pump and close the day tank feed valve.

3. Transfer/Recirc Automatic: Under this mode, pump runs continuously, either recirculating polymer back to the bulk storage tank and then transferring polymer to fill the day tank based on day tank level.

a. At startup, open polymer recirc valve BA-84-23 and verify day tank transfer valve is closed. When recirc valve opens, start selected duty pump.

b. When day tank reaches low level control point, automatically open the day tank feed valve BA-84-24, then close recirc valve BA-84-23.

c. When the day tank level rises to the high level control point, open the recirc valve and then close the day tank feed valve.

H. Display Polymer dilution status (running, alarm and speed) at the PICS workstation screens from the data link with the Gravity Belt Thickener PLC.

2.23 CONTROL STRATEGY – DEWATERING POLYMER SYSTEM

A. There are three dewatering polymer dilution units. These polymer dilution and feed units are controlled directly by the Centrifuge package control system.

B. The remainder of the dewatering polymer system includes one bulk storage tank, two transfer/recirculation pumps, two motor operated ball valves and one day tank.

C. Two transfer and recirculation pumps are provided, one duty and one standby. Allow the operator to select the duty pump at the PICS workstation.

D. Develop PICS screens for the pumps showing the transfer/recirc pump running and alarm status, motor operated valve position, day tank level and bulk tank level.

E. Set day tank level alarm points as follows:

1. Low level = 3-inches above tank bottom

2. High level = 8-inches below tank rim

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F. There are also day tank level control points (high and low level) to be monitored by PICS for control of the transfer/recirc pumps.

G. Allow the operator to select the mode of operation for the transfer/recirc pumps as follows:

1. Manual: Operator starts and stops the pump manually from the PICS workstation.

2. Transfer Automatic: Under this mode, pump starts and stops in repeating fashion based on day tank level.

a. When day tank reaches low level control point, automatically open the day tank feed valve BA-84-37, verify recirc valve BA-84-36 is closed, and start the selected duty pump.

b. When the day tank level rises to the high level control point, stop the pump and close the day tank feed valve.

3. Transfer/Recirc Automatic: Under this mode, pump runs continuously, either recirculating polymer back to the bulk storage tank and then transferring polymer to fill the day tank based on day tank level.

a. At startup, open polymer recirc valve BA-84-36 and verify day tank transfer valve is closed. When recirc valve opens, start selected duty pump.

b. When day tank reaches low level control point, automatically open the day tank feed valve BA-84-37, then close recirc valve BA-84-36.

c. When the day tank level rises to the high level control point, open the recirc valve and then close the day tank feed valve.

H. Display Polymer dilution status (running, alarm and speed) at the PICS workstation screens from the data link with the Centrifuge PLC.

2.24 CONTROL STRATEGY – ODOR CONTROL

A. The odor control system is started and stopped locally. PICS monitors the system only.

B. Develop PICS screens showing the operating and alarm status for the odor control fans. Include alarm display for odor control washer sump level alarms. Include display of the differential pressure across each Odor Control Unit (OCU-1, 2, 3) and of the air plenum pressure.

C. Activate alarms based on air plenum pressure settings as follows:

1. Low alarm below -3 inches w.c.

2. High alarm above +3 inches w.c.

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2.25 CONTROL STRATEGY – STORM WATER PUMPING

A. There is an existing storm water wet well and two existing storm water pumps. They are currently controlled by existing Control Panel CP-40. Reconfigure the controls to have PICS control the pumps.

B. Develop PICS screen showing the wet well level and pump operating and alarm status. Allow the operator to select the Lead/Lag status of the two pumps at the PICS workstation.

C. Existing wet well level transmitter calibration is 0-12 feet (El 729.0 to 741.0).

D. Preset the level control points as follows and allow the operator to adjust the settings from the PICS workstation if desired:

1. Lead pump on at El 736.0 rising / off at El 732.5 falling

2. Lag pump on at El 736.5 rising / off at El 735 falling

3. High level alarm at El 737.5 rising.

2.26 CONTROL STRATEGY – SWITCHGEAR CONTROL

A. There are two main breakers and one tie breaker at Unit Substation USS-5 on the 480-volt switchgear. Configure PICS to monitor and control those breakers.

B. Develop a PICS screen showing the breaker status and alarms. Display should be in one-line diagram format.

C. Allow the operator to trip or close the main and tie breakers from the PICS workstation.

2.27 CONTROL STRATEGY – ELECTRICAL METERING

A. The following breakers are provided with a Microprocessor Metering System to be monitored in PICS:

1. Unit Substation USS-5 Main Breaker Nos. 1 and 2

2. Motor Control Center MCC-51 Main Breaker Nos. 1 and 2






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B. The following data from each of these breakers are to be monitored in PICS via connection to the equipment over a Modbus link to PLC-RS in the Solids Handling Building.

1. Voltage (V)

2. Current (A)

3. Real Power (KW)

4. Reactive Power (KVAR)

5. Total Power (KVA)

C. Develop a PICS screen showing the main breakers in One Line Diagram format with the above parameters displayed for each breaker.

2.28 CONTROL STRATEGY – MISCELLANEOUS MONITORING

A. Develop PICS screens for the following:

1. Running and alarm status for the lime and polymer room sump pumps

2. Weather station data, including display of wind speed and direction, ambient temperature, humidity and barometric pressure, and rain gauge totalizer input. Time and date stamp these readings for storage in the PICS historian.

3. HVAC and plumbing alarms from the three temperature control panels.

PART 3 EXECUTION

3.1 ERECTION, INSTALLATION AND APPLICATION

A. General

1. Install all instruments and equipment in strict compliance with manufacturer's instructions.

2. Mount all gages and indicators in upright position.

3. Provide sufficient space around equipment for maintenance and removal of equipment.

4. Cover front panels, gages and indicators during construction for protection from dust, weld and paint splatter.

5. Unless otherwise impractical, mount all indicating instruments at eye level (5 feet).

6. Unless otherwise impractical, support instruments independent of process piping.

B. Installation Hardware

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1. Provide stainless steel nuts and bolts.

2. Provide aluminum or stainless steel support channels.

3. Provide 1/4-inch thick minimum, clear anodized aluminum equipment mounting plates.

4. Provide gaskets to prevent galvanic reaction between dissimilar metal surfaces.

C. Equipment Identification and Instrument Tags

1. Provide embossed stainless steel tags as specified in Section 13410.

2. Provide an engraved laminated plastic plate at each wall-mounted instrument and PLC panel, indicating panel and instrument function and tag.

3. Engraved laminated tag colors: Provide black lettering on white background. Mount tags at eye level.

3.2 FIELD QUALITY CONTROL

A. Tests and Inspection: Provide tests as required in Division 1.

B. Inspection: Demonstrate that instruments, panels, and PLC equipment,

1. Has not been damaged by transportation or installation,

2. Has been properly installed,

3. Has no mechanical defects,

4. Is in proper alignment, and

5. Has been properly connected.

C. Tests: Perform the following tests:

1. Field-calibrate all field instruments. Test all analog input loop zeroes and spans by disconnecting wiring at each transmitter and by connecting a 4-20 mA generator. PC-based OIS shall display correct value based on simulated 4-20 mA signal.

2. Perform Field Testing as specified in Section 13402 – Field Testing.

3. Perform Operational Availability Demonstration testing as specified in Section 13403 – Operational Availability Demonstration.

D. Manufacturers Field Service: Provide manufacturer field service for calibration, initial setup, programming and commissioning of each instrument.

END OF SECTION

AARHIP 13402-1

SECTION 13402

FIELD TESTING

PART 1 GENERAL

1.1 SUMMARY

A. This section describes the requirements for field testing.

1.2 SUBMITTALS

A. Include the following information in the submittal for this section.

1. Schedules, procedures, and sign-off forms for tests.

2. Loop checkout schedule. Include schedule arranged by unit process area. Include checkout procedures and signoff forms.

3. System performance test procedures.

B. After testing, submit the completed test sign-off forms.

1.3 GENERAL

A. Meet the following criteria prior to the start of the field test.

1. Complete submittals and resolve disputes.

2. Have approved test procedures.

3. Set a test date which is agreeable to all.

4. All parties agree that the complete system is ready for testing.

5. Schedule the integrated system test a minimum of 6-months after the date of final equipment submittal approval.

B. If a test or a portion of the test fails and needs to be rescheduled, the Contractor shall pay all expenses for retesting.

PART 2 PRODUCTS

NOT USED

AARHIP 13402-2

PART 3 EXECUTION

3.1 GENERAL

A. Perform field testing to verify the operation of the control system. Perform field testing sequentially and organize by plant area and by unit process within each area.

B. Field tests are to include the following:

1. Loop tests.

2. Function tests.

3. Integrated system test.

C. Begin testing immediately after installation of each major subsystem. A subsystem is an integrated, fully operational subset of the control system and includes:

1. Programmable logic controller (PLCs) and remote input/output (I/O) within a plant area.

2. At least one operator workstation (OWS) associated with the PLCs.

3. Communications equipment required for operation of the subsystem.

4. Field instruments, panels , termination cabinets , control devices and related interconnections for the plant area.

D. Meet the following conditions prior to the start of any testing:

1. Have documentation on-site pertinent to the part of the system being tested.

2. Have on site, labeled, and properly stored, spare parts, expendables and test equipment pertinent to the part of the system being tested.

3. Have Engineer and Owner reviewed test schedules and test procedures.

4. Recompile, relist and reload from supplied source code, programs which are source code and compiler dependent.

5. Have all parties certify that the system has been checked and is ready for testing.

E. Schedule all field testing through the Owner/Engineer on a daily basis.

1. The Engineer may redirect testing from one unit process to another. Make no claim for delay or additional costs for testing if the testing effort is redirected to a different unit process provided the following conditions are met:

a. The redirection does not cause more than a one hour interruption to the testing to move test equipment and test personnel to the new unit process.

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b. There is no change in the amount of test equipment or personnel requirements.

c. The redirection is not arbitrary. Process operational constraints, personnel availability, and other's work are valid reasons for redirection.

d. The redirection does not occur more than once in any workday subsequent to the daily scheduling meeting.

2. Perform no testing which may affect plant operation without Owner/Engineer concurrence.

F. Perform tests by following the operation and maintenance manuals word-for-word unless approved otherwise by the Engineer. Lack of complete, detailed manuals will be cause for declaring the test to have failed regardless of the actual test results.

G. Begin testing by performing the following steps:

1. Check equipment against shop drawing lists and submittals.

2. Verify that the equipment has been installed in accordance with Contract Documents and manufacturer's directions.

3. Power-up the equipment and run diagnostics to verify error-free operation.

4. Load software, including Owner furnished applications software. Owner’s application software programmer will assist in loading the Owner furnished applications software for PICS PLCs and OWSs.

H. The Owner/Engineer will participate in all testing activities except when they feel that their presence will not be necessary.

1. This participation will serve as a learning experience for plant operations and maintenance personnel.

2. This participation does not relieve the Contractor from the specified requirements for testing.

3. Recognize and adjust for Owner involvement in developing test procedures and schedules.

4. Owner participation and use generally will be such that it does not adversely affect specified testing requirements. Plant operations will dictate what can be affected/out of service. The Contractor shall schedule testing accordingly.

a. Delays in testing schedules resulting from necessary and reasonable plant operations shall not constitute basis for claims for delays.

b. Contractor may submit written request for delay/extension to the Owner/Engineer for unusual and unnecessary, in the Contractor's judgment, delay caused by plant operations.

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c. Disputes regarding delays shall be resolved by the Engineer.

3.2 LOOP TESTS

A. Check each loop from the end element to the respective control panel device or I/O card termination. Include instruments, control devices, panels, termination cabinets, PLC I/O cards and other devices in the loop to ensure proper operation.

B. This test is to be performed by the Contractor and may be witnessed on a random, periodic basis by the Owner.

C. Whenever possible, motion check the final control element through panels and/or local control stations. When not possible to perform a motion check, simulate the motion check at the final control element location.

D. Document loop checks and submit to the Engineer prior to the start of field testing. Include:

1. Loop number.

2. Loop description.

3. Termination information.

4. Loop drawing reference.

5. Type of test(s) performed.

6. Date tested.

7. Problem description, if any.

8. Signature of tester and date.

9. Signature of Owner and date (to be filled in after field testing).

E. Summarize loops found to contain defective or inoperable equipment on separate sheets and submit to the Engineer.

1. Correct and recheck your work.

2. The Engineer will coordinate correction of defective work by others. Perform rechecking as a part of this Contract.

3. Limit rechecking of defective work by others to 10 percent of the total number of loops. Do not perform additional checkout work unless directed by the Engineer.

4. Correct all defective or inoperable equipment and/or wiring within seven calendar days of the discovery of the defect.

3.3 PICS HARDWARE/SOFTWARE FUNCTION TESTING

A. Test each PICS PLC and OWS for operation as a stand-alone device and as part of the fully integrated system.

AARHIP 13402-5

B. Check each process area for proper control system software functions, including point addressing from the end element to the respective control display, including alarm handling, graphic displays and control strategies. Include instruments, control devices, panels, termination cabinets, PLC I/O cards and other devices in the loop to ensure proper operation.

C. This test is to be performed jointly by the Contractor and the Owner’s application software programmer after the Owner furnished application software has been installed on the PICS PLCs and the OWSs.

D. This test is an extension of the Loop Test to verify software functions and may be performed in conjunction with the Loop Test.

E. Document and submit test results to the Engineer. Include:

1. Description of function.

2. Tests performed.

3. Copies of messages, displays, reports, and trends which verify operation.

4. Signature of tester and date.

5. Signature of witness and date.

6. Problems, if any, with description.

F. Summarize loops found to contain defective or incorrect application programming and submit to the Engineer.

1. Allow the Owner’s application software programmer seven calendar days to correct the software programming before retesting.

3.4 INTEGRATED SYSTEM TEST

A. Perform integrated system testing to verify the operation and performance of the complete, integrated control system.

1. Perform integrated system test to demonstrate all control and monitoring functions, including hardware functions and interlocks, as well as software functions. This test involves actual operation of the process. During this test, perform as much loop tuning and setpoint adjustment as possible.

2. Begin integrated system testing after all other field tests have been completed.

3. Conduct the test for two calendar weeks, 24 hours per day.

4. Provide full-time, on-site assistance during business days and within four hours after call in for the test duration.

5. The Owner will monitor and participate in the test.

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B. Include:

1. Data communication, both normal and failure modes.

2. Fully loaded system response times.

3. Other system operations the Engineer may elect to perform.

C. Correct deficiencies within 24 hours of notice. If deficiencies remain uncorrected at the end of the test period, the test period will be extended on a day-to-day basis until specified operation can be demonstrated. Owner’s application software programmer will be required to correct software deficiencies in the PICS PLCs and OWS within the same 24 hour period.

END OF SECTION

AARHIP 13403-1

SECTION 13403

OPERATIONAL AVAILABILITY DEMONSTRATION

PART 1 GENERAL

1.1 SUMMARY

A. This section describes the requirements for an operational availability demonstration (OAD).

B. Related work specified elsewhere includes, but is not limited to:

1. Section 13400

1.2 SUBMITTALS

A. Include the following information in the submittal for this section.

1. Suggested revisions to failure report form, if any.

2. Additional procedures for notification and failure reporting.

3. Preventive maintenance schedule.

B. Submit reports as specified in this section:

1. Spares reports.

2. Repair reports.

3. Final maintenance reports. 1.3 DESCRIPTION

A. The OAD is a period of time during which the control system will be utilized by the Owner in day-to-day operations. Its purpose is to test the integrated control system's stability and completeness over time.

B. Start the OAD upon written notice from the Engineer and after successful

completion of field testing.

PART 2 PRODUCTS

NOT USED

AARHIP 13403-2

PART 3 EXECUTION

3.1 GENERAL

A. Furnish labor and materials to conduct the OAD and to meet the availability specified in the system description section over the OAD period.

1. Pay damages as specified in the performance warranty section for failure to

meet the availability.

2. If the system is defective because of excessively low availability, remove and replace component(s) which caused the low availability. Repeat the OAD to verify availability of the replaced work. Damages will be waived unless the replaced components also fail to meet availability requirements.

B. Provide the following:

1. Assistance to the Owner in the operation of the system.

2. Resolution of deficiencies noted during field testing and during OAD.

3. Correction of hardware and software failures.

4. Preparation of various reports.

3.2 ASSISTANCE TO OWNER

A. Assist the Owner in the step-by-step implementation and operation of the equipment and software furnished. The operation of the system will be performed by the Owner.

B. The Owner will implement new or make modification to existing control

strategies, reports, graphic displays, database and related items. Owner usage will not reduce the availability requirements unless the usage is in a manner contrary to documentation instructions and normal operational practice.

3.3 RESOLUTION OF DEFICIENCIES

A. The Engineer may permit some deficiencies noted during field testing to be corrected during the OAD period. Correct these items no later than 30 days after the start of the OAD period. The time in excess of 30 days is downtime.

B. Use of the system during the first 30 days of the OAD period may reveal

deficiencies not found during field testing. Correct deficiencies (excepting those which constitute downtime) no later than 60 days after the start of the OAD period. The time in excess of 60 days is downtime.

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C. During the period commencing 60 days after the start of the OAD period, correct deficiencies noted prior to end of the OAD period.

3.4 CORRECTION OF FAILURES

A. Upon notification of a failure, diagnose and repair or replace the failed equipment or software. Provide parts, material and labor necessary to return the equipment to operation.

B. To assure that the demonstration is representative of normal operating conditions,

use only the test and maintenance equipment which is furnished as part of this Contract. Use maintenance procedures set forth in the operating and maintenance manuals.

3.5 SPARES USE REPORT

A. Each month after installation (note, not after the start of OAD, but after installation), and lasting until the completion of the OAD, prepare and submit a “Spares Report”.

B. List identification and quantities of items used during the preceding month.

Include the average rate of use per month in the report. Describe each item by nomenclature, make, source of item including address, and the unit cost from the most recent available pricing information.

3.6 FINAL MAINTENANCE REPORT

A. Prior to final acceptance, prepare and submit a report summarizing the nature and time of the maintenance performed. List the equipment and spare parts used.

B. Include the following information:

1. Tasks performed and person hours required to perform them.

2. Numbers and types of components repaired by others (name and address of

repair firm), extent of repairs and time required for their completion.

3. Numbers and types of components replaced by new equipment.

4. Numbers and types of components recommended as additional spare parts that should be acquired.

5. Recommendations for additional test equipment, tools and other facilities for

maintenance.

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3.7 DEFINITIONS

A. A failure is the inability of a component to perform its function regardless of the cause or severity of the failure.

1. Failures may range in severity from loss of a single keyboard contact, to

inoperability of an operator station, to complete inoperability.

2. Failures may be caused by hardware or software faults. Software faults for package control systems will be charged against the appropriate hardware component. Software faults in software configured by the Owner’s application software programmer will be corrected by the Owner and will not be downtime charged against the contractor.

3. Failures may be continuous or intermittent. An intermittent failure is a

failure that occurs and then disappears before corrective maintenance can be completed. Examples of intermittent failures include, but are not limited to, the following:

a. Communication errors.

b. "Sticky" keyboard contacts.

c. Peripheral device errors.

d. Operating system errors.

B. Downtime is the period of time between notification that a failure has occurred and

notification that repair has been completed.

1. For intermittent failures, downtime is the accumulation of the greater of the actual duration of each intermittent failure or fifteen minutes per occurrence. This accumulation starts at failure notification and ends at repair complete notification, subject to verification of the repair by the Engineer.

2. Verify the end of downtime by testing repairs.

C. A component is any equipment which is consistent in nature and function as those

specified. Component examples include, but are not limited to, operator stations, programmable process controllers, disk drives, the central computer, data highways, modems and similar hardware.

D. Availability is the fraction of operating time a component is capable of performing

its intended function.

1. Component availability is the OAD duration less downtime divided by OAD duration for that component.

AARHIP 13403-5

2. System availability is the series product of the individual component

availabilities and non-specific availability.

3. Non-specific availability is any downtime assessed against the system as a whole. Downtime of this sort includes, but is not limited to, that assessed for failure to resolve deficiencies in a timely manner and that which cannot be attributed to a specific component.

4. In the calculation of availability, certain allowances will be permitted. These

will be subtracted from the downtime for any given failure. 3.8 NOTIFICATION OF FAILURES

A. Furnish and post as directed by the Owner, the location and telephone number of the service personnel. Provide a paging service such that calls are possible 24 hours per day, 7 days per week.

B. Notification of a failure is a telephone call to the designated number.

C. For cases where the designated telephone is busy, inoperative, or did not answer,

the Owner will retry every 15 minutes for the first hour and no less frequently than once per hour thereafter.

D. Do not make a temporary substitution of an alternate location or telephone number

for notification except upon written notice at least three working days prior to such substitution.

3.9 REPAIR AND REPORTING

A. A repair report form similar to that shown at the end of this section will be used to document failures. A separate form will be used to document each failure. Each form will have a consecutive number at the top starting at one (1).

B. In the event of a failure, the following occurs:

1. The person discovering the problem will complete Pan 1 of the next

consecutive report form.

2. This person or other designated person will perform the notification procedures and log the notification time.

3. Upon the service person's arrival on-site, report to the Owner's designated

representative. Loa and use the time of arrival as the start of repair time. The repair report will be given to the service person.

AARHIP 13403-6

4. Promptly diagnose and repair the failure and complete Part 2 of the form. Attach additional explanation sheets, spares used and other information as required for the various reports.

5. Jointly complete the Part 3 of the form with the Owner's representative.

6. If the equipment could not be promptly repaired, jointly determine with the

Owner's representative any "unavoidable delay time" and log such.

a. Valid reasons for delay include:

(1) Equipment or parts locked in cabinets to which the service person has no access.

(2) Disruption of operations considerations.

(3) Additional Owner training while affecting repairs.

b. Non-valid reasons for delay include:

(1) Lack of proper stocked spare parts.

(2) Lack of proper documentation or maintenance and test

procedures.

(3) Lack of knowledge as to proper procedures.

7. The acceptance check portion of the form will be completed within 48 hours. If the acceptance check proves the failure to have been corrected, the end of the time to repair is the repair completed time indicated. If the failure symptoms recur prior to the acceptance check, another failure will be logged.

8. The Engineer will retain the repair report.

C. The Owner/Engineer will complete a "Failure Summary Report" each month using

a form similar to that shown at the end of this section. Attend a monthly meeting at the site to review this report. Copies of the repair report and failure summary report will be available.

D. The Engineer will use the reports to compute the availability.

3.10 DOWNTIME ALLOWANCES

A. Travel time allowances will be: 1. The lesser of four hours or actual travel time from the first attempt at

notification during the first 30 days of the OAD.

AARHIP 13403-7

2. The lesser of 12 hours or actual travel time from the first attempt at

notification during the remainder of the OAD.

B. Unavoidable delay time, such as health and safety hazard, personal emergency, or events of disruption beyond Contractor control. The Engineer shall determine acceptability of unavoidable delays.

C. The time, if any, between completion of repair and acceptance checking.

D. Downtime to correct deficiencies provided the correction has been scheduled and

approved at least 24 hours in advance.

E. The conditions under which scheduled preventive maintenance exist and during which downtime will be allowed are as follows:

1. A proposed preventive maintenance schedule has been submitted at least

fifteen days before the first date on the schedule. State the date, beginning time and duration of maintenance and planned outage for the period.

2. Plan for not more than two outages of four hours each per month.

3. Conduct scheduled maintenance so as to minimize downtime.

F. Downtime resulting from the following causes will be allowed:

1. An outage of the main ac power supply provided that automatic shutdown

and restart or transfer to a redundant power source performed as specified.

2. Failure of a field sensor, equipment or facilities supplied by others provided that the system performed as specified.

3. Incorrect use by the Owner of system provided such use was not due to

incorrect instructions in the documentation or from your personnel.

4. Acts of God or other causes beyond the specified capability of the equipment. For claims relating to power transients, lightning strikes and environmental considerations, submit documentation to prove the cause of the damage.

5. Software faults in software configured by the Owner’s application software

programmer.

G. Downtime of any part of a component which does not cause a failure of the component function will be allowed. This downtime is due to failures of: one of two redundant power supplies, one of two redundant processors in a distributed

AARHIP 13403-8

process controller, spare or unused input/output (1/0) boards, and one of two redundant disks or diskettes in an operator station. Allowances are as follows:

1. Actual downtime up to a maximum of 48 hours per occurrence.

2. The sum of downtime for the component up to a maximum of 96 hours

during the OAD.

H. Component downtime due to an 1/0 point or an 1/0 board failure will be reduced provided other non-related functions of the component operate as specified. The downtime will be reduced to the greater of ten minutes or the actual downtime times the number of 1/0 points failed divided by the total number of 1/0 points of the same type provided.

I. Periods of downtime during the installation and testing of other phases of the work

provided the following conditions have been met:

1. The Work has been scheduled at least ten work days in advance and the anticipated duration of the downtime has been identified.

2. The downtime occurs between the hours of 7:00 a.m. and 5:00 p.m. and does

not exceed eight hours total for work involving tie-ins to the data highway or other system expansion activities. Perform activities requiring relocation of major components already in OAD to minimize the number and duration of downtimes.

3.11 PERFORMANCE (AVAILABILITY) WARRANTY

A. General 1. This section describes the calculations and liability for failure to meet

performance criteria as specified. B. Warranty

1. Warrant the control system to meet the availability criteria. 2. If the availability criteria is not obtainable due to reasons beyond your

control, mutually agreed extrapolated conditions may be used. C. Damages

1. Failure to meet the specified availability will result in actual damages to the

Owner by virtue of increased maintenance costs. These costs are uncertain and non-specific but are agreed to be approximated as defined herein. Damages are payable by reducing the outstanding amount owed to the

AARHIP 13403-9

Contractor as part of the contract price or by other means agreed to by both contracted parties.

2. Damages are separate and additive to damages specified in other sections. 3. Availability damages are in accordance with the following formulation:

a. ((1-A)/A - (1-S)/S) X 8760 X LR X PWF X K

Where A = Actual Availability S = Specified Availability 8760 = Hours per year

LR = Labor rate for repair technician ($30/hour including fringes, for example)

PWF = Ten years' present worth factor based on the 91-day U.S. Treasury Bill rate in effect at award of Contract. (6.903 for 7 3/8 percent for 10 years, for example) K = Weighting factor

= 1 for (S-A) less than 0.01 = 1.5 for (S-A) between 0.01 and 0.0199 = 2 for (S-A) between 0.02 and 0.0299 = 3 for (S-A) between 0.03 and 0.0399 = n for (S-A) between 0.0n and 0.0n99

b. An example calculation is shown for a specified availability of 0.997

and an actual availability of 0.985:

Damages = ((1-0.985 )/0.985 -(1-0.997)/0.997) X 8760 X 30 X 6.903 X 1.5 = $33,250

4. Damages will be limited to the current retail price of the total system

hardware complement or equivalent hardware.

END OF SECTION

AARHIP 13403-10

REPAIR REPORT PART 1

WHAT IS WRONG?

a.m.

PROBLEM FIRST OBSERVED ON / / AT: p.m. BY: a.m.

CONTRACTOR ARRIVED ON: / / AT: p.m. BY:

HOW WAS THE SYSTEM BEING USED AT THE TIME:

PART 2

a.m. CONTRACTOR ARRIVED ON: / / AT: p.m. BY:

CONTRACTOR’S DESCRIPTION OF PROBLEM:

CORRECTIVE ACTION TAKEN:

CAUSE OF PROBLEM, IF KNOWN:

a.m.

PROBLEM RESOLVED ON: / / AT: p.m. BY:

TOTAL DOWNTIME: HOURS

AARHIP 13403-11

PART 3

a.m. REPAIR COMPLETED ON: / / AT: p.m. BY:

UNAVOIDABLE DELAY TIME: : (HOURS:MINUTES)

REASON FOR DELAY:

a.m. ACCEPTANCE CHECK COMPLETED ON: / / AT: p.m.

BY: FOR THE CONTRACTOR

BY: FOR THE OWNER

AARHIP 13403-12

EXAMPLE OF FAILURE SUMMARY REPORT

1-12-96 TO 2-11-96 REPAIR REPORT

NO.

TRAVEL TIME

HH:MM

REPAIR TIME

HH:MM

UNAVOID DELAY TIME

DOWN TIME

HH:MM COMMENTS

2:15 :30 0 :30 PLC OZ Down

5:00 :45 0 1:45 Car broke down

3:30 1:45 1:30 :15 No key for cabinet

1:15 2:45 0 0 Operator error

8:30 :25 0 :25 Central down, 12 hour travel

:45 1:15 0 0 Control signal cable to valve operator broken

Prepared By:

AARHIP 13403-13

COMPONENT AVAILABILITY CALCULATION FORM Component _________________________________________ Downtime Summary

Date Total

Downtime (Hours)

Downtime Less Allowances

(Hours) Comments

Total ____________________________ Availability = (Duration OAD – Downtime Less Allowances)/(Duration OAD) Component Availability _______________________________

AARHIP 13403-14

(NO TEXT FOR THIS PAGE)

AARHIP 13420-1

SECTION 13420

FIELD INSTRUMENTS

PART 1 GENERAL

1.1 SUMMARY

A. Scope:

1. Provide all labor, materials, equipment and incidentals as shown, specified and required to furnish, install, calibrate, test, adjust and place into satisfactory operation all primary sensors and field instruments furnished under this Section.

2. Install all in-line flow elements and provide taps in the process piping

systems for installation of other flow, pressure, level and temperature sensing instrumentation.

3. Drawings and Specifications illustrate and specify functional and general

construction requirements of the sensors and field instruments and do not necessarily show or specify all components, wiring, piping and accessories required to make a completely integrated system. Provide all components, piping, wiring, accessories and labor required for a complete, workable and integrated system.

B. Instruments furnished under other Sections

1. Certain field instruments are specified to be included with the equipment

furnished by the vendor under other specification sections. These instruments shall generally meet the requirements specified in this section where applicable.

2. Instruments furnished by other equipment vendors/manufacturers are not

included in the schedule at the end of this section but are generally shown on the P&IDs.

C. Coordination: Coordinate the installation of all items specified herein and required

to ensure the complete and proper interfacing of all the components and systems. D. Related Sections:

1. Section 13400 - General Instrumentation and Control 2. Section 13431 - Panel Devices and Enclosure Construction

AARHIP 13420-2

3. Section 13451 - PLC Systems 4. Section 13453 - SCADA System


A. Comply with the requirements of Section 13400, General Instrumentation and Control.

B. Acceptable Manufacturers:

1. Furnish primary sensors and field instruments by the named manufacturers

or equal equipment by other manufacturers. 2. The named manufacturers have been specified to establish the standard of

quality and performance of the equipment to be supplied. 3. Obtain all sensors and field instruments of a given type from the same

manufacturer. 4. The primary sensors and field devices shall be interchangeable with similar

function existing primary sensors and field devices to minimize spare parts inventory.

C. Manufacturer's Responsibilities and Services:

1. Design and manufacture the primary sensors and field instruments in

accordance with the applicable general design requirements specified in Section 13400, General Requirements, and the detailed specifications herein.

2. Field supervision, inspection, start-up and training in accordance with the

requirements of Section 01820, Training. 1.3 SUBMITTALS

A. Comply with the requirements specified in Division 1 and Section 13400, General Instrumentation and Control.

1.4 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Comply with the requirements specified in Section 13400, General Instrumentation and Control.

B. Primary sensors and field instruments shall not be delivered to the site until all

product information and system Shop Drawings for the sensors and instruments have been approved.

AARHIP 13420-3

1.5 IDENTIFICATION TAGS

A. All sensors and field instruments shall have an identification tag meeting the following requirements: 1. Tag numbers for sensors and field instruments shall be as listed on the

Drawings as the equipment number. 2. The identifying tag number shall be permanently etched or embossed onto a

stainless steel tag which shall be fastened to the device housing with stainless steel rivets or self tapping screws of appropriate size.

3. Where neither of the above fastenings can be accomplished, tags shall be

permanently attached to the device by a circlet of 1/16-inch diameter stainless steel wire rope.

4. All sensors and field instruments mounted on or within panels shall have the

stainless steel identification tag installed so that the numbers are easily visible to service personnel.

1.6 SPARE PARTS:

A. Provide the following spare parts: 1. One complete ultrasonic level transmitter including transducer.

PART 2 PRODUCTS

2.1 GENERAL:

A. Provide components to operate on 115 volt ac, single phase, 60 hertz electrical service unless otherwise specified.

B. Provide two-wire transmitter power supplies as required. Loop power supplies are to be installed in the PLC cabinets complete with a separate fuse and blown fuse indicator for each analog circuit.

C. Provide fuses or switches for equipment as recommended by the instrument manufacturer.

D. Provide contacts for control of motor operated or electrically operated equipment rated minimum 10 amp at 115 volts ac, 60 hertz. Provide contacts for low level analog signal switching of the gold bifurcated, cross bar type.

E. Provide 4-20 mAdc analog output signals from all process transmitters.

AARHIP 13420-4

F. Where interposing relays are required to provide proper contact rating from devices interfacing to the PLCs, install the relays in the PLC cabinets. See Section 13430.

G. Furnish all necessary accessories for installation, including mounting brackets, floor stands, hardware and like items.

H. Provide tool kits and test equipment, as recommended by the manufacturer, necessary for assembling, calibrating and maintaining equipment.

2.2 ULTRASONIC LEVEL TRANSMITTERS

A. Noncontact measurement consisting of a transducer and transmitter/control unit. Echo-time measuring type utilizing an ultrasonic beam to detect the liquid level.

B. Transducer constructed of PVC or CPVC. Transducer suitable for mounting via

tank-top flange connection as scheduled and shown on the Plans. C. Transducer included beam angle of no greater than 12 degrees. Manufacturer to

certify that obstructions outside this beam angle will not cause false echos resulting in erroneous readings. Transducer dead zone no greater than 12-inches.

D. Transducer to have integral automatic temperature compensation for changes in

the speed of sound over ambient temperature range of -20 to 120 degrees F. Separate temperature transducer is not acceptable. Manufacturer to provide appropriate length of transducer cable between transducer and the transmitter.

E. Provide microprocessor based transmitter. Provide span adjustment from 2-30

feet. Manufacturer to match transducer range and frequency to the application. F. Transmitter enclosure NEMA 4 rated with front mounted digital level display in

engineering units. G. Signal output: isolated 4-20 mA dc into 0-600 ohms. H. Accuracy: +/- 1.0 percent of span. For volume applications, this includes the level

to volume linearization. I. Power requirement: 115-volt ac, 60 hertz. J. Provide five independent alarm relays adjustable over entire span. Relay outputs

to be SPDT rated at least 5 amps at 115-volt ac. Transistor outputs are not acceptable.

K. Manufacturer: Milltronics Hydroranger 200/XPS-15.

AARHIP 13420-5

2.3 MAGNETIC FLOW METER

A. Flow Elements

1. Electromagnetic type with pulsed dc coil excitation for zero stability. Suitable for aqueous solutions with minimum conductivity of 5 micromhos/cm. Insensitive to changes in fluid viscosity and density.

2. Flanged body design for 150 pound ANSI flanged pipe connections.

3. Sensor flow tube material: 304 stainless steel pipe, with 2 electromagnetic coils mounted on the exterior surface of the tube.

4. Furnish meter tube with a laying length of at least 1.3 times the nominal

meter size.

5. Provide meter with hard rubber or polyurethane liner and type 316 stainless steel electrodes.

6. Enclosure classification: NEMA 4 / IP67 and capable of accidental submergence in 30 feet of water for up to 48 hours.

7. Electrical terminal boxes for flow sensors located in underground vaults,

shall be backfilled with non-setting transparent potting material.

8. Hydraulically calibrate each meter at a flow facility against a master meter or other device which is traceable to the United States NIST. Submit certified calibration data and a calibration curve substantiating the stated accuracy. Submit information regarding the location of the flow facility and procedure being used to calibrate the meter.

9. Furnish and install meter with stainless steel grounding rings. Grounding electrodes will not be acceptable.

10. Meter accuracy: ±0.5 percent of actual flow rate for a range of 10 to 100

percent of maximum calibrated flow. Guarantee accuracy with no more than five pipe diameters of straight pipe run upstream from the meter.

11. Manufacturer: ABB mag meter,

B. Signal Converter:

1. Smart "Hart" protocol.

2. Provide integral mounted flow transmitter/converter, microprocessor based.

Provide transmitter with integral LCD display of flow rate.

AARHIP 13420-6

3. Provide input of configuration data, stored in EEPROM memory without

need for battery backup.

4. Outputs:

a. 4-20 mAdc into 0-600 ohm load linearly proportional to flow, calibrated as scheduled.

b. 24-volt dc scaled pulse totalizer output, 150 mA minimum, calibrated

1,000 gallons per pulse to drive a remote PLC input.

5. Accuracy: ±0.5 percent of actual flow over 10:1 flow range.

6. Provide input span adjustment from 1.5-30 feet per second at full scale flow. Meters requiring circuit or component changes to effect calibration changes will not be acceptable.

7. Operating ambient temperature: -4 to 140 degrees F.

8. Power requirement: 115 volts ac, 60 hertz.

9. Enclosure classification: NEMA 4 / IP67 2.4 PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES

A. Provide diaphragm sealed piston actuated type with Buna-N diaphragm. B. Single field adjustable setpoint with fixed deadband. C. Switch output: SPDT hermetically sealed, narrow deadband, 5A at 115 Vac rated

suitable for Class 1, Division 2, Group D hazardous areas. D. NEMA 4, epoxy coated aluminum enclosure suitable for installation in Class 1,

Division 2, Group D hazardous locations. E. Range:

1. Pressure: Range to be selected per the application.

2. Differential Pressure: 30 psid range with 500 psi working pressure. Allow

full reversal of differential without damage to sensing element. Preset switch to operate at 5 psid. Deadband no greater than 3 psid.

F. Manufacturer: Ashcroft L Series or equal.

AARHIP 13420-7

2.5 PRESSURE AND DIFFERENTIAL PRESSURE TRANSMITTERS

A. Differential capacitance cell type. Two-wire, 4-20 mAdc output signal. Loop powered from 24 volts dc nominal. Output load impedance of at least 550 ohms.

B. Microprocessor based "smart" electronics. HART protocol compatible. C. Accuracy: +\- 0.10 percent of calibrated span. D. Span and zero continuously adjustable, either locally or via hand-held digital

interface. E. NEMA 4 housing. Suitable for operation over ambient temperature range of 20-

120 degrees F.

F. FM approved for installation in Class 1, Division 1 hazardous areas. G. Ceramic or stainless steel wetted parts. Stainless steel bleed and drain fittings. All

metal external parts. H. Integral 4-digit LCD output indicator graduated 0-100 percent. Provide integral

mounting bracket suitable for wall or pipestand mounting. I. ½-inch NPT process connections. J. Manufacturer: ABB, Endress and Hauser Cerebar/Deltabar S, Rosemount 3051 or

equal 2.6 FLANGE MOUNT HEAD PRESSURE TYPE LEVEL TRANSMITTERS

A. Provide pipe-flange mount differential pressure transmitter with low pressure tap connected to the sludge gas reference pressure.

B. Meet the general requirements specified above for pressure and differential

pressure transmitters

C. Wetted parts: Ceramic or stainless diaphragm sensor, stainless steel flange.

D. 3-inch, ANSI flanged process connection. E. Manufacturer: ABB, Rosemount 3051L, Endress and Hauser Deltabar S FMD 230

2.7 FIELD MOUNTED DIGITAL INDICATORS

A. Type: Electronic, 4-Digit LED, 0.56-inch high display B. Input Impedance: no greater than 250 ohms.

AARHIP 13420-8

C. Power Source: 115 Vac, 60 hertz D. Input Signal: 4-20 mAdc E. Input Dampening: Adjustable F. Enclosure: Provide indicators for outdoor mounting with a NEMA 4 bezel rating

and a SST Nema 4X enclosure. Enclosure to include a red high level oil-tight indicating light, 115 Vac, LED type to be activated by a remote alarm contact input. See Section 13431 for indicating light requirements.

G. Accuracy: +/- 0.05 percent of span +/- 1 count H. Decimal Point: Selectable via DIP switches or keypad. I. Input Connections: Compression type screw terminals J. Range Selection: DIP switches, multiturn potentiometers, or keypad. K. Manufacturer: Precision Digital PD765 Trident with model PDA2701 enclosure

or equal.

L. Provide a sunshield for each level indicator panel. 2.8 COMBUSTIBLE GAS MONITORS

A. Provide single point gas monitors to measure and display a single gas concentration. Provide gas monitors for combustible gas (methane) using a poison resistant catalytic bead type sensor.

B. Provide sensor and preamplifier as an integral unit consisting of condulet housing for the electronics and a screw-in sensor which mounts directly to the condulet enclosure. Provide the assembly in a wall mount configuration.

C. Provide receiver/transmitter module with 4-digit LED display of gas concentration in percent LEL. Provide multi-module enclosure (Air Monitoring Panel) for the four sensors furnished. Provide enclosure with Nema 4X thermoplastic or fiberglass construction suitable for wall mounting. Provide multi-module enclosure with power supply module suitable for 115 Vac, 60 Hz power.

D. Provide each receiver/transmitter module with a 4-20 mAdc output into 0-1,000 ohms. Provide each module with two adjustable alarm settings. Provide each module with three SPDT alarm relays, assignable to either of the two alarm settings. In addition, provide a SPDT trouble alarm relay output for each module. Alarm relays to be rated for 10A at 120 Vac.

AARHIP 13420-9

E. Provide receiver/transmitter enclosure (Air Monitoring Panel) with relay outputs configured as follows:

1. One relay contact from each module parallel connected to activate the

audible alarm and beacon on the air monitoring panel. Set to activate at 50% LEL.

2. One relay contact from each module parallel connected to activate a common remote high level alarm to SCADA. Set to activate at 50% LEL.

3. One relay contact from each module parallel connected to activate a common sensor trouble alarm to SCADA.

F. Calibration: as scheduled.

G. Provide receiver monitor enclosure with a piezoelectric audible horn and a red

xenon strobe light visual alarm light on the top of the panel. Provide the audible and visual alarm powered from the panel.

H. Provide calibration kit and calibration adapter for sensors. Provide calibration zero

and span gas (one year supply) along with all necessary accessories for the gas being monitored.

I. Manufacturer: ATI Series A14 or equal.

PART 3 EXECUTION


A. General 1. Strictly follow manufacturer recommendation for installation of the field

instruments. The Contractor shall be responsible for any problems resulting from any deviation from manufacturer installation instructions.

2. Mount all transmitters vertically, with the integral indicators facing front or

sides. For pipe mounted instruments, provide sufficient clearance to permit 360° access to the units.

3. Seal all conduit and wiring entries into all instruments installed below

ground or in vaults with non-setting transparent potting material. Seals shall be water tight, suitable for accidental submergence in 30 feet of water.

4. Provide instrument loop surge protector at both ends of 4-20 mAdc loop

wiring for instruments installed in the field (outdoors or in underground vaults).

AARHIP 13420-10

a. Provide loop surge protectors as manufactured by Phoenix Contact, Joslyn or equal.

B. Ultrasonic Level Sensor Installation

1. Install sensors so that 12 degree included beam angle does not intersect tank

walls. 2. Mount sensor as scheduled and shown. Provide flange adapters for the

sensor mounting when attaching to floor castings through slabs or tank flanges.

3. Install sensors per manufacturer instructions and recommendations.

C. Interface with Other Products

1. Two-wire transmitter power supply: Coordinate power supply requirement

with panel-mounted instrument power supplies as specified in Section 13431.


A. Manufacturers Field Service 1. Secure the services of factory personnel for instrument start-up and

calibration. Calibrate each instrument, including its complete instrument loop. Indication at remote receiving instruments, including any SCADA system operator interface screens, shall be equal to readings at local transmitter indicators.

2. Provide at least two full days of on-site startup service by the ORP

analyzer’s factory service personnel. 3. Provide written loop-calibration report for each instrument loop, which shall

include, but not limited to the following: a. Date and time the final calibration was completed. b. Weather conditions at the time the final calibration was performed. c. Comparison of readings at the local transmitters with readings at the

remote receiving instruments. d. Verification of operation of all contact outputs, including those at the

receiving instruments. e. Description of method of calibration. f. Provide a table showing calculated and measured values at 0%, 25%,

50%, 75%, and 100%. g. Names and signatures of factory personnel performing calibration.

AARHIP 13420-11

h. Names and signatures of Owner representative witnessing calibration process.

3.3 INSTRUMENT SCHEDULE

Level Transmitters LE/LIT-416, 417, 418, 419 Number of units: Four (4) Type: Ultrasonic Calibration: 0-32.5 feet (El 736.00 to 768.50) Location: Transducer mounted in holding tank opening.

Transmitter mounted adjacent. Comment: Manufacturer to supply cable between sensor and

transmitter. Floor El at transducer = El. 771.00

Flow Meter FE/FIT-439 Type: Magnetic Pipe Size: 6-inch Operating range: 50 to 500 gpm Calibration: 0-500 gpm Location: Sludge transfer pump discharge line to liquid loading Flow Meter FE/FIT-438 Type: Magnetic Pipe Size: 4-inch Operating range: 25 to 250 gpm Calibration: 0-250 gpm Location: Sludge recirculation line to holding tanks Flow Meters FE/FIT-4445, 446, 447 Number of units: Three (3) Type: Magnetic Pipe Size: 4-inch Operating range: 25 to 250 gpm Calibration: 0-250 gpm Location: Sludge feed line to centrifuge Level Transmitters LE/LIT-420, 421 Number of units: Two (2) Type: Ultrasonic Calibration: 0-14 feet (El 736.00 to 750.00) Location: Transducer mounted in WAS tank opening. Transmitter

mounted adjacent. Comment: Manufacturer to supply cable between sensor and

transmitter. Floor El at transducer = El. 756.00

AARHIP 13420-12

Flow Meter FE/FIT-422 Type: Magnetic Pipe Size: 4-inch Operating range: 25 to 250 gpm Calibration: 0-250 gpm Location: GBT feed pump (GBTFP) discharge line to GBTs

Flow Meter FE/FIT-427 Type: Magnetic Pipe Size: 4-inch Operating range: 50 to 500 gpm Calibration: 0-500 gpm Location: Thickened sludge pump (TWASP) discharge line to

blend tanks

Combustible Gas Monitor AE/AIT-429-1, 429-2, 429-3, 429-4 Number of sensors: Four (4) Type: Catalytic bead Calibration: 0-100% LEL Alarm setting: 50% LEL Location: Sensors mounted on columns as shown.

Receiver/monitor (air monitoring panel) wall mounted as shown in Mechanical Room.

Comment: Mount sensors 10-feet above floor.

Level Transmitters LE/LIT-401, 402 Number of units: Two (2) Type: Ultrasonic Calibration: 0-15.33 feet (El 735.67 to 751.0) Alarm setting LSL: 2.16 feet (El 737.83) Location: Transducer mounted on top of blend tanks. Transmitter

mounted adjacent. Comment: Manufacturer to supply cable between sensor and

transmitter. Tank bottom at transducer = El. 735.67. Mount transducer at least 12” above top of calibrated range.

Flow Meters FE/FIT-463, 465 Number of units: Two (2) Type: Magnetic Pipe Size: 2.5-inch Operating range: 20 to 50 gpm Calibration: 0-75 gpm Location: Lime slurry feed line to sludge holding tanks

AARHIP 13420-13

Level Transmitters LE/LIT-430, 448 Number of units: Two (2) Type: Ultrasonic Calibration: LIT-430 0-9.833 feet (El 736’-6” to 746’-4”) LIT-448 0-14 feet (El 736’-6” to 750’-6”) Alarm setting LSH-430: 8.333 feet LSH-448: 12.50 feet Location: Transducer mounted on top of bulk polymer tanks.

Transmitter mounted adjacent. Comment: Manufacturer to supply cable between sensor and

transmitter.

Pressure Transmitter PIT-478 Type: Differential capacitance Calibration: -10 to +10 inches w.c.

Location: Odor control air plenum

Polymer Truck Unloading Level Indicator Panels LI/LLH-430, 448 Type: Local mount LED, weatherproof Calibration:

LI-430 0-9.833 feet LI-448 0-14.0 feet

Location: Polymer Truck Unloading Area Comment: Each panel to also include a high level indicating light

activated by the respective ultrasonic level transmitter alarm contact output.

END OF SECTION

AARHIP 13420-14


AARHIP 13431-1

SECTION 13431

PANEL DEVICES AND ENCLOSURE CONSTRUCTION

PART 1 GENERAL

1.1 SUMMARY

A. Section includes technical requirements for fabrication, engineering, wiring and installation of instrument panels and enclosures and providing the panel mounted instruments and equipment. These include, but are not limited to the following:

1. Panel Construction

2. Panel Wiring

3. Panel Mounted Equipment

B. Related Sections:

1. Section 13400 - General Instrumentation and Control 2. Section 13420 - Field Instruments 3. Section 13451 - PLC Systems 4. Section 13453 - SCADA System

C. Panels provided by manufacturer as part of package control systems:

1. Certain control panels are furnished by manufacturers of equipment specified under other Sections as part of a package control system. In general, those panels shall meet the requirements of this specification section.

1.2 SUBMITTALS

A. General: Provide submittals as specified in Division 1 and as required in section 13400.

B. Pre-Construction Submittals

1. Product Data: Submit manufacturer’s official and published product data, specifications, and installation recommendations for each item. Product data shall include terminal wiring details, and manufacturing and calibration data.

2. Shop Drawings: Include the following information:

a. Bill of materials

b. Front panel layout

c. Internal panel layout

AARHIP 13431-2

d. Internal wiring diagrams, including wire type, size and identification number

e. Terminal block layout

f. Nameplate lists

g. Color schedules

h. Elementary control diagrams

3. Provide loop diagrams conforming to ISA-S5.4 “Instrument Loop Diagrams”.


A. Comply with the applicable provision of the following codes and standards:

1. Underwriters Laboratory (UL)

2. Electrical Testing Laboratory (ETL)

3. National Electrical Code (NEC)

4. National Fire Protection Association (NFPA) 79, Electrical Standard for Industrial Machinery

5. Instrumentation Society of America (ISA)

B. All electrical materials and equipment shall be new and shall bear the label of the Underwriters’ Laboratory (UL), Inc., Factory Mutual (FM) or equivalent where standards have been established and label service regularly applies.

C. Provide integrated instrumentation systems. Assign complete responsibility for furnishing, coordination, assembly, and installation supervision of all equipment to one Systems Integrator regularly engaged in the manufacture, assembly and production of systems of type specified. Provide complete, satisfactory, and trouble-free operating installation.

D. Furnish like instruments from the same manufacturer. Minimize number of different manufacturers.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable manufacturers include the following:

1. Enclosure: Hoffman

2. Terminal Blocks: Phoenix Contact, Allen Bradley

3. Power Supplies: Phoenix Contact, Action Instruments, Sola / Hevi-Dudy

AARHIP 13431-3

4. Signal Isolators: Action Instrument, Moore Industries, Phoenix Contact

5. Pushbuttons, selector switches and pilot lights: Allen Bradley, Square D

6. Digital Panel Indicators: Precision Digital PD765 Trident or equal.

7. UPS: Powerware, APC or equal.

8. Totalizers: Veeder-Root or equal.

2.2 GENERAL REQUIREMENTS

A. Panels and enclosures shall meet the NEMA requirements for the type specified.

B. Sizes shown are estimates. Furnish panels and enclosures amply sized to house all equipment, instruments, front panel mounted devices, power supplies, power distribution panels, wiring, tubing and other components installed within.

C. Panels located inside control or electrical room areas shall be NEMA 12 rated unless specified otherwise. This requirement applies to the SCADA PLC Panel.

D. Panels located in process areas or outdoors (except areas classified as hazardous locations) shall be NEMA 4X stainless steel unless specified otherwise. This requirement applies to the Truck Unloading Indicator Panels and the Liquid Sludge Truck Loading Panel.

E. Network equipment panels shall be suitable for EIA 19-inch rack mounted equipment. This requirement applies to the Fiber Connect and Network Panel.

F. Provide lifting rings on panels in excess of 100 pounds.

G. Panels are to be sized by the integrator based on the equipment furnished. It is intended that the PLC panel be a single door enclosure of size 36” wide x 72” tall x 18” deep. If a panel wider than 36-inches is required, panel size may be increased to a maximum of 60”wide x 72” tall x 24” deep.

H. Panel Mounted Equipment

1. Unless otherwise specified, provide components to operate on 120 Volts AC single phase 60-Hertz power.

2. Provide 24Vdc two-wire transmitter power supplies as required.

3. Provide interposing relays and signal isolators to protect panel mounted equipment from electrical surges induced in field wiring.

4. Provide engraved laminated nameplates to identify each panel mounted component. The nameplates shall have black lettering on white background. Lettering height shall be 3/16-inch minimum.

AARHIP 13431-4

I. Panel Accessories

1. Provide panel heaters, corrosion inhibitors and breather drains for condensation and corrosion control inside panel. Panel heaters shall be of forced air types, provided with integral thermostatic control.

2. One UPS supply receptacle (PLC Panel only), 120 VAC, 20A duplex type.

3. One “service receptacle”, 120 VAC, 20A duplex, grounding type receptacle.

4. One 120 VAC fluorescent light fixture with 40 watt lamp and protective plastic shield. (PLC Panel only)

5. One 120 VAC, 20A, snap switch, to turn on the light, mounted in an outlet box with a cover and located so that it is easily accessible from access door. (PLC Panel only)

6. The PLC panel has two power feed circuits.

a. Provide the service light with switch, panel heater and the duplex service receptacle with its own circuit breaker and power feed (from separate lighting panel circuit).

b. Provide UPS supply receptacle with its own circuit breaker and power feed (from separate lighting panel circuit).

7. Provide a UPS inside the PLC panel to provide surge protection and backup power to the PLC equipment and network equipment. Size the UPS for the PLC and communication components furnished, both in the PLC panel and in the adjacent Network Equipment panel, designed to give 15 minute operation under full load. Provide rating of 500-VA minimum. Provide unit with hot-swappable batteries. Provide easily serviceable placement of the UPS within the panel.

a. Connect UPS to UPS supply receptacle via plug and cable.

b. Wire PLC enclosure via plug and cable into UPS output receptacle so that PLC equipment and network adapter are powered by the UPS. (When UPS fails, enable user to power PLC enclosure directly from duplex UPS supply receptacle.)

c. Wire the output of the UPS to also power the adjacent Network Equipment panel.

2.3 PANEL CONSTRUCTION

A. NEMA 12 Panels

1. Fabricate enclosures using minimum 14 gage steel for wall or frame mounted enclosures and minimum 12 gage for free standing enclosures. Steel shall be free of pitting and surface blemishes.

2. Continuously weld all exterior seams and grind smooth.

AARHIP 13431-5

3. Provide stiffening members for strength and stiffness as required.

4. Panel shall be flat within 1/16-inch over a 24-inch by 24-inch area, or flat

5. Use pan type construction for doors. Door widths shall not exceed 36-inches.

6. Mount doors with full length heavy duty piano hinge with stainless steel pin.

7. Provide oil resistant gasket completely around each door or opening.

8. Provide handle-operated, oil-tight, key-lockable three point stainless steel latches.

9. Use stainless steel fasteners throughout.

10. Provide interior mounting panels and shelves constructed of minimum 12 gage steel.

11. Provide steel print pocket with white enamel finish.

12. Provide enclosure mounting supports as required for floor, frame, or wall mount.

13. Provide all holes and cutouts for installation of conduit and equipment. Provide water tight conduit hubs. (Double locknuts are not acceptable.)

14. Completely clean all interior and exterior surfaces so they are free of dirt and corrosion.

15. One coat of primer shall be applied to all interior and exterior surfaces

16. All interior surfaces shall be painted with two coats of semi-gloss white

17. All exterior surfaces shall be painted with a minimum of three finish coats, ANSI 61 grey.

18. Provide one extra quart of touch-up paint for each exterior finish color.

B. NEMA 4X Panels

1. Fabricate NEMA 4X enclosures from 14 gauge (minimum) stainless steel.

2. Provide non-corrodible metal hardware including hinge and cover clamps.

3. Do not paint stainless steel enclosure exterior surface.

4. Sandblast, roughen, or chemically etch stainless steel enclosures to reduce gloss, reflections and glare.

5. Provide conduit knock-outs prior to installation of equipment inside enclosure. Provide water tight conduit hubs. (Double locknuts are not acceptable.)

6. Provide door clamps on three sides of enclosure door. Clamps shall be quarter-turn or similar tool-less means.

7. Rolled lip around three sides of door and along top of enclosure opening.

AARHIP 13431-6

8. Hasp and staple for padlocking.

9. Provide a clear plastic, gasketed lockable hinged door to encompass all non-NEMA 4 front of panel instruments.

C. Network Equipment Panels

1. Fabricate enclosures using welded steel frame with four rack angle mounting struts.

2. Provide two-door enclosures with two sets of L-shaped rack angles with holes spaced according to EIA spacing standards. Provide rack angles with tapped holes.

3. Provide 23-inch cabinet model that is configured to mount 19-inch equipment. Panel height to be 7’-0” tall.

4. Provide removable doors with reversible hinges. Front door shall have smoke gray acrylic viewing window. Rear door shall have louvers at the bottom half. Side panels are to be removable.

5. Provide network equipment panel configured to mount the fiber optic patch panels and the network switches and media converters along with their power supplies specified in Section 13453.

6. Configure the network equipment panel to receive power from a UPS backed power feed from the adjacent PLC-RS Panel.

2.4 PANEL GROUNDING

A. Provide ground busbars, which shall be directly wired and connected to facility grounding system.

B. Provide dc ground bus (for analog cable shield termination) bonded to chassis ground.

C. Provide nickel-plated copper busbars, with current rating of 100 amperes.

D. Provide each busbar with at least twenty (20) screw clamp terminal blocks, each capable of accepting #10 AWG conductors.

2.5 PANEL WIRING

A. Terminate all wiring, to and from field devices, at panel terminal blocks, not on equipment terminals.

B. Do not terminate more than two wires at the same terminal. Wiring splices and wire nuts will not be permitted within the enclosure.

C. Provide wire identification at each wire end. Utilize computer-generated, heat-shrink type wire markers.

AARHIP 13431-7

D. Install all wiring in plastic wiring ducts, provided with snap-on covers. Size ducts to include at least 100% spare capacity. Restrain all wiring outside of ducts with plastic ties.

E. Group and wrap all wires passing a door hinge in protective wire harness. Provide abrasion protection for wire bundles passing through holes or across sheet metal edges.

F. Provide panel wiring of stranded copper with 600-volt rated thermoplastic insulation.

1. Power wiring: No. 14 AWG minimum

2. Control wiring: No. 18 AWG minimum

3. Electronic signal wiring: No. 18 twisted shielded pair minimum

4. Ethernet network wiring: Category 5e minimum

5. Other serial communication cables: As recommended by equipment manufacturer.

G. Wire color convention shall comply with NFPA 79 (1994), part 16:

1. Line, load, and control conductors: black.

2. Neutral: white.

3. Equipment safety ground: green.

4. AC control circuit: red

5. DC control circuit: blue

6. Foreign voltage control wire: yellow

H. Physically separate AC wiring from DC wiring.

1. Where AC and DC wiring runs in parallel, provide at least 2-inch separation.

2. Where AC and DC wiring cross, they shall cross at 90°.

I. Do not daisy-chain neutral wiring and grounding conductors at equipment terminals. Provide terminal blocks that accept jumper bridges.

2.6 TERMINAL BLOCKS

A. Provide terminal blocks for field wiring and equipment wiring terminations. Provide unique identification at each terminal block.

1. Arrange terminal blocks in consecutively, based on standard alphanumeric order.

2. Group terminal blocks based on voltage level and function.

AARHIP 13431-8

3. Color code foreign voltage terminal block identification to match wire insulation.

B. Provide at least 25% spare terminal blocks for each type used in each enclosure.

C. Provide high-density modular type terminal blocks suitable for mounting on standard DIN rails.

1. Material: Nylon

2. Termination type: tubular screw with serrated pressure plate.

3. Current carrying parts (metal bodies): nickel or tin-plated copper.

4. Ground terminal blocks shall be dual color type: Green and Yellow.

5. Maximum conductor size: No. 8 AWG stranded.

6. Current rating: Up to 15 amperes at 250 volts AC.

7. Supply manufacturer jumper bridges, designed to fit on terminal blocks. Do not daisy-chain wiring.

D. Provide fused terminal blocks for panel power distribution.

1. Provide disconnect lever and fuse-puller mechanism.

2. Provide illuminated indication to indicate status of load-side power.

3. Fuses shall be standard 1/4" by 1-1/4", and sized to protect load.

E. Provide two-level type terminal blocks for PLC discrete input and outputs. Both levels shall be of the feed through types.

F. Provide three-level type terminal blocks for analog signal wiring. Top and center terminations shall be feed through types. Bottom termination shall be grounded to isolated mounting railing, connected to the dc ground bus.

2.7 PANEL MOUNTED EQUIPMENT

A. Interposing Relays

1. Provide interposing relays to interface all PLC discrete outputs with field-mounted equipment.

2. Provide high density, DIN rail mounted type relays, with coils, contacts, and voltage ratings as required. Contacts shall be rated 10 Amperes at 120 volts minimum. Relays shall have LED indicator to indicate coil status.

3. Relays for control of motor starters larger than NEMA size 1 shall be DPDT, rated 15 Amperes at 250 VAC.

AARHIP 13431-9

B. Regulated Power Supplies

1. Provide regulated DC power supply as required for PLC discrete inputs, 2-wire analog loops and instrument power. Size power supplies to include 100% spare capacity.

2. Power supplies shall be as follows:

a. Input power: 110 Volts AC, 60 Hz.

b. Output power: 24 Volts DC at 200 mA or 500 mA

c. Output regulation: <1%

d. Operating temperature: 0 to 50° C

e. DIN Rail mountable.

C. Control Devices and Pilot Lights

1. General: Pushbuttons, selector switches, and indicating lights shall be heavy-duty types, oiltight, watertight and corrosion resistant. Provide a legend plat at each device.

2. Contact block current rating: 10 amperes at 240 volts AC.

3. Pilot lights shall be super-bright LED type with 120V lamps, color cap, and push-to-test feature. Provide flashing types where indicated.

D. Signal Isolators

1. Provide 4-wire type for use as a signal isolator, converter and/or repeater.

2. Input Signal: 4-20 mA dc, field configurable for other signal ranges.

3. Input Impedance: No greater than 50 ohms.

4. Isolation: 1000-volt RMS output from input, power and ground; fully floating

5. Output Signal: 4-20 mA dc into 800 ohms minimum. Where dual signal isolator is shown, provide isolator that “splits” a 4-20 mAdc process signal input and delivers two identical, completely isolated outputs to two separate control devices.

6. Accuracy: +/- 0.1% of span

7. Power Supply: 120-volt ac, 60 hertz or 24-volts dc

8. Enclosure: designed for high density DIN rail mount

9. Isolators are not scheduled.

a. Provide isolators on all analog inputs to the PLC (unless the PLC is provided with isolated analog input modules).

b. Provide as shown and as necessary to eliminate ground loop problems when connecting instruments to other instrument loops.

AARHIP 13431-10

E. Digital Panel Indicators

1. Type: Electronic, 3-1/2 Digit LED, 0.56-inch high display

2. Input Impedance: no greater than 250 ohms.

3. Power Source: 110-volt ac, 60 hertz

4. Input Signal: 4-20 mAdc

5. Input Dampening: Adjustable

6. Enclosure: 1/8 DIN, general purpose for indoor flush panel mount. Indicators for outdoor panels shall have a NEMA 4 bezel rating or be mounted behind a weatherproof gasketed door assembly.

7. Accuracy: +/- 0.05 percent of span +/- 1 count

8. Decimal Point: Selectable via DIP switches or keypad.

9. Input Connections: Compression type screw terminals

10. Range Selection: DIP switches, multiturn potentiometers, or keypad.

F. Totalizers

1. Electronic liquid crystal display, 6 digit, manual reset type designed for flush panel mounting.

2. Furnish suitable for 24 volt DC or 115 volt AC count inputs or dry contact closure inputs (as required) with a minimum impulse on-time of 10 milliseconds.

3. Provide front mounted reset button and an internal battery for up to 10 years count retention.

4. Manufacturer: Veeder Root Mini-LX, or equal.

2.8 SOURCE QUALITY CONTROL

A. Tests and Inspection

1. Test each panel in conjunction with factory acceptance test as described in Section 13400.

PART 3 EXECUTION

3.1 PREPARATION

A. Sequence enclosure installation as follows:

1. Prior to installation, remove enclosure door, internal panels and equipment from enclosures.

2. Install enclosures and conduits, and pull field wiring into enclosures.

AARHIP 13431-11

3. Seal all wire entries with non-setting silicon compound to prevent moisture from entering enclosure.

4. Cover enclosure installation thoroughly with heavy-duty plastic sheet to protect against moisture, paint splatter and dirt. Cover until 120-volt power is available, and enclosure is ready to receive internal panel.

5. Prior to installation of internal panel, thoroughly clean enclosure internal and external surfaces. (Vacuum and wipe surfaces with clean cloth.)

6. Install internal panel and enclosure door.

7. Terminate field wiring on terminal blocks.

8. Energize panel heater and keep enclosure door closed when no work is being performed in enclosure. (Do not energize any other equipment prior to field wiring termination check.)

9. Check accuracy of field wiring termination. Thoroughly test for continuity.

10. Energize panel mounted equipment only after all wiring has been thoroughly checked and tested.

11. Energize panel heater to prevent condensation inside the panel.


A. Do not install control panels or enclosures directly against concrete walls. Provide stainless steel channels between wall and enclosure. Mount enclosure to stainless steel channels.

B. Install enclosures and panels level and plumb. Touch up all nicks, scratches, etc. with materials recommended by enclosure manufacturer.

C. Sunshield: Provide fabricated aluminum sunshield to cover the Polymer Truck Unloading Indicator Panel enclosures and shield the readouts from exposure to the sun.

D. Vacuum and clean all panel interior surfaces prior to system commissioning.


A. Tests and Inspection

1. Demonstrate that each enclosure and each panel mounted equipment:

a. Has not been damaged during transportation or installation.

b. Has been properly installed.

c. Has no mechanical defects.

d. Is in proper alignment.

e. Has been properly wired and connected.

AARHIP 13431-12

3.4 DEMONSTRATION

A. Test all control function as described in Division 1 and Section 13400. In addition, perform the following:

1. Calibrate all process variable indications.

2. Adjust all alarm setpoints.

3. Tune all control function to achieve optimum and stable control.

3.5 SCHEDULES

A. Provide the following panels and enclosures:

1. Solids Handling PLC Panel PLC-RS

2. Two polymer truck unloading indicator panels. These panels are also specified in Section 13420 – Field Instruments since they are essentially local indicators for polymer level.

3. Liquid Sludge Truck Loading Panels

4. Fiber Connect and Network Switch Cabinet

B. Provide other control panels for equipment package control systems which meet the general requirements of this section.

C. See drawings and specification Section 13400 for enclosure function and enclosure mounted equipment.

END OF SECTION

AARHIP 13451-1

SECTION 13451

PROGRAMMABLE LOGIC CONTROL (PLC) SYSTEMS

PART 1 GENERAL

1.1 SUMMARY

A. This section includes requirements for providing a Programmable Logic Control (PLC) system, local operator interface systems and all appurtenances required for monitoring and control of equipment and unit processes. The PLC will serve as the digital PICS SCADA system interface to field devices and signals. The PICS SCADA system includes multiple PLCs throughout the facility connected to the SCADA workstations in the Solids Handling Building Control Room. PICS SCADA workstations are specified in Section 13453.

B. Programming and Software Configuration

1. All programming and software configuration for the main PICS PLCs (PLC-

BT and PLC-RS) will be performed by others (the OWNER’S Application Software Programmer) under the direction of the City of Ann Arbor.

2. All programming and software configuration of the package control system

PLCs shall be included as part of this contract work C. Provide all submittal documents within 90 days of Notice to Proceed. D. Provide assistance to the OWNER’S Application Software Programmer personnel

during field testing and system startup. Provide the services of two technicians for four weeks minimum, at five days per week.

E. Work includes all elements of the systems specified. Provide all control hardware

complete with power supplies, enclosures, accessories, and other appurtenances. Provide installation of new equipment, and testing necessary for the proper operation of the control system.

F. Provide programming training as specified.

G. Work includes the following:

1. New PLC in the Solids Handling Building (PLC-RS) 2. Modifications to the existing PLC (PLC-BT) in the Gravity Thickener

Building

AARHIP 13451-2

H. Interface with PLCs Furnished as part of Package Control Systems under other Sections of the Specifications:

1. Certain Equipment furnished under other Sections are specified to be

provided with package control systems including PLCs. 2. Package control PLCs shall generally meet the requirements specified under

this Section, including the requirement for a dedicated small UPS in the package control PLC panel.

3. The package control systems listed below are shown having direct Ethernet

communication links to the PICS system PLCs for information exchange. The configuration of these interfaces shall be the responsibility of the system integrator. a. Gravity Belt Thickener Control System b. Centrifuge Control System c. Pugmill and Pebble Lime Storage and Feed Control System d. Sludge Hopper Control System

I. Interface with Valve/Gate Actuator two-wire control network.

1. Provide Modbus communication module (channel #1) in the PLC to

communicate directly with the actuator two-wire network Master Station as shown.

2. This interface shall allow direct monitoring and control of the valves and

gates from the SCADA system, either manually or automatically as specified.

J. Interface with electrical Microprocessor Metering System (MMS) network.

1. Provide Modbus communication module (channel #2) in the PLC to

communicate directly with the electrical system Microprocessor Metering System as shown.

2. This interface shall allow direct monitoring of switchgear electrical

parameters from the SCADA system.

K. Related Sections

1. Section 13400 - General Instrumentation and Control 2. Section 13420 - Field Instruments 3. Section 13431 - Panel Devices and Enclosure Construction 4. Section 13453 - SCADA System

AARHIP 13451-3


A. Existing System 1. The existing main PLC in the Solids Handling Building (PLC-RS) is to be

removed and replaced with a new PLC as specified herein. The existing PLC is an Allen-Bradley PLC-5.

2. The existing Lime Slaker package control system is to be retained. That

system includes a PLC (Allen-Bradley SLC-5/04) connected to the existing main PLC-RS via Data Highway Plus™ interface for monitoring (no control) of the lime slaker operation from the PICS system. Provide a new Allen Bradley ControlLogix gateway with Ethernet and DH-Plus gateway interface modules in the new PLC-RS panel to allow the existing Lime Slaker PLC to talk to the new main PLC-RS.

3. The existing main PLC in the Gravity Thickener Building (PLC-BT) is to be

retained. Program modifications will be performed by others (OWNER’S Application Software Programmer) as required to accommodate the new and revised equipment at the Gravity Thickener Building. The existing PLC is an Allen-Bradley PLC-5. Connect that PLC to the new Solids Handling PLC via fiber optic Ethernet data link as shown. The existing I/O schedule for this PLC is included at the end of this section. The schedule shows the required new and/or revised signal definitions.

B. Design Requirements

1. Provide Ethernet-based PLC network as described in Section 13400 and as

shown on drawings. 2. Configure the PLC network to communicate with the PICS SCADA system

specified in Section 13453. 3. PICS PLCs will be programmed by others (OWNER’S Application

Software Programmer) to achieve control and monitoring described in Section 13400.

4. Package system control PLCs are to be programmed by the equipment

manufacturer in accordance with this section to meet the functional requirements described in Section 13400 and in the specification section for the corresponding equipment.

5. Fully configure PLC system and appurtenances to form a complete working

system.

AARHIP 13451-4

C. City Standards: Provide all PLC programming, including that for package control systems, conforming to the following City of Ann Arbor Process and Information Control System standards documents (also available electronically):

1. Application Configuration Design Guide, dated March 20, 1998 and updated

February 2007.

2. PLC Standard Modules for PLC Programming, printed April 2007. D. Provide complete systems, which shall include, but not be limited to I/O racks or

chassis, power supplies, input and output modules, special communication modules, local operator interface systems, and power and communication cables.

E. Provide one copy of PLC programming software and one copy of operator

interface system programming software as specified herein. Software licensing to be for the City of Ann Arbor. Turn all software and manuals over to city personnel at job completion.

1.3 SUBMITTALS

A. Submit product data as required in Section 13400 and as specified in Division 1. 1. Submit data sheets and catalog literature on each type of equipment. 2. Submit programming and installation manuals for each type of equipment.

B. Training Submittals

1. Include the following information in the first submittal for this section:

a. A course syllabus for each course in the training program. b. A training schedule for each course.

2. Prior to scheduling training, obtain approval of the Owner and Engineer on a

submittal of the training schedule. C. Documentation:

1. Provide all documentation related to PLC configuration. 2. Furnish all manuals and PLC documentation.

D. Operation and Maintenance Manuals: Submit operation and maintenance manuals

in accordance with Division 1. 1.4 SPARE PARTS

A. Provide the following spare parts:

AARHIP 13451-5

1. One PLC processor 2. One digital input module of each type utilized 3. One digital output module of each type utilized 4. One analog input module of each type utilized 5. One analog output module of each type utilized 6. One power supply assembly of each size utilized 7. One dozen fuses of each size furnished

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. General 1. Provide PLC hardware in accordance with the following specifications. For

purposes of compatibility with the existing PICS PLC system at the treatment plant, provide the following Allen Bradley hardware platform as specified. Do not substitute.

B. PLC System for PLC-RS:

1. CPU: Allen Bradley ControlLogix processor with

memory sized by integrator for the application. Allen Bradley 1756-L6(x).

2. Power Supply: Allen Bradley 1756-PA(x), 120 Vac, 60 Hz

input power, with backplane output current rating sized by the integrator for the installed chassis components.

3. I/O Rack or Chassis: Allen Bradley 1756-A(x), 10-slot minimum.

Where multiple chassis are required to accommodate the I/O summarized at the end of the section, provide appropriate size chassis and chassis interconnect cables.

4. Discrete Input Module: 16-point, 120 Volts AC, high-density

module. Allen Bradley 1756-IA16. 5. Discrete Output Module: 16-point, 120 Volts AC, to be utilized in

conjunction with interposing relays as specified in Section 13431. Allen Bradley 1756-OA16.

AARHIP 13451-6

6. Analog Input Module: 6-point, 16-bit resolution, 4-20 mA DC input module. Fully isolated inputs. Allen Bradley 1756-IF6I.

7. Analog Output Module: 6-point, 13-bit resolution, 4-20 mA DC

isolated output module. Allen Bradley 1756-OF6CI.

8. Chassis Slot Filler: Filler module to occupy spare, unused slots.

Allen Bradley 1756-N2.

C. Programming Software:

1. Provide the latest version of Windows® compatible RSLogix 5000 Enterprise Series Software, Professional Edition, part no. 9324-RLD700NXENE.

2. Programming software to be turned over to City at the completion of the

project.

D. Operator Interface Panels 1. Color Touchscreen: 10-inch diagonal, AMTFT, touch screen

panel, provided with replaceable backlight. Communication shall be via Ethernet/IP. Allen Bradley PanelView 1000 Color Touchscreen.

2. Software: The latest version of Windows® compatible

Allen Bradley PanelBuilder32 software.

E. Special Communication Modules

1. Modbus Interface Processor: ProSoft Technologies Inc. MVI56-MCM,

provided with two Modbus ports, each configurable as Modbus master or slave. Alternately, integrator may implement Modbus communication by using the serial port on the processor and executing specific ladder logic routines in the controller.

F. Ethernet to Data Highway Plus™ Gateway

1. Chassis: Allen Bradley 1756-A(x).

AARHIP 13451-7

2. Power Supply: Allen Bradley 1756-P(x), with backplane output current rating sized by the integrator for the installed chassis components.

3. Ethernet Adapter: Provide gateway which supports 10 Mbps

Ethernet communication. Provide with RJ45 jack. Allen Bradley 1756-ENBT.

4. Data Highway Plus Adapter: Provide communication interface gateway

which supports Data Highway Plus (DH+) communication at up to 57.6 Kbps. Allen Bradley 1756-DHRIO.

G. Ethernet Rail Switch

1. Provide each PLC panel with 8-port, 10/100 autosensing switch. 2. 10BaseT/100BaseTX compliant with Plug and Play (PnP) operation. 3. Panel or DIN rail mounting 4. Power: 24Vdc. Provide panel mounted DC power supply. 5. Manufacturer: Contemporary Controls CTRLink model EIS8-100T, N-Tron

508TX or equal. H. Copper network cable:

1. Provide Category 5e unshielded twisted pair (UTP) cable for all

10/100Base-TX Ethernet network segments. 2. RJ-45 connectors at both ends.

2.2 ENCLOSURES

A. Provide the PLC in the enclosures specified in Section 13431. 2.3 POWER SUPPLY

A. Provide a small UPS at each PLC panel as described in Section 13431 for power conditioning and short duration power outages. This requirement also applies to package control systems with PLCs.

2.4 TRAINING – PLC PROGRAMMING

A. This section describes the requirements for ControlLogix training. B. Provide all courses conducted by and at Rockwell Automation training centers.

AARHIP 13451-8

C. Travel Coordination

1. Coordinate off-site training, travel, and accommodation needs with affected

treatment plant staff and their supervisors before scheduling training. Provide for students’ airfare, ground transportation (car rental), meals, and lodging. Meals and miscellaneous charges per diem cost is $50.00 per student.

D. Training Courses

1. General

a. Provide training for the listed Rockwell Automation ControlLogix applications and configuration programming for three (3) students.

b. Schedule training within 30–90 days of approval of training

submittals. 2. ControlLogix Courses

a. Provide the training courses and course lengths listed below, which reflect current Rockwell Automation offerings. Courses are to be attended in the order listed.

b. Course lengths specified for training are for instruction time, not

including course preparation time, travel, etc.

COURSE COURSE LENGTH ControlLogix System Fundamentals (CCP146) 2 Days

Basic Ladder Logic Programming (CCP151) 2 Days

Project Development (CCP143) 4 Days

Funtion Block Programming (CCP152) 2 Days

ControlLogix Maintenance and Troubleshooting (CCP153) 4 Days

PART 3 EXECUTION

3.1 INSTALLATION AND APPLICATION

A. Inputs and Outputs Isolation

1. Design PLC discrete inputs to monitor dry contact closures, sourced from the PLC enclosure.

AARHIP 13451-9

2. Design PLC discrete outputs are to energize terminal block style interposing relays as specified in Section 13431.

B. Provide all communication cables necessary for complete working systems.

Provide surge protection on all communication ports as necessary. C. Interface with Other Products

1. Provide all special interface modules necessary for complete working

systems. These shall include all necessary cables and connectors as required.

2. PICS PLC will be programmed by others (OWNER’S Application Software

Programmer) to communicate with the other package control PLCs as specified.

3. PICS PLC and Modbus Interface module will be programmed by others

(OWNER’S Application Software Programmer) to communicate to the Actuator Master Control Station (AMCS) gateway (for gates and valves) via Modbus serial communication:

D. Testing

1. Test all control function as described in Division 1 and Section 13400.

3.2 INPUT/OUTPUT SIGNAL SUMMARY SCHEDULE

A. Input and output signals are shown on the drawings. The I/O is summarized by location in the following schedules.

B. There are two schedules attached.

1. The first schedule is for the existing PLC-BT in the Gravity Thickener

Building. This PLC is being retained. The schedule indicates existing signals which are being retained and signals which have been deleted and/or redefined.

2. The second schedule is for the new PLC-RS in the Solids Handling

Building. The existing PLC-RS is being abandoned after installation of the new equipment.

C. The I/O summary does not include any data obtained via Ethernet communication

links with package control PLCs specified in other Sections or data obtained via Modbus communication link with the valve actuator two-wire network. These schedules only represent the SCADA PLC hard-wired inputs and outputs specified in this Section.

AARHIP 13451-10

D. Provide minimum 10 percent installed spare I/O of each type. Round up to the nearest whole signal number.

E. Signal types are as follows:

1. DI Digital (discrete) Input 2. DO Digital (discrete) Output 3. AI Analog Input 4. AO Analog Output

END OF SECTION

AARHIP 13453-1

SECTION 13453

SCADA SYSTEMS

PART 1 GENERAL

1.1 SUMMARY

A. This section includes requirements for providing a computer based SCADA (Supervisory Control and Data Acquisition) system workstations, software and local area network (LAN) components and wiring as indicated.

B. Work includes all hardware and software elements of the SCADA system specified. Provide a complete SCADA system including software (but not programming) as part of the work.

C. Related work specified in other sections includes:

1. Section 13400 - General Instrumentation and Control 2. Section 13420 - Field Instruments 3. Section 13431 - Panel Devices and Enclosure Construction 4. Section 13451 - PLC Systems


A. Provide a personal computer (PC) based data acquisition system which uses Programmable Logic Controllers (PLCs) as the Input/Output system to monitor and control facility process operations on a real-time basis.

B. Provide Microsoft® Windows XP Professional based SCADA software with drivers capable of accessing the PLC system data registers. Design the SCADA system so that the PLCs contain the distributed database from which the SCADA server workstations obtain the plant operational information.

C. Configure the SCADA system to allow access to the SCADA server from any view node workstation on the SCADA LAN using the Ethernet network media.

D. SCADA workstations: Provide two new complete SCADA workstations, including hardware and software, at the Solids Handling Building as follows:

1. Primary SCADA server (development version) in Main Control Room

2. Client View node (development version) operator workstation in Centrifuge Control Room

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3. Two system printers:

a. One laser printer for reports at Main Control Room b. One laser printer for reports at Centrifuge Control Room

4. Provide configuration for the workstations such that the user is able to access the entire solids handling facility data from either of the two SCADA or View client workstations.

E. Furnish the SCADA software which will be configured by others to achieve system control as described in Section 13400 – General Instrumentation and Control. These shall include, but not be limited to the following:

1. Hierarchical secured access system

2. Graphical user interface for process visualization and equipment control

3. Alarm notification and recording.

4. Process variable trending

5. Access to alarm, event, and trend history

6. Links to Microsoft® Office products

F. Note: All software configuration programming will be performed by others (the OWNER’S Application Software Programmer) under the direction of the City of Ann Arbor.

G. Provide hardware and software, which are Windows® XP Professional ready.

1.3 SUBMITTALS

A. Submittals shall be as required in Division 1 and Section 13400.

1. Provide all documentation corresponding to SCADA software development and configuration.

2. Furnish all manuals and application programmer’s notes.

3. Provide hard-copy printouts of all graphics screens.

4. Provide two digital copies of the fully configured system submitted in CD-ROM format.


A. The SCADA system shall be provided by a single system integrator who also supplies the PLC systems described in Section 13400 and 13451.

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1.5 DELIVERY, STORAGE AND HANDLING

A. Deliver, store and handle all products and materials as specified in Division 1 and Section 13400.

PART 2 PRODUCTS

2.1 GENERAL

A. Provide equipment to operate on 115 volt ac, single phase, 60 hertz electrical service.

B. Provide workstation components assembled on the computer console in the Blower Building Control Room.

C. Provide all necessary items for installation, including mounting brackets, interconnecting cables, adapters, hardware and appurtenances.

2.2 SCADA SOFTWARE

A. The SCADA software shall be Windows® XP Professional compatible GE Fanuc Proficy iFIX version 4.0.

B. Provide software licenses for each workstation as listed in subsection 1.2 SYSTEM DESCRIPTION.

2.3 SCADA SYSTEM COMPUTERS

A. Provide workstations manufactured by Dell or Hewlett Packard.

B. Workstations: Provide complete SCADA system hardware, which shall be as follows:

1. Computer:

a. CPU: Intel Core-2 or better, fastest speed available at the time of purchase

b. Minimum RAM size: 2 Gigabytes SDRAM or RDRAM

c. Hard drive: 200 Gigabytes (minimum)

d. Removable media:

(1) CD-ROM - 48X max variable Read/Write CD-RW drive (2) DVD+/-RW drive

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e. Network interface: (1) Provide two 10/100Mbps Ethernet ports for the SCADA server

workstation allowing simultaneous connection to two different network segments.

(2) Provide one 10/100Mbps Ethernet port for the View client workstation.

2. Monitor:

a. Monitor type: Flat panel LCD

b. Screen size: 20” diagonal, minimum

c. Resolution: Up to 1280 x 1024 pixels at 60 Hz

d. Screen type: Thin Film Transistor (TFT) active matrix liquid crystal display (AMLCD)

3. Platform support: Windows® XP Professional.

4. Business Software Suite: Provide each computer with Microsoft® Office, Professional Edition, latest version at the time of purchase.

2.4 NETWORK HARDWARE

A. General

1. The SCADA system network shall be TCP/IP over Ethernet, operating on a combination of 10/100Base-T(X) and 10/100Base-X (fiber optic) media.

2. Provide all necessary equipment to transmit and receive data via the communication network links shown, including fiber optic cable and local area network cable and 10/100Mbps switches.

3. Provide all network equipment installed in the Fiber Connect and Network Switch Cabinet in the Solids Handling Facility Main Control Room.

B. Ethernet Switches:

1. Provide 24-port Ethernet network switches in the Fiber Connect and Network Panel located in the Control Room. Provide two switches:

a. One switch for the PLC network segment. b. One switch for the PICS network segment.

2. Provide Extreme Networks, Summit X250-24P with 24 ports of 10/100 with PoE on all ports and two fiber uplinks available.

C. Fiber Media Converters

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1. Provide industrial media converter to connect the new Ethernet switches to the existing fiber link to the existing Gravity Thickener Building PLC-BT. The existing link is 10Base-FL fiber to a SynOptics model 504A transceiver at the PLC-BT panel.

2. Provide a media converter designed to connect 10Base-FL to 10BaseT.

3. Provide ST style fiber connectors and one RJ45 copper port.

4. Provide N-Tron model 102MC-FL or equal.

D. Fiber Optic Termination Panels

1. Provide fiber optic termination/patch panels in the Fiber Connect and Network Switch Cabinet located in the Control Room.

2. Patch panels shall be configured to terminate two 60-fiber trunk cables and one 12-fiber cable. The 60-fiber cables are future and will be provided by others as part of the plant Ethernet backbone. The 12-fiber cable is to connect the Solids Facility to the Gravity Thickener PLC-BT panel.

3. Use zip cables for patch cords and jumpers. Breakout/patch boxes shall be as manufactured by Corning Cables Systems, Hubbell, Opticonx or equal.

E. Fiber-optic Cable:

1. Provide 12-fiber Heavy duty breakout cable for each link connecting the PLC enclosures. For each Ethernet link, use one pair of fibers for communications with the remaining five pairs for future use. Cable requiring breakout kits will not be acceptable.

2. Provide fiber optic cable consisting of multimode 62.5 micron/125 micron (core/clad) fiber cable with color coded elastomeric jacket encasing each optical fiber and its surrounding aramid strength member and a PVC overall outer jacket suitable for indoor or outdoor ductbank installations. Provide Optical Cable Corp. type OFNR, BX12-125D-WLS/900-ONFR, multimode, 62.5/125 µm, 250 µm cladding, 900 µm secondary buffer, 850 nm/3.5 dB/km at 200 MHz-km, and 1300 nm/1.0 dB/km at 500 MHz-km breakout cable or equal.

3. Termination - Terminate the end of each fiber optic cable segment with ST style connectors.

F. Copper network cable:

1. Provide Category 5e unshielded twisted pair (UTP) cable for all 10/100/1000Base-T network segments.

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2. RJ-45 connectors at both ends.

2.5 UNINTERRUPTIBLE POWER SUPPLY

A. Control Rooms:

1. Provide a UPS for the PICS workstations in both the Main Control Room and the Centrifuge Control Room to allow continued PICS system operation during short term power outages.

2. Provide 15 minutes runtime at full load. Full load for the purpose of this spec is power drawn by the PICS Workstations and monitors.

3. Size the UPS for the power requirements of the workstations and monitors furnished.

4. Provide Powerware (Best Power) Ferrups FE series.

B. Input power: 120 Vac, +15%, -20%, 6-foot power cord with Nema 5-15P.

C. Output power: 120 Vac +/-3%, minimum of four Nema 5-15R receptacles

D. Transfer time: 0 milliseconds

E. UL classification

F. Operating conditions: 0-40 degrees C, 0-95% RH.

G. Install the UPS beneath the control room desk console. Provide a Plugmold outlet strip installed below the desk surface with a cord connector. Plug the Plugmold into the outlet on the UPS and then plug the UPS input power cord into the nearest lighting panel supplied receptacle. Locate the Plugmold cord so that the UPS may be bypassed for service with the Plugmold plugged directly into the lighting panel receptacle.

2.6 SCADA SOFTWARE – GENERAL

A. The SCADA software shall be Windows® compatible GE Fanuc Proficy iFIX version 4.0. This software has been standardized for all plant HMI applications. Do not substitute.

B. Configure the solids facility SCADA system with a single SCADA server located in the Main Control Room. Provide a view client workstation located in the Centrifuge Control Room.

C. Include all necessary software licensing for the SCADA application software as part of the work. Provide original software on CD-ROM along with operating

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manuals and purchase receipts to document the City of Ann Arbor as the license holder.

D. Furnish the SCADA application software to provide the following functions as a minimum:

1. Data acquisition and database creation

2. Display generation and process monitoring

3. Alarm processing

4. Event logging

5. Historical data and reporting

6. Laboratory and miscellaneous data entry

7. Networking and Distributed Operation

8. Security

9. Calculations

10. Historic trending

11. Process control

12. File conversion and manipulation

E. Provide the application software completely user configurable without prior programming knowledge through graphical and fill-in-the-blanks procedure.

2.7 DATA ACQUISITION AND DATABASE CREATION:

A. Allow the user to add, delete or revise signal definitions at any time without suspending normal system operation. Provide configuration by a menu driven, fill in the blanks method. Allow the assignment of engineering units scaling factors as well as high and low alarm limits for each analog input.

B. Allow the enabling or disabling of data associated with a signal's field sensor for maintenance purposes.

C. For digital inputs, provide the capability of accumulating equipment run time for display or reporting purposes.

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2.8 DISPLAYS AND PROCESS MONITORING:

A. Include standard displays that do not require user formatting and that give the user the capability of configuring custom displays through a user friendly graphic display editor. Provide graphics generation capability with alphanumeric characters and process symbols available from a symbol library.

B. Provide the following displays as a minimum:

1. Alarm History

2. Event File

3. Sign-on, security

4. Main Menu

5. Display Menu

C. Allow development of multiple custom displays with the contents of each display being configurable by the user. Provide for displays containing tabular text or graphic data, or a combination of both.

D. Allow the operator to view the plant process in color graphic format and allow process variables and control parameters to be shown as "live data". Present data automatically updated to allow reviewing of changing process conditions.

2.9 ALARM PROCESSING:

A. Provide capability of alerting the operator of any alarm condition within the system. Alarms may be a contact closure on monitored equipment or an analog value that has gone beyond a preset limit. Provide for setting limits for any analog variable monitored through the keyboard. Provide capability of four limits for each analog signal.

B. Provide alarm notification based on disagreement logic for all equipment; i.e. generate alarm if equipment is called to run and is not running or vice versa.

C. As alarms occur, notify the operator via an audible alarm as well as a flashing of the alarmed point on the display. Display the alarm on the appropriate alarm summary screen.

D. Allow for printing of the alarm on a status/alarm printer with the date and time of occurrence. The printing feature will not be used initially, but must be available for future use. Place the alarm (with the date and time of occurrence) in an alarm history file. Make entries in the alarm history file available for inclusion in the daily report, if desired by the City.

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E. Include the time the message occurred, the name of the alarm signal, the signal value, and the type or status of the alarm in the alarm history file.

F. On the alarm display, show the alarm file in reverse chronological order with the most recent alarm shown first. Make use of color and/or blinking to distinguish between acknowledged and unacknowledged alarms.

G. Provide for silencing the audible alert at the keyboard. Allow an alarm acknowledgment to be printed on the alarm printer (and stored in the alarm log file) when the alarm is silenced.

2.10 EVENT LOGGING:

A. Record every significant event reported to, or initiated by, the SCADA Server in an event file. A significant event is defined as an event or action that directly affects the system and includes the following:

1. alarms and alarm acknowledgments and purge operations

2. equipment operating status changes

3. signal value changes made by the operator

4. operator changes in the time or date

5. operator sign-on or sign-off or changes in passwords

6. changes associated with central computer functions.

B. Maintain the journal file on the disk and provide the operator with the ability to print and/or display the journal file in chronological order. Provide page forward and backward capabilities for examination of the file on the graphic display.

C. Allow the future printing of all alarms and status change events with time and date stamp on a future alarm/status change printer as they occur.

2.11 HISTORICAL DATA ARCHIVING:

A. Provide a data historian database consisting of the historical values of the signals being monitored as well as calculated data and data which is manually entered. Store the data in date stamped files of no more than 24 hours in length. Save 10-minute values of all data.

B. Allow archive data to be stored on either the local or a remote file server hard drive. Configure the system for this project to store (archive) all historic data on the SCADA server hard drive. Allow the data files to be automatically purged after a preset number of days. Initially disable this function so that all data is

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retained. Provide for immediate trending of this information. Recall historic data from the SCADA server hard drive for trend display.

2.12 LABORATORY AND MISCELLANEOUS DATA ENTRY CAPABILITY:

A. Allow an operator to enter laboratory and miscellaneous data into the database to be included in displays and periodic reports.

B. Allow development of custom data entry screens for the manual data entry. Design the system so that the data entered automatically becomes part of the real time database available for report purposes and archiving.

C. Configure four laboratory data entry template screens as part of the work from formats furnished by the City during the Construction phase.

2.13 NETWORKING AND DISTRIBUTED OPERATION:

A. Configure the system in accordance with the system architecture description in Section 13400.

B. Provide a system having a distributed, client/server system architecture which employs a local area network (LAN) as the method for communicating among stations. Each computer may be assigned one or more tasks.

C. Data must be available to all computers and individuals on the network that have been provided access. Provide real-time data access directly across the network from the computer that acquired it from the process hardware. Configurations that require each computer to contain copies of the database tags it needs to access will not be acceptable.

D. Configure the system such that the failure of any one computer will not affect the operation of others on the network. It is recognized that data contained in a failed Server will be unavailable to other machines requesting it. However, the system shall automatically failover to the secondary Server so that re-starting or re-configuring other stations to take over is unnecessary.

E. Configuration and Expansion:

1. Provide an on-line installation and configuration program for configuring the various computers on the network. Allow assigning unique node names to each computer as well as selecting the functions that the machine will perform.

2. Allow additional computers to be added to the network while on-line, without disrupting the operations of the other machines.

F. Local Area Network (LAN) Architecture and Use:

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1. Configure the system to utilize TCP/IP over Ethernet

2. The system must also be capable of running simultaneously with other LAN users who are not operating the data acquisition system software (but who might be using a LAN manager or file transfer software).

2.14 SECURITY - INHERENT TO SCADA:

A. Provide a password security system to ensure that access to the system is limited to authorized users. Structure the system to provide user Groups, such as Operators or Supervisors.

2.15 CALCULATIONS:

A. Provide software capability to perform calculations on monitored data. Provide for user defined calculations through a menu driven display. Provide for calculated values based on acquired (monitored) values, constants, manually entered data or other calculated values. Include the functions of addition, subtraction, multiplication, division, square root, exponents, integration, and any level of parentheses.

2.16 HISTORIC TRENDING:

A. Provide for the trending of user specified individual signals or signal groups of up to four signals from current or historic data on the color monitor. When multiple signals are shown, provide separate colors for each trend line.

B. Display trends with time on the X-axis and engineering units on the Y-axis. Provide for trending of any analog variables in the data base, including computed variables.

2.17 PROCESS CONTROL:

A. Provide for operator initiated manual start-stop and open-close control of equipment and valves.

B. Provide for operator manual entry of the pump speeds and flow setpoints.

2.18 FILE CONVERSION AND MANIPULATION:

A. Allow historic data files to be saved in ASCII format or imported into Excel spreadsheets for future analysis.

2.19 PERIODIC REPORTING:

A. Provide capability for periodic report generation. This feature will not be used for this project but must be available for future use.

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PART 3 EXECUTION

SEE SECTION 13400

END OF SECTION

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SECTION 13851

SIGNALING AND ALARM

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for fire alarm and smoke detection systems including the furnishing of all labor, equipment, materials and performing all operations relating to the installation. When equipment and wiring is to be installed in hazardous locations, provide equipment and wiring meeting the requirements for NEC Class 1 Group D, Division (1) (2) hazardous locations."

B. Related Work Specified in Other Sections Includes, But is Not Limited to, the

Following:

1. Section 16050 - Basic Electrical Materials and Methods 2. Section 16130 - Electrical Raceway Systems 3. Section 16121 - Wires and Cables - 600 Volts and Below 4. Section 16075 - Electrical Identification

1.2 REFERENCES:

A. Codes and standards referred to in this Section are:

1. NFPA 70-National Electrical Code 2. NFPA 72-National Fire Alarm Code 3. NFPA 101-Life Safety Code

1.3 DEFINITIONS

A. E.M.I.: Electro magnetic radio interference

B. R.F.I.: Radio frequency interference 1.4 SYSTEM DESCRIPTION

A. Location: Provide fire alarm and smoke detection system for each of the following buildings:

1. Gravity Thickening Facility. 2. Solids Handling Building. 3. New Truck Loading Facility.

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B. System Type: Provide a zoned, addressable, noncoded, continuous sounding, electrically supervised fire alarm and smoke detection system with provisions for remote transmission of all alarm and trouble signals.

C. General Operation: Use supervised closed loop initiation circuits, individual zone

supervision, and individual audio and visual signal circuit supervision in the system. Include all control panels, annunciators, manual pull stations, smoke detectors, heat detectors, bells, strobe lights, all wiring, raceways, outlet boxes, and all other necessary material for a complete operating system.

D. Standby Mode Operation: Display a "SYSTEM IS NORMAL" message on the

front panel and the current time and date. Flash the appropriate LED (Alarm, Supervisory, or Trouble) when an abnormal condition is detected. Pulse the panel audible signal for alarm conditions and sound steadily for trouble and supervisory conditions.

E. Alarm Sequence Operation: Provide the following system alarm operation

resulting from the alarm activation of any manual station or automatic detection device:

1. Sound audible and audio/visual alarm indicating appliances until silenced by

the alarm silence switch at the control panel.

2. Send signal to building temperature control panels for fan shutdown. Only C building signal initiating devices shall initiate this signal.

3. Provide a supervised signal to notify the fire department or an approved

central station.

4. Display the alarm on an 80 character LCD display with 40 characters used to represent the point label, and 40 characters used to represent the device type identification.

5. Flash the system alarm red LED on the control panel.

6. Sound the remote annunciator and an alarm tone until acknowledged at the

control panel or the remote annunciator.

7. Flash subsequent alarms received from other zones on the control panel and remote annunciator.

8. Show the new alarm information on the LCD display.

F. Smoke Detection Operation: Initiate an alarm verification operation upon the

activation of any system smoke detector as follows:

1. Reset the activated detector and wait for a second alarm activation.

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2. If, within one (1) minute after resetting, a second alarm is reported from the

same or any other smoke detector, process the alarm as described previously.

3. If no second alarm occurs within one minute resume normal operation.

4. Design the alarm verification system to operate only on smoke detector

alarms.

5. Process other activated initiating devices immediately.

G. Acknowledgment of System Activity: Design the system to have an alarm list key that allows the operator to display all alarms, troubles, and supervisory service conditions with the time of occurrence.

H. Alarm Silencing: Design the system alarm silencing as follows:

1. Pressing the "Alarm Silence" button causes all audible alarm signals to cease

operation. All visual devices shall continue to operate until the system is reset.

2. Signals can not be silenced during alarm silence inhibit mode.

I. System Reset: Design the system reset operation as follows:

1. The "System Reset" button returns the system to its normal state after an

alarm condition has been remedied. Provide a LCD display to step the user through the reset process with simple English language messages.

2. Should an alarm condition continue to exist and the system remains in the

abnormal state, do not reset the system.

3. Display the message, "SYSTEM RESET INHIBITED" when the alarm silence inhibit function is active.

J. Circuit Supervision: Provide independently supervised initiation circuits so that a

fault in any one zone does not affect any other zone.

1. Provide independently supervised and independently fused indicating appliance circuits for alarm devices.

K. Initiating Devices: Furnish alarm initiating devices in zones that automatically

cause the following operations with activation of any device:

1. Activate audio and visual alarms continuously.

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2. Indicate the alarm location at the Control Panel and Annunciator Panel.

L. Power Supply: Power the system from the building's 120-volt a c power system. Provide the control panel, the annunciators, and all system communication devices with a minimum of 60-hours of battery standby with 10-minutes of alarm operation at the end of this period. Supervise and annunciate all normal operating, supervisory, and battery power and fault conditions.

M. Control Panel: Provide all circuits requiring 24-volt d c system operating power

with individual fusing at the control panel. Provide a minimum of five amps auxiliary fused power at the control panel.

N. Equipment Environment: All equipment shall be suitable for installation in the

environment where it is located. One of the areas that may require particular attention is the areas of the facility where atmospheric gasses and/or moisture may be present. There can affect certain circuit boards and other materials in a manner negative to their reliability or expected service life.

1.5 SUBMITTALS

A. General: Provide all submittals, including the following, as specified in Division 1 and Section 16050.

B. Product Data Information: Provide manufacturer's original catalog data and

descriptive information for all components of the equipment to be supplied. Include a complete list of current drain requirements during normal supervisory, trouble and alarm conditions and battery standby calculations showing total standby power required to meet the specified system requirements.

C. CONTRACTOR's Shop Drawings: Furnish a riser diagram, device layout locating

all devices and wiring diagram of the complete fire alarm system.

D. Operations and Maintenance Manuals: Submit, prior to field testing of the system, operation and maintenance manuals including a list of spare parts for the fire alarm and smoke detection system as specified in Division 1.

E. Testing Instructions: Submit five complete, comprehensive, step-by-step, testing

instructions giving recommended and required testing frequency of all equipment, methods for testing each individual piece of equipment, and a complete trouble-shooting manual explaining what might be wrong if a certain malfunction occurs and explaining how to test primary internal parts of each piece of equipment.

F. Quality Control: Submit six copies of the certified final checkout report as attested

to by the manufacturer's representative.

G. Record Drawings: Upon completion of the system installation and testing, submit five complete sets of reproducible Record Drawings, showing installed wiring and

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color coding and wire tag notations for exact locations of all installed equipment, specific interconnections between all equipment and internal wiring of the equipment.


A. Codes: Furnish a system conforming to the following codes and standards:

1. NFPA 70 - National Electrical Code (NEC) 2. NFPA 101 - Life Safety Code 3. State code having jurisdiction 4. Underwriters Laboratories Inc. (UL) 5. NFPA 72 - National Fire Alarm Code 6. National Electrical Manufacturer's Association (NEMA) 7. Local codes and ordinances 8. NFPA 820–Fire Protection in Waste Water Treatment&Collection Facilities.

B. UL Label: Provide UL Listed equipment.

C. Compatibility of Components: Furnish control panels, detectors and all other

components that are products of, or approved for use by, the fire alarm control panel manufacturer.

D. Manufacturers Experience:

1. Furnish equipment manufactured by a firm with a minimum of 10 years

experience manufacturing fire alarm systems.

2. Furnish products similar to those the manufacturer has used satisfactorily in installations for not less than five years.


A. General: Deliver, store and handle all products and materials as specified in Division 1 and as follows:

1. Store and handle all components in accordance with the manufacturer's

instructions.

2. Receive equipment at site; verify applicable components and quantity delivered.

3. Handle equipment to prevent internal components' damage and breakage, as

well as denting and scoring of enclosure finish.

B. Acceptance: Do not install damaged equipment.

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C. Storage and Protection: Store equipment in a clean, dry space and protect from dirt, fumes, water, construction debris and physical damage. After installation, protect equipment from damage and from environmental conditions.

1.8 SPARE PARTS

A. Provide the following spare parts:

1. Two smoke detectors of each type 2. Two heat detectors of each type 3. Two sensor bases. 4. One manual pull station 5. One audible/visible device of each type 6. One visible device of each type 7. Two complete replacements for each indicator lamp. 8. Two complete replacements for each fuse.

B. Pack spare parts in containers bearing labels clearly designating contents and

related pieces of equipment. Deliver spare parts in original factory packages. Identify all spare parts with information needed for reordering.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below. Other manufacturers of equivalent products may be submitted.

1. The fire alarm system specified is manufactured by the Simplex/Grinnell

Co. Catalog and model numbers are intended to establish the type and quality of equipment and system design as well as exact operating features required. The manufacturer's Specification sheets of each item so listed is considered to be part of the specification and binding therein.

2. Other acceptable manufacturers:

a. Siemans/Pyrotronics. b. GE Security/Edwards c. Honeywell/Notifier

2.2 COMPONENTS

A. Control Panel (FACP): Furnish a Simplex modular Fire Alarm Control Panel, series 4010 with reliable and long lived solid state, microprocessor based electronics. Display on the panel at all times controls and visual indicators essential to operation during an alarm condition. Provide a keypad for

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programming, control and maintenance behind a locked door. Design each control panel with the following features:

1. Indications: Activate audible and visual indicators during alarm, trouble or

supervisory conditions. Provide a different audible sound for each condition. Provide audible acknowledgment at the panel of all keypad entries.

2. Controls: Provide the following controls and indicators visible through a

front access panel:

a. Eighty character backlit liquid crystal display. b. Individual red system alarm LED. c. Individual amber supervisory service LED. d. Individual yellow trouble LED. e. Green "power on" LED. f. Alarm acknowledge key. g. Supervisory acknowledge key. h. Trouble acknowledge key. i. Alarm silence key. j. System reset key.

3. Additional Controls: Provide provisions for a power disconnect, manual

evacuation and elevator recall bypass.

4. Contact Outputs: Provide auxiliary Form C contact outputs for each zone and each trouble conditions for remote monitoring.

5. Listings: Provide the following listings available from the point lists menu:

a. All points list by address. b. Monitor point list. c. Signal list. d. Auxiliary control list. e. Feedback point list. f. Pseudo point list. g. LED switch status list.

6. Historic Logging: Design each control panel with the ability to store 300

events in an alarm log plus 300-events in a trouble log along with time and date of occurrence. Store these events in a battery protected random access memory.

a. The historic alarm log events consists of: System Reset, Alarm

Silence, Alarm Acknowledgment, Alarm Conditions, and Alarm Historic Log Cleared.

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b. The historic trouble log events consists of: Trouble Conditions, Trouble Acknowledgment, Supervisory Acknowledgment, Alarm Verification Tallies, Walk Test Results, and Trouble Historic Log Cleared.

7. Walk Test with Historic Logging: Design the system with the capability of

being tested by one person.

a. While in the testing mode, silently log the alarm activation of an initiating device circuit as an alarm condition in the historical data file. Provide an automatic reset feature on the panel after logging of the alarm.

b. Silently log the momentary disconnection of an initiating or

indicating device circuit as a trouble condition in the historical data file. Provide an automatic reset feature on the panel after logging of the trouble condition.

c. During an alarm condition occurring when in the walk test mode,

perform all specified standard programmed alarm sequences.

8. Sensitivity Testing Reports: Provide extensive and automatic diagnostics for system devices to reduce maintenance and comply with NFPA 72 sensor tests.

9. Software: The fire alarm system shall allow for loading and editing

instructions and operating sequences as necessary. The system shall be capable of 100% on-site programming to accommodate system expansion and facilitate changes in operation. All programming shall be capable of being accomplished via the front panel and via a lap top computer. All software operations shall be stored in a non-volatile programmable memory within the FACP. Loss of primary and secondary power shall not erase the instructions stored in memory.

10. Standby Power: Furnish sealed rechargeable lead calcium batteries capablof

providing 60-hours of complete fire alarm operation upon loss of primary power.

a. Provide an automatic, current limiting, combination high rate/float

maintenance rate battery charger capable of returning fully discharged batteries to 70-percent of charge within 12-hours. Provide a battery voltmeter and charging current ammeter module.

11. Equipment Enclosures: Furnish each Control Panel in a locked cabinet of

sufficient size to accommodate the specified equipment. Furnish the panel with transparent door panels for full view of visual indicators and controls.

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12. Wiring/Signal Transmission:

a. Transmission shall be addressable signal transmission, dedicated to fire alarm service only.

b. System connections for initiating (signaling) circuits and notification

appliance circuits shall be Class B.

c. Circuit Supervision: Circuit faults shall be indicated by a trouble signal at the FACP. Provide a distinctive indicating audible tone and alphanumeric annunciation.

13. Provide adequate number of modules as required to supply all the

Notification device circuits needed to carry out the design.

14. Provide a duel RS-232 mode for a laptop PC connection and provision for off site troubleshooting.

2.3 ACCESSORIES

A. Annunciator: Provide Simplex Type 4606 l LCD annunciators to indicte alarm, trouble or status of any system operation or condition. Design each annunciator with the following features:

1. Enclosure: Mount each annunciator in a NEMA 12 enclosure.

2. Communications: Design each annunciator to communicate with a control

panel over one twisted shielded pair of wires.

3. Power Supply: Provide 24-volt d c operating power for each panel, fused at the panel.

4. Provide each annunciator with a common alarm and trouble circuit

consisting of:

a. Control push button switches for alarm silence, trouble silence, system reset and manual evacuation duplicating the control panel switches.

b. Key "enable" switch to activate or deactivate the control switches.

c. System trouble LED.

d. Power on LED.

AARHIP 13851-10

B. Initiating Devices: Provide the following addressable signal initiating devices:

1. Pull Stations: Provide Simplex single action manual pull stations with raised white lettering and a smooth high gloss finish. Key the stations alike with the fire alarm control panel. When a station is operated, lock the handle in a protruding manner to facilitate quick visual identification of the activated station.

2. Heat Detectors:

a. Simplex Type 4098 heat detectors, rated at 135 – 155 degrees F fixed

temperature and rate-of-rise. Provide True Alarm sensor base.

b. Thermotech Type 302 moisture and corrosion resistant. Provide IAM addressable module.

c. High temperature 190 degrees F fixed temperature detector. Provide

IAM addressable base.

d. Explosion-Proof Heat Detectors: Simplex Type 2098-9431 rated at 135 degrees F rate-of-rise and fixed temperature, moisture proof and explosion-proof heat detectors. Provide IAM addressable base.

3. Smoke Detectors.

a. Provide Simplex Type 4098, True Alarm photoelectric smoke

detectors. Provide detectors having a completely closed back to restrict entry of dust and air turbulence and 30-mesh insect screen. Shield the electronics of the unit to protect against false alarms from electro-magnetic interference and radio-frequency. Furnish units with a red LED that pulses to indicate power on and glows continuously to indicate alarm. Provide detectors having a magnetically operated functional test switch and capable of being supplied with a remote alarm LED indicator. Provide units having a True Alarm sensor mounting base with terminal strip.

b. Provide Simplex Type 4098 True Alarm ionization type smoke

detectors with adjustible sensitivity settings. Incorporate automatic compensation for lens contamination. Provide detectors with a normal status indicator, alarm indicator and a trouble indicator. Provide a True Alarm sensor base.

c. Provide Simplex Type 4098 True Alarm photoelectric air duct smoke

detector with appropriate sampling tubes and test ports. Provide LED indication of condition. Mount in duct or where no duct is present, over air exhaust (on open exhaust fan intakes).

AARHIP 13851-11

C. Audible/Visible Devices:

1. Provide Simplex Type 4903 non-addressable wall mounted audible/visible devices. Provide units to operate audio and visual separately using the SmartSync system. Design the unit's enclosure to contain a high intensity Xenon strobe flashing light with a horizontal white translucent lens imprinted with the word "FIRE" in red and a horn. Strobes shall provide synchronized flash outputs. Horn shall provide an audible output of 84dba at 10 feet per UL 464. Provide candle power flash intensity as shown on drawings and a flash rate of one to three flashes per second. Operate both audible and visible units independently on the same supervised circuit.

2. Provide Cooper Wheelock wall mounted Strobes for independent “strobe

only” locations (primarily small rooms) and strobes with horns (in weatherproof locations). Provide synchronized operation as for Simplex units. Provide candlepower flash intensity as indicated on drawings.

D. Printer: Provide 24 pin “Dot Matrix” printer to record FACP events and print

reports. Printer shall support system maintenance. Locate adjacent to the FACP.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all fire alarm and smoke detection system in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Supervision: A UL Inc. certified service technician from the manufacturer of the

fire alarm equipment shall supervise the following:

1. Preinstallation visit to the job site to review equipment submittals and verify the system wiring method.

2. Periodic visits to the job site to verify installation and wiring of the system.

3. Verify final connections, program the FACP, final checkout and certification

of the system.

4. Date and document all job site visits in writing and submit reports. Note any discrepancies on this Document.

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C. Power: Provide 120-volt, 1-phase, 3-wire 60-hertz primary power to each Fire Alarm Control Panel.

D. Conduits: Install the entire wiring system in conduit. Size raceways, boxes,

fittings and the like, to accommodate the manufacturer's equipment as specified in Section 16130.

E. Color Code: Color code all system wiring in accordance with local codes and as

recommended by the manufacturer. Provide wiring meeting the requirements of NFPA 70 article 760 and as specified in Section 16121.

F. Pull Station Installation Height: Install manual pull stations 48 inches above the

finished floor.

G. Audible/Visible Device Installation Height: Install audible/visible devices 80-inches above the finished floor or 6 inches below ceiling whichever is lower.

H. Adjustments: If detectors are found to interfere with other equipment or locations

interfere with proper operation of the detectors, adjust their locations as required.

I. Provide zone maps under frame at the FACP and FAAP locations to aid in locating the alarmed devices.


A. Tests: Perform testing of the system in accordance with the procedures outlined in NFPA Standard 72A and as follows:

1. Operate every fire alarm device to demonstrate proper operation and correct

annunciation at the Fire Alarm Control Panel and Remote Annunciator.

2. Perform one half of all tests on battery standby power. Where applying heat would destroy any detector, devices may be manually operated. Open at least two locations per zone in each initiating circuit and each signaling circuit to check for the presence of correct supervisory circuitry.

B. Confirmation: After satisfactory completion of all testing, provide certification

attesting to the satisfactory completion of the fire alarm equipment installation. 3.3 OPERATION DEMONSTRATION

A. Perform an operational demonstration of the system.

B. Give a minimum of 8 hours of operational instructions and training to the OWNER and/or his representative on the system.

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3.4 CLEANING AND PAINTING

A. Shop Painting: Shop paint meeting the requirements of Section 09900.

B. Field Painting: Clean and touch up scratched or marred surfaces to match the original finish.

END OF SECTION

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AARHIP 14212-1

SECTION 14212

ELECTRIC TRACTION ELEVATOR

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Electric traction passenger elevator as shown on drawings and specified herein. Work includes but is not limited to commercial, geared/gearless electric traction passenger elevator, elevator car enclosure, hoistway entrances and signal equipment, operation and control systems, accessibility provisions for physically disabled persons, equipment, machines, controls, systems and devices as required for safely operating the elevator at the specified rated speed and capacity and all materials and accessories required for a complete installation of the elevator.

B. Related Work Specified In Other Sections Includes, But is Not Limited to, the

Following:

1. Section 02316 – Excavation 2. Section 03310 - Cast-In-Place Concrete

3. Section 05500 - Metal Fabrications

4. Section 15406 - Plumbing Specialties

5. Section 16050 - Basic Electrical Materials and Methods

6. Section 16411 - Disconnect Switches

1.2 REFERENCES

A. General: Codes and standards referred to in this section are:

1. ASTM A 366/A366M - Specification for Steel, Carbon, Cold-Rolled Sheet, Commercial Quality

2. ASTM F 1066 - Specification for Vinyl Composition Floor Tile

3. AISI - Stainless Steel Type and Finish

4. NEMA 12 - Industrial Enclosure

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5. NEMA LD3 - Industrial Laminate

6. ASTM F1066 - Specification for Vinyl Composition Floor Tile

7. NFPA 80 - Standard for Fire Doors and Windows

8. ASME A17.1 - Safety Code for Elevators and Escalators

9. CABO A117.1 - Buildings and Facilities - Providing accessibility and usability for physically handicapped people

10. ADA - Americans with Disabilities Act-Accessibility

Guidelines for Buildings and Facilities

11. AWS D1.1 - Structural Welding Code for Steel. 1.3 SYSTEM DESCRIPTION

A. General: Provide the elevator system meeting the following operating conditions:

1. Control: Passenger, Traction geared

2. Capacity: 10,000 pounds, Class C2.

3. Minimum Speed: 100 fpm-up under full capacity.

4. Operation: TAC50

5. Clear Car Size: 8’-0” wide by 10’-0” front to back.

6. Cab Height: 9’-0” nominal

7. Travel Distance: 52’-0” feet.

8. Hoistway Entrance Size: 6’-0” wide X 8’-0” high 9. Door Type: Two Speed side strike 10. Seismic Requirements: Zone 1

9. Electric Supply: 460-volt, 3-phase, 60-hertz.

10. Control Circuit: 120-volt, single-phase, 60-hertz,

derived from 208/120-volt power source.

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11. Emergency

Electric Source: 120-volt battery pack for emergency operation of the car lights and alarm bell.

12. Machinery

Room Location: Top Floor at Floor Elev. 810’-0”

13. Stops: 5

14. Openings: a. Front: 3 b. Rear: 4

15. Signals: In-use lights

Emergency alarm bell Call bell

16. Special Features: Furnish NEMA 4 electrical equipment enclosures in the

hoistway and NEMA 12 in the Elevator Machine Room. 1.4 SUBMITTALS

A. General: Provide all submittals following as specified in Division 1.

B. Exposed Finishes: Provide samples of exposed finishes of car enclosures, hoistway entrances, and signal equipment. Provide 6-inch- to 8-inch-square samples of sheet materials and 10-inch to 12-inch lengths of running trim members.

C. Operations and Maintenance Manuals: Provide bound manuals for the elevator,

with operating and maintenance instructions, parts listing, recommended parts inventory listing, purchase source listing for major and critical components, emergency instructions, and similar information.

D. Certificates and Permits: Provide copies of all inspection/acceptance certificates

and operating permits as required by governing authorities to allow normal, unrestricted use of elevators.

E. Shop Drawings: Show equipment arrangement in the machine room, pit and

hoistway. Provide plans, elevations, sections and details of assembly, erection, anchorage, and equipment location. Indicate elevator system capacities, sizes, performance, safety features, finishes and other pertinent information. Show floors served, travel distances, maximum loads imposed on the building structure at points of support and all similar considerations of the elevator work. Indicate electrical power requirements and branch circuit protection device recommendations.

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F. Furnish operation and maintenance instructions and parts list, with recommended parts inventory.


A. Installer Qualifications: Engage the elevator manufacturer or an installer approved by the elevator manufacturer and who has completed elevator installations similar in material, design, and extent to that indicated for this Project which have resulted in installations with a record of successful in-service performance.

B. Regulatory Requirements: The following codes and standards apply to the

fabrication and installation of the elevator system:

1. Elevator Code: Comply with requirements as indicated or imposed by governing regulations. Comply with applicable requirements of ASME A17.1, (hereinafter referred to as the "Code").

2. NFPA Code: Comply with applicable NFPA codes, and specifically with

sections relating to electrical work and elevators.

3. Fire Resistance of Entrances: Comply with NFPA No. 80, and provide units bearing UL labels with 30-min. temperature rise on labels.

4. Standards for the Disabled: Comply with CABO A117.1 requirements for

the handicapped and ADA guidelines including clearances, raised and braille designations locations for signal equipment and similar provisions, except as otherwise indicated.

5. Applicable state and local codes.

6. Limit piping and conduit passing through the machinery room to that

required for operation of the elevator.

7. Fire rated entrance assemblies: Opening protective assemblies including frames, hardware and operation shall comply with ASTM E2074, CAN4-S104 (ULC-S104), UL10(b), and NFPA Standard 80. Provide entrance assembly units bearing Class B or 1 ½-hour label by a Nationally Recognized Testing Laboratory.

C. Inspection and Testing: Elevator installer shall obtain and pay for all

required inspections, tests, permits and fees for elevator installation arrange for inspections and make required tests. Deliver to Owner upon completion and acceptance of elevator work.

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1.6 MAINTENANCE SERVICE

A. Initial Maintenance Service: Provide full maintenance service by skilled, competent employees of the elevator installer for a period of 12 months following acceptance of the completed installation. Include monthly preventive maintenance performed during normal working hours. Include repair or replacement of worn or defective parts or components and lubricating, cleaning, and adjusting as required for proper elevator operation in conformance with specified requirements. Include 24-hours-per-day, 7-days-per-week emergency callback service. Exclude only repair or replacement due to misuse, abuse, accidents, or neglect caused by persons other than installer's personnel.

B. Continuing Maintenance Service: Provide a continuing maintenance proposal in

the form of a standard yearly maintenance agreement starting on date construction contract maintenance requirements are concluded. State services, obligations, conditions and terms for agreement period and for future renewal options.

PART 2 PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A. General: List includes acceptable manufacturers. Other manufacturers of equivalent products may be submitted for approval.

1. Elevator System

a. ThyssenKrupp Elevator, Memphis, TN

2.2 MATERIALS

A. General: Provide the manufacturer's standard pre-engineered elevator systems that will comply with or fulfill the requirements or, at manufacturer's option, provide custom-manufactured elevator systems that will fulfill requirements. Provide standard components as published by the manufacturer as included in standard pre-engineered elevator systems and as required for a complete system where components are not otherwise indicated.

B. Colors, patterns, and finishes: As selected by the Architect from manufacturers

full range of standard colors, patterns, and finishes.

C. Steel:

1. Shapes and bars: Carbon. 2. Sheet: Cold-rolled steel sheet, commercial quality, Class 1, matte finish.

AARHIP 14212-6

3. Finish: Factory-applied baked enamel.

D. Stainless Steel:

1. Shapes and bars: No. 4 brushed on No. 8 polished stainless. 2. Tubing: No. 4 brushed or No. 8 polished stainless.

E. Bronze:

1. Drawn pipe: Red Brass. 2. Sheet: Muntz metal

3. Extrusions: Architectural bronze.

F. Aluminum:

1. Sheet and Plate: Commercial quality. 2. Extrusions: Commercial quality.

G. Cast Iron: Extrusions with mill finish. H. Plastic laminate: Decorative high-pressure type, complying with NEMA LD3,

Type GP-50 General Purpose Grade, nominal 0,050” thickness.

I. Glass: Clear laminated safety glass, complying with ANSI Z97.1, nominal 9/16-inch thickness.

2.3 HOISTWAY EQUIPMENT

A. Platform: Fabricated frame of formed or structural steel shapes, gusseted and rigidly welded with non-skid steel flooring. Underside of the platform shall be fireproofed.

B. Sling: Steel stiles bolted to a steel crosshead and bolstered with bracing members

to remove strain from the car enclosure.

C. Guide Rails: Dry, non-lubricated steel, fastened to the building with steel brackets.

D. Guides: Roller guides, with a minimum of three tires, shall be mounted on top and bottom of the car and counterweight frame and be held in contact with the guide rail by adjustable devices.

AARHIP 14212-7

E. Buffers: Provide substantial buffers in the elevator pit. Mount buffers on continuous channels fastened to the elevator guide rail or securely anchored to the pit floor. Provide extensions if required by project conditions.

F. Machine: The hoisting machine shall be a geared traction type, consisting of AC

motor, brake and driving sheave mounted on a rigid bedplate. A large diameter, forged shaft shall serve as a support for the motor armature and for the removable drive sheave and brake drum/disc. It shall be supported by roller bearings.

1. Steel deflector sheaves of adequate diameter and strength shall be provided as

necessary.

G. Drive System:

1. The drive system shall be of the nonregenerative Variable Voltage Variable Frequency (VVVF) type.

2. The system shall be a vector controlled pulse-width modulated AC drive. The

variable voltage variable frequency drive shall convert the AC power supply using a two step process to a variable voltage variable frequency power supply for use by the hoist motor.

3. The speed control shall be by means of vector control providing independent

excitation and torque current. A digital absolute velocity encoder shall be provided giving feedback to the controller on armature position and motor speed.

H. Motor/Machine: The motor shall be AC with class “F” insulation. The motor

armature shall be dynamically balanced and supported by roller bearings of ample capacity. The armature and driving sheave shall be properly balanced for smooth, high-speed elevator performance. The machine shall be mounted in a machine room above the elevator shaft. Elevator contractor shall supply anchors as required to support the up-pull of the machine. In addition, elevator contractor shall provide deflector sheaves (as required), overhead sheaves, and sheave mounting beams. General contractor shall supply supports for the anchors andn mounting beams.

I. Brake: The brake shall be a spring applied electric brake; held open by an electro-

magnet actuated by a digital brake controller and designed to work as an integral part of the motor controller to provide smooth positive stops. The brake shall be designed to automatically apply in the event of interruption of power supply from any cause. Operation and control of the brake shall be all digital. The setting and lifting of the brake shall be software based and all electronic. All adjustments and setup of the brake shall be made using a PC interface. No contactors or resistors shall be used in the actuation of the brake.

AARHIP 14212-8

J. Ropes: Steel hoist ropes of size and number to ensure proper wear qualities shall be used. Wedge shackles design for use with steel ropes shall be used. Furnish adequate compensation for weight of hoist ropes when required to maintain proper counterbalance ratio. Governor rope shall be 3/8-inch iron.

K. Counterweight: Counterbalance each elevator for smooth and economical

operation by using iron or steel plate weights securely fastened in steel counterweight frame. Counterweight shall equal the weight of the complete elevator car and approximately 40-45 percent of the specified capacity load.

L. Safety and Governor: Car Safety shall be mounted on the bottom members of the

car frame and be operated by a centrifugal speed governor. The governor shall be designed to cut off power to the motor and apply the brake whenever the governor indicates the car has excessive speed. The governor shall function when the car over speeds in either the up or down direction. The governor will be mounted above the car.

M. Emergency Terminal Limits: Place electric limit switches in the hoistway near the

terminal landings. Limit switches shall be designed to cut off the electric current and stop the car if it runs beyond either terminal landing.

N. Automatic Self-Leveling: Provide each elevator car with a self-leveling feature to

automatically bring the car to the floor landings and correct for over travel or under travel. Self-leveling shall, within its zone, be automatic and independent of the operating device. The car shall be maintained approximately level with the landing irrespective of its load.

2.4 HOISTWAY ENTRANCES

A. Doors and Frames: 1. Provide complete hollow metal type hoistway entrances at each hoistway

opening. 2. Select from manufacturer’s standard entrance design consisting of 14 gauge

frames with 2-inch profile, 18 gauge doors, hangers hanger supports, hanger covers, fascia plates, sight guards, and necessary hardware.

3. Provide information for wall interface with hoistway entrance assembly.

4. Doors shall be o the flush construction type:

a. All landing: Stainless steel, no. 4 brushed finish.

5. Frames shall be of the formed construction type: a. All landing: Stainless steel, no. 4 brushed finish.

AARHIP 14212-9

B. Interlocks: Equip each hoistway entrance with an approved type interlock, tested as required by code. Interlock shall be designed to prevent operation of the car away from the landing until the doors are locked in the closed position as defined by code and shall prevent opening the doors at any landing from the corridor side unless the car is at rest at that landing or is in the leveling zone and stopping at that landing.

C. Door Hanger and Tracks: Provide sheave type two point suspension hangers and

tracks for each hoistway sliding door. 1. Sheaves: Polyurethane tires with ball bearings properly sealed to retain grease. 2. Hangers: Provide an adjustable up-thrust device on each door hanger roller. 3. Tracks: Provide integral or drawn steel shapes, smooth surface and shaped to

conform to the hanger rollers. D. Hoistway Sills: Cast Iron, with grooves in top surface. 2.5 PASSENGER ELEVATOR CAR ENCLOSURE A. Car Enclosure: 1. Walls: Cab type TKS, reinforced 16 gauge cold-rolled steel. Walls shall be

constructed of 5WL rigidized stainless steel. 2. Canopy: Reinforced 14 gauge cold-rolled steel with hinged exit. Finish: baked

enamel on steel.

a. Ceiling: fluorescent lights flush with canopy.

3. Cab Columns, Front, and Transom: Provide panels faced with brushed stainless steel.

4. Doors: Horizontal sliding car doors reinforced with steel for panel rigidity.

Hang doors on sheave with polyurethane tires that roll on a polished steel track and are guided at the bottom by non-metallic sliding guides.

a. Door Finish: Stainless steel panels: No. 4 brushed finish. b. Cab Sills: cast iron, mill finish. 5. Handrail: Provide 2'' flat metal bar on side and rear walls on front opening cars

and side walls only on front and rear opening cars. Handrails shall have a stainless steel, no. 4 brushed finish. Provide one 12” oak plank bumper rail on each side wall @12” a.f.f.

AARHIP 14212-10

6. Ventilation: Provide two speed exhaust fan mounted on the car top. 7. Pad Buttons: not required 8. Finished Floor: Finished flooring is non-skid steel. B. Car Top Inspection: Provide a car top inspection station with an "Emergency Stop"

and Inspection/Automatic switch and constant pressure “safe”, "up” and “down" direction buttons. The Inspection switch shall make the normal operating devices inoperative when in the Inspection position and give the operator complete control of the elevator. Mount the car top inspection station in the door operator assembly.

2.6 DOOR OPERATION A. Door Operation: Provide a direct or alternating current motor driven heavy duty

operator designed to operate the car and hoistway doors simultaneously. The door control system shall be digital closed loop and the closed loop circuit shall give constant feedback on the position and velocity of the elevator door. The motor torque shall be constantly adjusted to maintain the correct door speed based on its position and load. All adjustments and setup shall be through the computer based service tool. Door movements shall follow a field programmable speed pattern with smooth acceleration and deceleration at the ends of travel. The mechanical door operating mechanism shall be arranged for manual operation in event of power failure. Doors shall automatically open when the car arrives at the landing and automatically close after an adjustable time interval or when the car is dispatched to another landing. AC controlled units with oil checks, or other deviations are not acceptable.

1. No Un-Necessary Door Operation: The car door shall open only if the car is

stopping for a car or hall call, answering a car or hall call at the present position or selected as a dispatch car.

2. Door Open Time Saver: If a car is stopping in response to a car call assignment

only (no coincident hall call), the current door hold open time is changed to a shorter field programmable time when the electronic door protection device is activated.

3. Double Door Operation: When a car stops at a landing with concurrent up and

down hall calls, no car calls, and no other hall call assignments, the car door opens to answer the hall call in the direction of the car's current travel. If an onward car call is not registered before the door closes to within 6 inches of fully closed, the travel will reverse and the door will reopen to answer the other call.

4. Nudging Operation: The doors shall remain open as long as the electronic

detector senses the presence of a passenger or object in the door opening. If door closing is prevented for a field programmable time, a buzzer will sound. When the obstruction is removed, the door will begin to close at reduced speed. If the infra-red door protection system detects a person or object while closing on

AARHIP 14212-11

nudging, the doors will stop and resume closing only after the obstruction has been removed.

5. Limited Door Reversal: If the doors are closing and the infra-red beam(s) is

interrupted, the doors will reverse and reopen partially. After the obstruction is cleared, the doors will begin to close.

6. Door Open Watchdog: If the doors are opening, but do not fully open after a

field adjustable time, the doors will recycle closed then attempt to open six times to try and correct the fault.

7. Door Close Watchdog: If the doors are closing, but do not fully close after a

field adjustable time, the doors will recycle open then attempt to close six times to try and correct the fault.

8. Door Close Assist: When the doors have failed to fully close and are in the recycle mode, the door drive motor shall have increased torque applied to possibly overcome mechanical resistance or differential air pressure and allow the door to close.

B. Door Protection Device: Provide a door protection system using 150 or more

microprocessor controlled infra-red light beams. The beams shall project across the car opening detecting the presence of a passenger or object. If door movement is obstructed, the doors shall immediately reopen. A mechanical reopening device shall not be acceptable.

2.7 CAR OPERATING STATION A. Car Operating Station, General: The main car control in each car shall contain the

devices required for specific operation mounted in an integral swing return panel requiring no applied faceplate. Swing return shall have a brushed stainless steel finish. The panel shall consist of the following pushbuttons, key switches and indicators:

1. The bottom of the Car Operating Station shall contain the "door open," "door

close," "alarm" buttons and a keyed "emergency stop" switch.

2. The Intermediate area of the station shall contain floor buttons which illuminate when a call is registered and remain illuminated until the call is answered. Raised floor indications and handicap symbols shall be located to the left and immediately adjacent to the floor buttons. No applied symbols or floor indications or symbols on the buttons shall be permitted.

3. The next level shall contain supplied options switches. 4. The top of the Car Operating Station shall contain fire service features, including

operating instructions, in accordance with ASME A17.1 and any local code.

AARHIP 14212-12

B. Position Indicator: A position indicator shall be contained above floor push buttons. As the car travels, its position in the hoistway shall be indicated by the illumination of the alpha/numeric character corresponding to the landing which the elevator is stopped at or passing.

C. Column Mounted Car Riding Lantern: Not required for this application. E. Emergency Light: An emergency light and capacity plate shall be provided. The

Emergency Light shall illuminate automatically upon loss of the building's normal power supply. The light shall meet the illumination requirements of the A-17.1 and/or local code requirements.

F. Communications: Provide an emergency communications device mounted integrally

within the swing return. Emergency communications device shall comply with Americans with Disabilities Act (ADAAG) requirements.

G. Auxiliary Operating Panel: Provide an auxiliary operating panel in each car. The

panel shall match the main car operating panel and include illuminated pushbuttons for the landings served, 'door open', 'door close', and an 'alarm' button, a dot matrix position indicator and an emergency light.

H. Include the following special controls: 1. Independent service switch. 2. Inspection switch. 3. Two speed fan/light switch. 4. Certificate frame. 2.8 CONTROL SYSTEMS A. Controller: The elevator control system shall be microprocessor based and software

oriented. The system shall operate in real time, continuously analyzing the car(s) changing position, condition, and work load. All controller and operational circuits including the brake control and drive system shall be digital. Control of the elevator shall be automatic in operation by means of push buttons in the car operating panel numbered to correspond to floors served, for registering car stops, and by "up-down" push buttons at each intermediate landing and "call" push buttons at terminal landings:

1. Momentary pressing of one or more buttons shall dispatch the car to the

designated landings in the order in which the landings are reached by the car, irrespective of the sequence in which the buttons are pressed. Each landing call shall be canceled when answered.

AARHIP 14212-13

2. When the car is traveling in the up direction, it shall stop at all floors for which car buttons or "up" hall buttons have been pressed. The car shall not stop at floors where "down" buttons have been pressed, unless the stop for that floor has been registered by a car button or unless the down call is at the highest floor for which any buttons have been pressed. Pressing the "up" button when the car is traveling in the down direction shall not intercept the travel unless the stop for that floor has been registered by a car button or unless the up call is the lowest for which any button has been pressed.

3. When the car has responded to its highest or lowest stop, and stops are registered

for the opposite direction, its direction of travel shall reverse automatically and it shall then answer the calls registered for that direction. If both up and down calls are registered at an intermediate floor, only the call corresponding to the direction of car travel shall be canceled upon the stopping of the car at the landing.

4. A car that is stopping for the last hall call in the preference direction and that hall

call is for the opposite direction with no onward car calls, shall reverse preference when the selector position advances to the landing at which the car is committed to stop. A car that is stopping for the last hall call in the preference direction, and that hall call is for the same direction, shall hold its preference until the door is almost closed allowing time for a passenger to register an onward car call which will maintain the preference. If no car call is registered before the door is almost closed, the car will lose its preference and shall be available to accept calls in either direction.

B. Operation: Selective Collective - ETA based. The system is optimized to get a car to

the floor where a hall call has been registered, in the shortest time. The system receives input information from standard call pushbuttons located in the hall, car position and car load information from individual car loadweighers.

Where group operation is required, the group supervisory operation shall be

embedded within selected car controllers. No separate group controller shall be supplied. The microprocessor shall constantly scan the system for hall calls. When hall calls are registered, the control system shall immediately calculate the estimated time of arrival using such information as, number of floors to travel from the current position, the time it takes to travel one floor at top speed, calls assigned to a car, and car reversal time to respond to a call in the opposite direction of travel. When a car's status changes or additional hall calls are registered, the estimated time of arrival shall be recalculated and calls reassigned if necessary.

1. Traffic Pattern: The microprocessor shall provide flexibility to meet well

defined patterns of traffic, including up peak, down peak, and heavy interfloor demands, and adjust for indeterminate variations in these patterns which occur in buildings.

AARHIP 14212-14

2. Fuzzy logic: Fuzzy logic shall be an integral part of the group control system software. The enhanced fuzzy logic will optimize the interfloor traffic performance. Inputs for the fuzzy logic shall include accurate passenger load from an electronic loadweigher, probable car calls generated from each hall call, type of building and observed traffic patterns.

C. Load Weighing Device: Provide a load weighing device on each car which, when the

particular car is filled to an adjustable percentage of the capacity load, shall cause the car to bypass landing calls but not car calls. The passed landing calls shall remain registered for the next following car.

1. The device shall be unaffected by the action of compensating chain or rope. The

device shall detect a 15 pound (7 Kg.) load change under all conditions. 2. The load sensor shall use a linear variable differential transformer to accurately

measure the weight in the car. The information shall be transferred via a serial link to the elevator controller.

D. Anti-Nuisance Call Control: The microprocessor control system shall evaluate the

number of people on the car and compare that value to the number of car calls registered. If the number of car calls exceeds the number of people by a field programmable value, the car calls shall be canceled after the first call has been answered.

E. Position Selector: The position selector shall be part of the microprocessor system.

The car position in the hoistway shall be digitized through a primary position encoder. The microprocessor control system shall store the floor position and slow down points in memory.

F. Motion Control: The drive control system shall be dual-loop feedback system based

primarily on car position. The velocity profile shall be calculated by the microprocessor control system producing extremely smooth and accurate stops. The velocity encoder shall permit continuous comparison of machine speed to velocity profile and to actual car speed. This accurate position/velocity feedback shall permit a fast and accurate control of acceleration and retardation.

G. Motor Pre-Torque: Current shall be applied to the elevator drive before the brake is

released and the speed pattern is dictated to eliminate roll back and sling shot effects of unbalanced loads in the car. The electronic loadweigher shall determine the load on the car which will be used in determining a pre-torque reference to send to the drive.

H. Elevator Monitoring Systems: Not required

I. Emergency Power Operation: (Group 10-D4A) Upon loss of normal power,

building-supplied standby power is available to the elevator on the same wires as the normal power. Once the loss of normal power has been detected and standby

AARHIP 14212-15

power is available, one elevator at a time from each group will be lowered to a pre-designated landing and will open the doors. After passengers have exited the elevator, the doors are closed and the car shuts down. The next available car in the group will then be selected to lower, allow passengers to exit, close the doors and shutdown. This process is repeated until all cars in the group have been lowered and parked. At this time, an elevator is automatically allowed to continue service using the building-supplied standby power. A manual selection switch is available to override the automatic selection and allow and car in the group to provide service to the building. When normal power is restored, the elevators automatically resume operation.

J. Limited Access Features: None required.

2.9 HALL STATIONS A. Hall Stations, General: Buttons shall illuminate to indicate call has been registered

at that floor for the indicated direction. Provide one set of pushbutton risers with faceplates having a brushed stainless steel finish.

1. Each terminal station shall contain one illuminating push button.

2. Each intermediate station shall consist of two illuminating pushbuttons, one for the up direction and one for the down position. 3. Phase 1 firefighter’s service key switch, with instructions, shall be incorporated into the hall station at the designated level.

B. Floor Identification Pads: Provide door jamb pads at each floor. Jamb pads shall

comply with Americans with Disabilities Act (ADA) requirements and, when required by local code: Section 407 in ICC A117.1.

C. Hall Position Indicator: An electronic dot matrix position indicator shall be

provided and mounted for optimum viewing. As the car travels, its position in the hoistway shall be indicated by the illumination of the alphanumeric character corresponding to the landing which the elevator is stopped or passing. When hall lanterns are provided, the position indicator shall be combined with the hall lanterns in the same faceplate. Faceplates shall match hall stations. Provide at main landing only.

D. Hall lanterns: A hall lantern with adjustable chime shall be provided at each landing

and located adjacent to the entrance. The lanterns, when illuminated, shall indicate the elevator car that shall stop at the landing and in what direction the car is set to travel. When the car reaches a predetermined distance from the floor where it is going to stop, the corresponding hall lantern shall illuminate and the chime shall sound. The hall lantern shall remain illuminated until the car doors close in preparation for leaving the floor. Illumination of the arrow shall be with LED’s. Faceplates shall match the hall station finish. Provide at all landings.

AARHIP 14212-16

E. Car Control Stations: Provide a car control station with flush mounted metal

faceplates containing call buttons for each landing served and other buttons, switches, and controls required for specified car operation and control. Mount the station at a height complying with ASME A117.1 and ADA. Mount the control panel in the return panel adjacent to the car door. Provide operating device symbols as required by the Code, [ASME A117.1 and ADA]. Mark other buttons and switches with the manufacturer’s standard identification for required use or function.

F. Telephone: Provide a telephone hand set in [each] the car, contained in a flush-

mounted cabinet and complete with identification and instructions for use. Connect the telephone to a central telephone exchange system. Provide a fireman's telephone cabinet or fireman's telephone jack in the main elevator lobby.

G. Alarm System: Provide an emergency alarm bell properly located within the

building and audible outside hoistways, equipped to sound automatically in response to emergency stops and in response to the "Alarm" button on each car control station.

2.10 FIREMAN'S EMERGENCY RETURN FEATURE

A. General: Provide a key box and key switch as required by local authorities and as required by ASME A17.1 Code, including Phase 1 and Phase 2. Fabricate the key box and switch of No. 4 satin stainless steel.

2.11 EMERGENCY POWER OPERATION

A. General: Provide emergency power for alarm bell and car lights of the automatic selection with pre-pack feature type as defined in ASME A17.1.

2.12 PERSONAL PROTECTIVE DEVICES

A. Handrails: Provide the manufacturer's standard stainless steel handrails on side walls and the back wall in either continuous or segmented units.

B. Door Edge Protective Device: Provide a retractable edge shoe on the leading

edges of the elevator entrance doors that causes doors to stop and reopen upon contacting an obstruction in the entrance.

C. Photo-Eye Detection Device: Provide an electronic photo-eye device with timed

cutout, projecting dual light beams across car entrance at 5-inch and 29-inch heights, that when interrupted will cause closing doors to stop and reopen. Provide a keyed switch in the car operating panel or toggle switch in the service cabinet for disconnecting the photo-eye protective device.

D. Nudging Feature: Sound a loud buzzer and initiate door closure at a reduced rate

of speed through activation of the detection device or door edge protective device,

AARHIP 14212-17

after the car doors are prevented from closing for a predetermined adjustable time period. Allow the doors to continue to close unless the door edge protective device is activated, which causes the doors to reopen. Repeat the process continuously until the obstruction is removed from entrance

PART 3 EXECUTION 3.1 EXAMINATION A. Before starting elevator installation, inspect hoistway, hoistway openings, pits and

machine rooms, as constructed, verify all critical dimensions, and examine supporting structures and all other conditions under which elevator work is to be installed. Do not proceed with elevator installation until unsatisfactory conditions have been corrected in a manner acceptable to the installer.

B. Installation constitutes acceptance of existing conditions and responsibility for

satisfactory performance. 3.2 INSTALLATION A. Install elevator systems components and coordinate installation of hoistway wall

construction. 1. Work shall be performed by competent elevator installation personnel in

accordance with ASME A17.1, manufacturer's installation instructions and approved shop drawings.

2. Comply with the National Electrical Code for electrical work required during

installation. B. Perform work with competent, skilled workmen under the direct control and

supervision of the elevator manufacturer's experienced foreman. C. Supply in ample time for installation by other trades, inserts, anchors, bearing plates,

brackets, supports, and bracing including all setting templates and diagrams for placement.

D. Welded construction: Provide welded connections for installation of elevator work

where bolted connections are not required for subsequent removal or for normal operation, adjustment, inspection, maintenance, and replacement of worn parts. Comply with AWS standards for workmanship and for qualification of welding operators.

E. Coordination: Coordinate elevator work with the work of other trades, for proper time

and sequence to avoid construction delays. Use benchmarks, lines, and levels designated by the Contractor, to ensure dimensional coordination of the work.

AARHIP 14212-18

F. Install machinery, guides, controls, car and all equipment and accessories to provide a

quiet, smoothly operating installation, free from side sway, oscillation or vibration. G. Sound isolation: Mount rotating and vibrating elevator equipment and components on

vibration-absorption mounts, designed to effectively prevent the transmission of vibrations to the structure, and eliminate sources of structure-borne noise from the elevator system.

H. Alignment: Coordinate installation of hoistway entrances with installation of elevator

guide rails for accurate alignment of entrances with cars. Where possible, delay final adjustment of sills and doors until car is operable in shaft. Reduce clearances to minimum safe, workable dimensions at each landing.

I. Erect hoistway sills, headers, and frames before erection of rough walls and doors;

erect fascia and toe guards after rough walls finished. Set sill units accurately aligned and slightly above finish floor at landings.

J. Lubricate operating parts of system, including ropes, as recommended by the

manufacturer. 3.3 FIELD QUALITY CONTROL A. Acceptance testing: Upon completion of the elevator installation and before

permitting use of elevator, perform acceptance tests as required and recommended by Code and governing regulations or agencies. Perform other tests, if any, as required by governing regulations or agencies.

B. Advise Owner, Contractor, Architect, and governing authorities in advance of dates

and times tests are to be performed on the elevator. 3.4 ADJUSTING

A. Make necessary adjustments of operating devices and equipment to ensure elevator operates smoothly and accurately.

3.5 CLEANING A. Before final acceptance, remove protection from finished surfaces and clean and

polish surfaces in accordance with manufacturer's recommendations for type of material and finish provided. Stainless steel shall be cleaned with soap and water and dried with a non-abrasive surface; shall not be cleaned with bleach-based cleansers.

B. At completion of elevator work, remove tools, equipment, and surplus materials from

site. Clean equipment rooms and hoistway. Remove trash and debris.

AARHIP 14212-19

3.6 PROTECTION A. At time of Substantial Completion of elevator work, or portion thereof, provide

suitable protective coverings, barriers, devices, signs, or other such methods or procedures to protect elevator work from damage or deterioration. Maintain protective measures throughout remainder of construction period.

3.7 DEMONSTRATION A. Instruct Owner's personnel in proper use, operations, and daily maintenance of

elevators. Review emergency provisions, including emergency access and procedures to be followed at time of failure in operation and other building emergencies. Train Owner's personnel in normal procedures to be followed in checking for sources of operational failures or malfunctions.

B. Make a final check of each elevator operation, with Owner's personnel present,

immediately before date of substantial completion. Determine that control systems and operating devices are functioning properly.

END OF SECTION

AARHIP 14212-20


AARHIP 14550-1

SECTION 14550

SHAFTLESS SCREW CONVEYORS AND CAKE HOPPERS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing, installing, testing and placing in satisfactory operation one complete shaftless screw conveyor system, complete with seven (7) shaftless screw conveyors for the conveyance of sludge cake and lime sludge cake to the four sludge cake storage hoppers complete with live bottoms and supports for truck loading. Conveyance equipment includes shaftless screw conveyor drives, electrical controls, tests, and all accessories and appurtenances necessary for a complete installation. Locate the conveyance equipment and cake hoppers as shown in the Solids Handling Building and the Truck Loading Facility.

B. The shaftless screw conveyor equipment includes the following:

1. Troughs, Liners and Covers 2. Spiral Fighting 3. Chutes 4. Odor Ductwork Connections 5. End Shafts 6. Electric Motors and Gear Reducers 7. Mounting and Support Structure 8. Slide Gates 9. Electrical Control Panels 10. Safety Accessories 11. Spare Parts

C. The live bottoms and cake storage hoppers equipment includes the following:

1. Reinforced stainless hoppers with steel support legs 2. Live bottoms with four screws 3. Chutes 4. Odor Ductwork Connections 5. Electric Motors and Gear Reducers 6. Mounting and Support Structure 7. Inlet Electrically Operated Slide Gates 8. Level Sensors and Transmitters 9. Discharge Pneumatically Operated Slide Gates 10. Electrical Control Panels 11. Safety Accessories

AARHIP 14550-2

12. Spare Parts

D. Related Work Specified in Other Sections Includes:

1. Section 05035 – Galvanizing 2. Section 09900 – Painting 3. Section 11505 – Centrifuge Equipment 4. Section 15250 – Mechanical Insulation 5. Section 15810 - Ductwork 6. Section 16055 – Electrical Requirements for Shop-Assembled Equipment 7. Section 16155 – Electric Motors

1.2 REFERENCES


1. ANSI - B105.1 2. NEMA - Design C 3. AISI - 1045 4. API-620 - Design and Construction of Large, Welded, Low

Pressure Storage Tanks 5. NEC 6. OSHA 7. NBS Handbook 44 8. ANSI B20.1-1976 - Safety Standards for Conveyors and Related

Equipment 9. CEMA - Class 300 10. ISA-RP 74.01 - Application and Installation of Continuous Belt

Weighbridge Scales. 11. American Institute of Steel Construction – Manual of Steel Construction

1.3 SHAFTLESS SCREW CONVEYOR SYSTEM DESCRIPTION

A. General: Provide shaftless screw conveyors complete with spiral flighting, troughs and liners, chutes, covers, end shaft, motor reducer, mounting and support structure, electrical controls, safety accessories, controls and auxiliary equipment necessary for a complete installation.

B. Fabricate and assemble all equipment under this section in full conformity with

this specification and as shown in the contract drawings.

C. Furnish equipment complete with all supports; all mechanical equipment required for proper operation, including complete drive units; all steel and other metal construction specified herein; and all additional materials or fabrication as required by the supplier's design.

AARHIP 14550-3

D. Screw Conveyors and intermediate hanger bearings will not be acceptable for this project.

E. Conveyor rotational speeds shall not be greater than herein specified, unless

availability of the reducer ratio requires slight adjustment (+- 3 rpm) or if shown by the conveyor manufacturer calculations to be required to meet design load. Deviations from specified speed cannot be utilized to reduce the conveyor trough and spiral size. Faster speeds are utilized to prevent the fluidization or apparent thinning when conveying dewatered sludge, to reduce liner and spiral wear from abrasive material such sludge cake and lime sludge cake.

F. Design Conditions: Conveyor selection design standards are to be based on the

operational experience of the manufacturer with shaftless screw conveyors, and not shafted screw conveyors. Materials used in the fabrication of the equipment under this section shall conform to the following and the attached table at the end of this specification section.

1. Chutes, Troughs, End Plates,

Covers, Hoppers & Supports AISI 316 stainless steel

2. Spiral Flighting Special Chrome-Alloy Steel w/minimum 225 Brinnell Hardness

3. Wear Liner UHMW Polyethylene, Duraflo SPX™,

BioWear™

4. Hardware AISI 316 stainless steel

G. All hanging supports furnished by the conveyor manufacturer will be one (1) foot longer than required for field fit by the Contractor, who will supply connections approved by the Engineer. The Contractor will be responsible for all fasteners both for hanging and floor anchors.

1.4 SUBMITTALS

A. General: Provide all submittals, including the following, as specified in Division 1.

B. Shop Drawings: Submit working drawings, including arrangement and erection

drawings of the equipment and control equipment, substantial templates, schematic control diagrams, electrical connection diagrams, and complete description of the control system. As a minimum provide the following for review and approval:

1. Descriptive literature regarding the conveying equipment to be supplied.

2. Reference information and certifications as required under subsection 3.

AARHIP 14550-4

3. Detailed specifications for the Equipment proposed

4. Manufacturer’s certification, signed by a corporate officer, confirming that the proposed Equipment fully complies with these specifications, including paragraph 2.1.A of this section.

5. General arrangement drawing(s) for the proposed Equipment.

6. Cut sheets for electric motors and ancillary items manufactured by others.

7. Conveyor torque requirement calculations.

8. Torque calculations for the gear reducers and reducer motors

9. Horsepower calculations for the drive motors.

10. Utilize spiral strength calculations for spring (spiral) compression and

elongation showing the supplied spiral meets or exceeds spring effect intent of 2.2.B herein.

11. Complete schematic diagrams for electrical control panels.

12. A structural calculation for hoppers and supports demonstrating all

equipment meets all local and seismic codes signed and stamped by a Michigan registered PE.

13. The contractor is responsible for coordination of all mechanical & electrical

equipment, and structural interconnecting or otherwise interfacing with the conveyor and any site measurements required for a detailed conveyor submittal.

C. Quality Control Submittals: Submit manufacturer's certified performance and

material records as required.

D. Operation and Maintenance: Submit operation and maintenance manuals in accordance with Division 1.

1.5 WARRANTY

A. General: Provide a guarantee that the system will operate at the design capacities specified. Any adjustments or modifications necessary to attain design capacity shall be made without any increase in Contract Price. Furnish shaftless screw conveyor complete with installation instructions including allowable clearances and tolerances, and all start-up, checkout and operating procedures.

B. Design: Design all conveyor equipment and cake hopper equipment as specified,

to handle the materials indicated at the capacities specified.

AARHIP 14550-5


A. Qualifications: Provide shaftless screw conveyor and cake hopper equipment produced by a manufacturer who regularly engages in the design, manufacture, assembly and production of screw conveyor and cake hopper equipment of the size and type specified.

1.7 ASSEMBLY REQUIREMENTS

A. General: Include all material and equipment necessary to provide a 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: Furnish 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. Provide equipment of such design that piping and electrical connections, ductwork and auxiliary equipment can be assembled and installed without causing major revisions to the location or arrangement of any of the facilities.

C. Fabricated Sections: Furnish all fabricated steel sections shop assembled into units

as large as practicable and as shipping regulations will permit and match marked for field assembly. Provide mechanical equipment and components shop mounted on the steel sections as much as practicable for shipment, in order to keep field assembly to a minimum. Furnish required lifting lugs.

D. Miscellaneous Components: Shop Assemble all screws, bearings, end plates,

trough liners, and trough lids.

E. Identification: Clearly identify all loose items by equipment number and erection mark numbers to facilitate assembly.


A. Deliver, store, and handle all products and materials as specified in Division 1. 1.9 SPARE PARTS

A. Furnish spare parts for each size of conveyor as follows:

1. One (1) of each size or type set of gear reducer standard seal, packing, or spare parts.

2. One (1) Trough liner full length for each conveyor.

AARHIP 14550-6

3. Two (2) liner removal tools

4. One (1) Emergency Stop Switch (with enclosure)

5. One (1)-Motion failure probe

6. One (1) Packing gland set, for each conveyor supplied

7. One (1) Spiral, complete 20’-0” for the sludge conveyors and one compete screw for the lime sludge conveyors and one complete live bottom screw.

8. One (1) Electric and Pneumatic Actuator for gate, one of each type and size

Supplied

9. Furnish lubricants of the type and quantity as recommended by the conveyor manufacturer for start-up and one year’s operation.

PART 2 PRODUCT

2.1 MANUFACTURERS

A. A single supplier who will be responsible for the design, coordination, and the satisfactory operation of the system will furnish all equipment included in this section. For optimum quality control, spirals furnished with the shaftless conveyors and live bottoms are to be produced from spiral manufacturing equipment actually owned by the conveyor/hopper supplier, no exceptions.

B. Provide evidence of at least fifteen (15) years demonstrable experience in the

design and manufacture of shaftless conveyor systems and shaftless screw live bottom storage systems. The Supplier is to have at least fifteen (15) full-scale shaftless conveyors and live bottom storage systems operating successfully for at least five (5) years at municipal wastewater treatment plants that were designed and furnished under the Supplier’s own name. Equipment bought and re-sold; or supplied under a license or marketing agreement shall not be considered for meeting the experience clause.

C. Any re-design costs required to accommodate alternate equipment approved by the

Owner shall be borne entirely by the Contractor and/or equipment manufacturer.

D. Acceptable manufacturers are listed below.

1. Spirac, Inc., Newnan, GA 2. BioSec Enviro 3. KWS Environmental Inc. 4. JDV Equipment Corporation

AARHIP 14550-7

2.2 SHAFTLESS SCREW CONVEYORS

A. General: Spiral flighting for the shaftless screw conveyors are to be designed to convey material without a center shaft or hanger bearings. Screws reinforced with shafting will not be accepted for conveyors but may be used on the live bottoms.

B. Shaftless Conveyors: Spiral flights are to be cold-formed high strength chrome

alloy steel with a minimum hardness of 225 Brinnell. To prevent future fatigue failures and micro cracking screws in the excess of 250 Brinnell hardness will not be accepted. For long life, spirals with less than 220 Brinnell hardness will not be accepted. The equipment supplier will provide documentation that the steel used for the spirals has been used successfully for over 10 years. Design the spiral flights with adequate stability to prevent distortion and jumping in the trough. Provide a second, inner spiral, concentric with the outside spiral. For lime sludge cake conveyors the spiral will have a third outer section approximately 9/16” thick to prevent the lime sludge cake from sticking to the trough. Spirals without the outer scraper and inner section will not be acceptable for lime sludge cake. The torsional rating of the auger flighting will exceed the torque rating specified in paragraph 2.7.C. The "spring effect" of the spiral will not exceed + 1.0 mm per 100 mm of length at maximum load conditions. The minimum main spiral thickness will be as specified in the design table.

C. To prevent micro-cracking spirals over 3.25” deep, manufactured in a one step

process where the screw is rolled and pulled to pitch in one step will not be accepted.

D. Form the spiral flighting in sections from one continuous flat bar and it will be

concentric to within +2mm. Sectional flighting formed from plate will not be permitted.

E. Provide spiral flighting with full penetration welds at all splice connections. Align

the flights to assure true alignment when assembled in the field and it will be made in accordance with the supplier's requirements. Couple the spiral flights to the end shaft by a flanged, bolted connection.

F. A gland-packing ring consisting of two Teflon fiber-packing rings is to seal the

drive shaft at its penetration through the end plate, along with a greased labyrinth sealing system.

G. The connection of the spiral to the drive system is to be through a flanged

connection plate that is welded to the spiral forming a smooth and continuous transformation from the flange plate to the spiral. The drive shaft is to have a mating flange and be bolted to the spiral connection plate. Additionally, a grease lubricated labyrinth seal will be shaft mounted internally in the conveyor between the back plate and spiral coupling connection.

AARHIP 14550-8

H. Conveyor Hold Down Provisions: In order to avoid excessive wear and increased maintenance the conveyors shall be designed without the uses of steel hold down bars. Hold-down guide liners mounted under the lids will be accepted that do not interfere with the flow of conveyed product.

I. Live Bottoms: Live bottoms may use shafted or shaftless screws, but in either case,

the supplier must demonstrate that the system will load trucks evenly. Each hopper and live bottom combination must be capable of loading a twenty five (25) cubic yard truck within twenty (20) minutes. Also, the supplier must guarantee that no regular maintenance will be required inside the hopper or live bottom assembly for a period of not less than 15 years. Each live screw is to have an independent drive. Multiple screws utilizing a single drive will not be allowed. Only direct drive hollow shaft reducers shall be utilized to drive live bottoms screws. Chains, belts or gears to drive the live bottom screw will not be allowed. Drives that extend further from the hopper and limit through space will not be allowed.

If spirals are employed, the flights are to be cold-formed high strength chrome alloy steel with a minimum hardness of 225 Brinnell. Design the spiral flights with adequate stability to prevent distortion and jumping in the trough. Provide a second, inner spiral, concentric with the outside spiral. Provide the spiral with a third outer section approximately 9/16” thick to prevent the lime sludge from sticking to the trough and also the main spiral section to be re-enforced with ¾ -inch section. Spirals without the outer scraper, inner section and reinforcement will not be acceptable for hoppers. The torsional rating of the auger flighting is to exceed the torque rating at 100% loading. The "spring effect" of the spiral will not exceed + 1.0 mm per 100 mm of length at maximum load conditions. The minimum outer and reinforcement spiral thickness will be 1.75-inches. The minimum horsepower for each shaftless screw live bottom is 5.0 horsepower with a speed of 5.0 RPM. If shafted screws are used, the screw shall use a center tube of a minimum of 6”, Schedule 40 pipe constructed from A36. The screw flights shall be ribbon type and shall be a minimum of ½” thick by 4” deep and constructed from AR400 plate. The flights shall be supported by posts evenly spaced at 90 degrees and the posts shall penetrate through the center tube and be welded continuously around all such penetrations. The screws shall be designed such that the maximum deflection of the center tube shall be less than 1/4”. The flights shall be variable pitch such that drawn down from the hoppers and loading of the truck is even controlled. The screws shall be supported by a flanged bearing at the non-drive end and by an external, pillow block bearing at the drive end. All bearing shall have an L10 life of not less than 100,000 hours and shall include an automatic lubrication system.

AARHIP 14550-9

2.3 HORIZONTAL AND INCLINED TROUGHS

A. Provide troughs that are U-shaped and similar to the dimensional standards of CEMA 350 and enclosure classification IIE.

B. Place stiffeners across the top of the trough and fastened to both sides of the trough

to maintain trough shape and act as a face seal for the covers; apply a continuous gasket, one inch width, to the entire top face of the trough top flange and stiffeners.

C. Provide a flanged drain outlet with each conveyor to facilitate cleaning if required

by the Contract Drawings. Pipe the drain outlet to a drain as shown on the Contract Drawings, with adequate cleaning facilities. Drain flushing connections are to be provided if and where specified by the contract drawings. The Contractor will furnish all labor and materials to connect the conveyor flush water and/or drains with the plant water and drain system.

D. Equip each trough with inlet and/or discharge openings and/or motor actuated

gates as shown on the Contract Drawings. If required, each inlet and discharge opening will be flanged suitable for interconnection to other devices. Any interconnecting devices such as chutes and hoppers shall be fabricated from the same grade of material as the troughs and with a gauge thickness to suit the application requirements.

E. Electro-mechanically actuated conveyor discharge gates are described below under

the subpart headed “SLUDGE CAKE HOPPERS”.

F. Provide the three inclined conveyors (receiving sludge from the centrifuges) with a flushing/rinse water connection with solenoid valve located at the low end of the conveyor. When the conveyor is run in reverse, (whenever a centrifuge is started up, shut down or washed out) the wash water solenoid valve will be energized open. Provide two rinse water spray nozzles mounted on a spray water header with and a ½ inch solenoid valve and connection for a total 30-gpm per conveyor. Locate the solenoid valve and connection on the side of the conveyor.

2.4 TROUGH COVERS

A. Cover the portion of each trough that is not covered by inlet chutes by a bolted cover. Provide covers constructed of 1/8-inch AISI Type 316L stainless. Limit length of cover sections to a maximum of 5-feet lengths. To prevent unsafe access to the conveyors, quick opening covers will not be allowed unless they are also bolted to prevent access during operation. Fix each conveyor with the appropriate warning labels to call for lock out – tag out of the electrical system before the covers are removed. If required, inspection hatches or sample ports with finger guards will be supplied as indicated on the Contract Drawings.

AARHIP 14550-10

B. Provide 2-inch flanged connection for odor ductwork to connect to shaftless screw conveyor trough covers. Locate flange 6-inches above trough cover. Locate flanged connection for odor ductwork as shown on Contract Drawings.

2.5 WEAR LINER

A. Line the inside trough surfaces of both the sludge conveyors and hoppers with a layer of ultra high molecular weight polyethylene UHMW-PE. The wear liner shall be SPIRAC Duraflo SPX two-color liner, BioSec BioWear two color liner or equal. Alternative material will only be considered if a full size trough section is provided demonstrating the ability to provide a two color liner formed in one piece; along with the sample shall be documentation the material has been successfully used in sludge cake and lime sludge cake applications. Provide the liner of a single piece, formed and bonded with two (2) layers, each of a different color, to provide a visible indication when the liner is nearing the end of its useful life. Supply the liner in maximum five foot long sections to provide ease of replacement. The liner shall be held in place with stainless steel clips; no fasteners will be allowed. Liner thickness shall be at a minimum ½” for sludge cake conveyors and 9/16” for lime sludge cake conveyors and hoppers. Liners less than the specified minimum thickness and molecular weight will not be acceptable.

B. The liner material shall have the following physical properties, as a minimum:

Property

Value/Unit

Testing Method

Density 61.2 lbs/ft3 DIN53479 Molecular Weight 9.2x106 g/mol Margolies Ball Indentation Hardness 5,946 lbs/in2 DIN53456 Shore Hardness D 64 DIN53505 Crystalline Melting Range 278º F Dynamic Coefficient of friction 0.1-0.12 ratio

of tension/load Plastic to steel

2.6 CONVEYOR SUPPORTS

A. Furnish each conveyor complete with supports suitable for mounting on the surfaces provided and as required by the supplier's design. Fabricate the supports from structural steel shapes and plates designed to support the required loads. Assemble and fit the supports to the conveyor prior to its delivery to the jobsite. Match marked and shipped supports and conveyor segments to the jobsite for field assembly. Provide each conveyor with supports at the inlet and discharge end and intermediate supports 10 feet (maximum) on center.

Fabricate supports of AISI 316 stainless steel with a minimum thickness of 0.25-inches. The supports are to be shop fabricated from structural steel shapes and plates, and assembled and fitted to the conveyor prior to its delivery to the jobsite.

AARHIP 14550-11

Supports and conveyor segments will be match marked and shipped to the jobsite for assembly by the contraction others. The manufacturer shall allow for 1 inch of grout beneath each support footpad for the Contractor to compensate for uneven floor elevation. At a minimum, each conveyor shall be provided with supports at the inlet and discharge end, with intermediate supports as required.

B. Make all shop welding to conform to the latest standards of the American Welding

Society (AWS). Design the supports to avoid interference with other equipment or equipment supports.

C. Design all structural supporting members such that the ratio of the untraced length

to least radius of gyration (slenderness ratio) does not exceed 120 for any compression member and does not exceed 240 for any tension member (for angles about Z-Z axis). In addition, design all structural members and connections so that the unit stresses do not exceed the American Institute of Steel Construction allowable stresses by more than 1/3 when subject to loading of twice the maximum design operating torque of the screw conveyor drive motors.

2.7 DRIVE UNITS

A. Drive each screw conveyor and live bottom by a constant-speed integral gear reducer/motor drive unit mounted to a bell housing adapter flange mounted to the end plate of the conveyor. Allow the adapter flange to leak 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 is not acceptable.

B. Provide certain screw conveyors designed for reversing, bi-directional operation as

listed in the “Shaftless Screw Conveyor Design Table” at the end of this section.

C. Provide rigid support to the drive unit so there is no visible "wobble" movement under any operating condition. Design the drive system so that it is capable of starting the conveyor, even in the event of a prolonged power failure or emergency, from a dead stop with the trough filled at twice the design load for loads designed up to 67 percent fill rate and 1.5 times the load designed exceeding the 67 percent fill rate.

D. Provide 1,800 rpm, 460 volt, 60 Hz, 3 phase motors conforming to Section 16155.

Provide high efficiency motors, 40C ambient rated, 1.15 services factor, with Class F insulation. Furnish motors with TEFC enclosure with Design B speed/torque characteristics.

E. Provide all gears AGMA Class II, single or double reduction, helical gear units

with high capacity roller bearings. Design bearings for the thrust loads from the fully loaded startup condition and with an AFBMA B10 life of 30,000 hours. Provide standard air-cooled reducer units with no auxiliary cooling. Size the gear

AARHIP 14550-12

reducer 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.

2.8 SLUDGE CAKE HOPPERS

A. General: Size the four (4) sludge cake storage bins per the dimensions provided on the Contract Drawings. Manufacture the bins from 304 stainless steel with ASTM A36 steel supports as shown on the Contract Drawings. Additional leg supports will not be accepted. The sludge cake hoppers are not to be shipped in no more than two pieces plus the live bottoms and supports.

B. Provide the top of the hopper with a non-slip finish to allow maintenance

personnel to walk on the top of the hopper. Bolt, at each end of the sludge cake hopper a bolted man way to allow access to the live bottom for maintenance. Provide on the top of the sludge cake hopper two-bolted man ways to allow access and maintenance the screws as required. Provide 8-inch flanged connection for odor ductwork to connect to sludge cake hopper covers. Locate flange 6-inches above trough cover. Locate flanged connection for odor duct for each sludge cake hopper as shown on Contract Drawings. Three (3) level sensor attachment points per hopper shall be located adjacent the inlet slide gates and shall be designed to be compatible with the specified level sensor probes.

C. Supports for the hoppers shall be ASTM A36 steel members. The supports shall

be shop fabricated from structural steel shapes and plates, and shall be assembled and fitted to the hoppers prior to its delivery to the jobsite. Supports and hopper segments shall be match marked and shipped to the jobsite for assembly by the contraction others. The manufacturer shall allow for 1 inch of grout beneath each support footpad for the Contractor to compensate for uneven floor elevation.

D. The hoppers shall be watertight and designed on the basis of being completely full

of dewatered biosolids.

E. The hoppers shall be constructed of 304 stainless steel plate without internal attachments or fixtures that may impede the flow of material. The side slope angles of the hopper shall not be less than 70˚ from the horizontal line. The hopper stiffening members to be designed to limit deflection of the hopper to 1/270 of span.

F. The hoppers shall be design, fabricated, welded, erected inspected and tested

generally in accordance with API-620. The Manufacturer shall submit a Quality Assurance and Quality Control Plan demonstrating general compliance with the requirements of API-620. The Engineer shall be solely responsible to determining the acceptability of the Plan. The Manufacturer shall be responsible for meeting these requirements for all work including inspections and testing performed up to delivery to site. The Contractor shall be responsible for performance and documentation of all inspections and tests for work performed in the field.

AARHIP 14550-13

G. Set the six support legs on load cells, which shall feed back into the corresponding hopper master control panel.

1. Weigh Elements and Weight Indicators: Provide six (6) weigh elements for

weight measurement for each of the four (4) hoppers to allow for the measurement of product being dispersed into the dewatered cake trailer trucks. Secure mounting base plates to the foundation with ASTM A325 anchor bolts pre-cast into the foundation in accordance with Uniform Building Code (UBC) Section 27-7. Use leveling nuts and hardened washers to allow for adjustment for optical alignment during installation. Following alignment, grout the base plates with a minimum of 2-inches of high strength grout. Mount the weigh elements to the base plates using ASTM A325 bolts and tighten per UBC Section 27-7. Mount structural steel and calibrate weigh elements per manufacturer’s instructions. Supplier is to be responsible for verifying required weigh element capacity and should provide larger capacity elements if required.

2. Provide weigh elements that are suitable for installation in a humid outdoor

environment. The design and construction of the weigh elements must satisfy seismic design loading requirements.

3. Provide weigh element sensors of the strain gauge type capable of producing

an output voltage which is proportional to the weight. Provide weigh elements capable of continuous operation throughout the temperature range of -30o to 150o F. The weigh elements are to provide full temperature compensation through the range of 0o to 100o F and have an accuracy of 0.25 percent of rated capacity with a repeatability of 0.1 percent of rated capacity. Design the weigh elements and install them such that the elements can be maintained and replaced. Ship elements with restraints installed for protection during shipment and erection.

4. Provide a weight indicator in a NEMA 4X stainless steel enclosure. The

weight indicator shall operate on 115 VAC, 60 HZ power. The weight indicator should be capable of continuous operation through out the temperature range of -5o to 120o F and a humidity range of 0 to 95 percent non-condensing inside the enclosure. The weight indicator should provide excitation voltage and signal conditioning to the weigh elements. Provide weight indicators with a digital display that indicates weight. The display shall have six digits, 3/8-inch characters with the range of 0 to 999,999 with two fixed zeroes. Provide weight indicators with two relay outputs. Relay outputs set points are to be programmable and independent. Weight indicating transmitters are to have LED status indicators for each relay set point. Provide relays of the single pole, double throw (SPDT) type and have contacts rated for 2.0 amps at 250V AC resistive and 0.5 amps AC inductive. Equip the weight indicators with a DSP filter to minimize inaccurate measurements due to vibration. The weight indicators are to interface with the main sludge hopper control system.

AARHIP 14550-14

H. The live bottom will be a flanged bolt up the hopper. The hopper supports are to

support the live bottom. The live bottom is to be a minimum of 7’-0” wide and the full length of the hopper length. The live bottom will consist of a minimum of four (4) screws that are a minimum of 16-inches in diameter. Provide either shaftless screws that extend the whole length of the live bottom and will be a combination right and left hand to promote the flow of sludge cake to the evenly spaced discharge points or shafted screws with similar flighting or with variable pitch flights to promote the flow of sludge and even drawn down from the hoppers.

I. If the live bottom screws are shaftless and to prevent spiral lifting the non-drive

end shall be pinned by proven live bottom configuration; the method should not require any maintenance or promote wear on the screw or live bottom. The two center screws will have hold downs at the connection point between the left hand and right hand screw to prevent lifting. The hold-downs are to be 304 ss and shall not promote bridging.

J. Provide four pneumatically actuated gated discharges in each cake hopper to fill

each truck in approximately 20 minutes. Evenly space the discharges so the trucks do not have to move during the filling operation. Locate the discharges in a staggered arrangement such that each discharge is fed by two live bin screws.

K. Provide three electrically actuated gated inlets to each cake hopper from the in-

feed screw conveyor to allow even filling of the cake hoppers. The farthest downstream inlet to the second cake hopper (farthest downstream conveyor outlet chute) will not require an electrically actuated gate.

L. Chutes, Discharge Boots and Gates: Furnish inlet and discharge chutes of the same

gauge and construction material as the conveyor troughs, at locations as shown on the Contract Drawings. Flanges shall be a minimum 3/16” thick.

M. Furnish single-ply flanged discharge boots at locations as shown on the Contract

Drawings. Provide flexible boots of EPDM rubber hose, neoprene, Linatrile by Linatex Corporation, or approved equal.

N. Electro-Mechanically Operated Slide Gates for Conveyors: Design the slide gates

for a maximum vertical dimension of 4-inches excluding the electric motor operator. Design the slide gates so that in the full, open position at least one pitch rotation of the spiral is exposed to the opening in the direction of transport and where layout permits 1.5 times the spiral pitch opening. The slide gates are to have an opening at least the full width of the conveyor trough. Fabricate the slide gates entirely of AISI 316 stainless steel and suitable non-metallic (UHMW PE) components, all minimum 3/16-inches thickness. The UHMW PE is to have a machined groove to accept the gate blade and give a positive seal. Roller gates are not allowed due to increased and difficult maintenance requirements.

AARHIP 14550-15

O. The conveyor manufacturer shall provide Rotork Model IQ 10 electric motor actuators for the conveyor gates. Rate the actuator for NEMA 4X duty. Support the actuator underneath the conveyor trough by supports designed and supplied by the conveyor and cake hopper manufacturer. Provide the actuator with two-wire actuator network (PacScan) interface modules to allow the actuators to be integrated into the facility actuator network for monitoring and control of the actuators.

P. Pneumatically Operated Outlet Knife Gates for Bins: Design the knife gates for

flow from two live bottom screws. Provide the gates that are constructed of Type 316 stainless steel. Gate blades are to be constructed of Type 316 stainless steel. Gate blades are to be supported on 1-1/4-inch stainless steel rollers which are to be located out of the material flow. Provide rollers with bronze bushings requiring no lubrication. The leading edge of the gate blade is to be beveled to facilitate travel through the material. Line all product contact surfaces with ¼-inch thick Type 316 stainless steel. Provide gate wiping seals of UHMWPE. Seal contact the top of the gate blade along the perimeter of the throat opening. Seals are to be retained by a bolted stainless steel bar which forms the inlet throat lining of the slide gate Provide an expanded metal guard above and below the retracting area of the gate blade.

In the closed the position, design the gate to prevent the leakage of sludge cake; design the unit to bubble tight at 150 psi. Slide gates of the same design as used for the conveyors will not be acceptable. Provide pneumatic cylinder actuators for the gates complete with air set, 4-way solenoid valve and limit switches. Design the system to open the gate when the solenoid valve is energized and close the gate when de-energized. Provide solenoid valves suitable for 115 Vac, 60 Hz operation with Nema 4 rating. Provide a vertical auxiliary air receiver with inlet check valve for connection to the existing facility air supply system. This receiver is to provide a dedicated air supply reserve for the operation of the bin discharge knife gates. Manufacturer is responsible to size the receiver for the gate operator cylinders provided.

Q. Beacons: Provide a surface mount blue beacon mounted to a junction box adjacent to each hopper outlet gate. Locate the junction box to provide visibility from both sides of the truck bay. Provide 120Vac strobe type beacon with blue Lexan dome suitable for wet areas. Provide Federal Signal model 371DST or equal.

R. Level Sensors: Provide each sludge hopper with ultrasonic level sensors at each

inlet gate location to detect the fill level of each hopper and to control loading the hopper evenly. Connect each level sensor back to the corresponding sludge hopper Main Control Panel. The location, measuring range and mounting of the sensors shall be determined by the hopper system manufacturer. Provide Siemens/Milltronics Airanger XPL or equal.

AARHIP 14550-16

2.9 OPERATION AND CONTROL

A. General: Provide the sludge hopper control system as a prepackaged, PLC based, factory wired and assembled piece of equipment ready for installation, meeting the requirements of Section 16055. Provide the system operation, monitoring and control as described below. All equipment at the sludge cake hopper, the “Main Control Panel" and “Truck Loading Local Control Panels” is to be provided with the cake hopper equipment and installed with the equipment. Provide all appropriate sensing devices and contact points for connection to the control system and for the signaling of all fault conditions. Provide all interlock and alarm switches required. Provide push buttons, selector switches and indicating lights in accordance with Section 16445, Motor Control Centers.

B. Configuration: There are two independent sludge cake hopper systems, one for

each truck loading bay. Each system comprises two hoppers. 1. Provide each sludge cake hopper system (pair of hoppers) with a sludge

cake hopper Main Control Panel meeting the requirements of Section 16055. Each pair of sludge hoppers is to operate independently and is to be controlled by the corresponding Main Control Panel. Include a main breaker, starters, transformer, fuses, fuse block, selector switches, repeat cycle timers, delay timers and running lights to operate the equipment package as specified.

2. Provide each sludge cake hopper system (pair of hoppers) with two Truck

Loading Local Control Panels. The local control panels are to be located on the truck loading platform with one panel serving each hopper in the pair.

3. Provide each Main Control Panel with an Allen Bradley SLC-5/05

programmable logic controller (PLC) and a Panel view 1000 Series graphic local Operator Interface Terminal (OIT). Provide all PLC components, including the OIT in accordance with the requirements of Section 13451. PLC Programming shall meet the City standards requirements specified in Section 13400 and 13451.

4. All interconnecting wiring and conduit between the main and local control

panels for the hoppers and between hopper panels and local hopper devices (instruments, gates, etc) shall be the responsibility of the system supplier.

5. Overall control system programming of the sludge cake hopper system shall

be the responsibility of the system supplier. Configure the control logic for startup, shutdown and monitoring of the complete cake hopper system in accordance with manufacturer’s “know-how” procedures and incorporating the control provisions specified herein. Coordinate with City representatives regarding the programming and graphic standards requirements.

6. All aspects of the equipment must be coordinated and interconnected to

provide a complete system.

AARHIP 14550-17

C. Sludge Cake Hopper System: For purposes of control and monitoring, the “sludge

cake hopper system” refers to the hoppers, inlet gates, live bottoms and screws, outlet gates and associated instrumentation corresponding to a complete system serving a designated truck loading bay. The “sludge cake hopper system” is divided into two “subsystems” with distinctive control functions: 1. Cake Storage – acceptance of dewatered sludge cake and storage (spreading)

in the sludge hoppers. 2. Cake Loading – loading of sludge cake from the hoppers into the trucks in

the loading bays. D. Sludge Conveyors: Sludge Conveyors will be started and stopped (and discharge

gates opened and closed) by the plant PICS (SCADA) system. Separate starters are provided in the motor control centers for the conveyors. Starting and stopping of the conveyors and opening and closing of the discharge gates is sequenced within the PICS system with the equipment feeding and receiving sludge from the conveyors. Provide each conveyor with the following alarm devices to be wired to the motor control centers for alarm and shutdown.

1. Tag-Line Shutdown: Furnish each conveyor with an emergency trip cord

(tag-line) and safety switch. Run the cord the full length of each conveyor. Provide the trip switch with DPDT contacts to immediately stop the conveyor and activate the fault alarm to SCADA when the switch is actuated. In addition, provide safety limit switches on the trough covers to stop the conveyor whenever the conveyor is operating and the trough cover is open. The switch shall be RS type by Conveyor Components Corporation or approved equal.

2. Loss of Motion Failure Alarm Unit: Provide an external conveyor mounted

loss of motion failure alarm, Siemens/Milltronics Model MFA-4. Provide with a NEMA 4 enclosure with MSP-12 sensing probe. Power to be 115 Vac, 60 Hz. Provide SPDT output to MCC as shown.

Conveyor gates will generally be controlled by the PICS system over the actuator network based on the selected sludge flow path. The exception to this is the hopper inlet gates. The hopper inlet gates are to be controlled directly through hardwired connections by the sludge cake hopper system PLC. These gates are also still connected to the actuator network for monitoring (but no control) by the PICS system.

E. Sludge Cake Storage: Each pair of sludge hoppers is to operate independently.

Configure the controls to automatically fill each sludge hopper in the pair evenly based on the level in the hoppers as sensed by the ultrasonic level transmitters under each inlet point from the in-feed conveyor.

AARHIP 14550-18

1. Hopper Feed “Permissive” a. PLC issues permissive to PICS (SCADA) indicating that the hopper

system is ready to accept sludge. PICS system monitors this status condition to confirm that it is permissible to run the sludge equipment and conveyors feeding the hoppers.

b. If both hoppers reach a high level alarm setting or either hopper

sustains a fault mode, the “Hopper Permissive” to PICS shall be de-activated.

c. The “Hopper Permissive” interlock is active in both MANUAL and

AUTO operating modes.

2. Provide MANUAL/OFF/AUTO soft mode selector at the Main Control Panel LOI for the storage (filling) operation.

3. MANUAL: In Manual mode, the inlet gates to the hopper from the in-feed

conveyor may be opened and closed manually from the Main Control Panel LOI. PLC issues “hopper permissive” to PICS.

4. OFF: Storage feed is disabled. PLC deactivates “hopper permissive” and

all inlet gates are closed. 5. AUTO: Automatic Hopper Filling:

a. PLC issues “hopper permissive” to PICS. PICS controls the feed

conveyors to the hoppers based on other equipment operation as long as the “Hopper Permissive” interlock is active. Feed to the hoppers may be intermittent based on other equipment operation.

b. Hopper system PLC is to monitor sludge cake hopper level at each

feed gate position to control even loading of the hoppers. Configure controls so that as hopper fills, inlet gates sequence open and closed as required to distribute sludge uniformly in the hopper based on sludge cake level measurement.

F. Sludge Cake Loading: Each pair of sludge hoppers is to operate independently.

The local control panels located on the truck loading platform shall serve as the normal control interface for the truck driver to control the cake loading operation. 1. Provide MANUAL/OFF/SEMI-AUTO soft mode selector at the Main

Control Panel LOI for the truck loading operation. 2. MANUAL: In Manual mode, the hopper outlet gates and the live bottom

screws conveyor may be controlled manually from the Main Control Panel

AARHIP 14550-19

LOI. This is considered a maintenance function and is not a normal mode of operation.

3. OFF: Truck loading is disabled. Live bottom screws are inoperable and all

outlet gates are closed. 4. SEMI-AUTO: Semi-Automatic Hopper Filling based on operator issued

start/stop commands (described further below). 5. Truck entry/exit: Operation of the overhead doors is not integrated with the

loading system. Provide truck sensing system that visually notifies the truck driver that the truck is in proper position. The exact sensing and visual display system provided shall be determined by the manufacturer.

6. “Truck Warning” Interlock: The sludge hopper system PLC shall issue a

“truck warning” interlock bit to the PICS system to indicate that the truck loading sequence has been activated and it is not safe to move the truck. PICS system will use the status of this bit to activate the truck control light box on the wall near the truck cab. The truck control light box is generally green until the “truck warning” interlock bit is active, at which point it turns red. This interlock is further described below.

7. SEMI-AUTO Sequence: Configure the Truck Loading Local Control Panel

controls to allow the truck driver to manually initiate the truck filling operation and to manually stop the fill operation. Configure the controls to allow the driver to manually pause and restart the truck fill operation with different gates at the bottom of the hopper to maximize the load in the truck. Provide control system to operate in accordance with the following control description:

a. Provide Truck Loading Local Control Panels located on the elevated

platform between the truck bays. Provide one panel for each hopper. Provide each panel with the following: (1) System Start/Stop pushbuttons (2) “Select” pushbutton and “Selected” amber indicating light for

each pneumatically actuated discharge gate (four at each panel).

(3) “Loading” indicator light (red) (4) “Finish” pushbutton (5) Lamp Test pushbutton

b. Driver opens overhead door, enters truck bay and positions truck as

long as the truck control light box is illuminated green. System activates visual confirmation truck in positioned properly.

c. Driver closes overhead door, either at door or at loading platform.

AARHIP 14550-20

d. Driver selects one or more hopper gates to discharge to the truck by pressing the “Select” pushbutton for the desired gate(s). “Selected” indicator light on the panel illuminates and the gate beacon located near the gate illuminates at the selected gate(s). When the first gate is selected, PLC is to activate the “truck warning” interlock bit to the PICS system. When this interlock bit is active, PICS turns the truck control light box to Red (stop) to alert the drive not to move the truck.

e. If driver selects an incorrect gate, pressing the Stop pushbutton will

cancel the gate selections and allow him to start over.

f. Once the desired gates are selected, driver presses the Start pushbutton to commence loading. When the Start pushbutton is pressed, configure the controls to automatically activate the live bottom and open the gate(s) selected to fill the truck. Simultaneously activate the “Loading” indicator light. At the start of the loading sequence, store the beginning hopper weight in a PLC register.

g. Once the loading cycle is started, selection controls of the other gates

shall be unavailable. h. When truck has filled to a desired level at the selected gates, driver

presses the Stop pushbutton. When the Stop pushbutton is pressed, deactivate the live bin bottom screws, close the selected gates and deactivate the “Selected” indicator lights and gate beacons. “Loading” indicator light stays illuminated. “Truck warning” interlock bit deactivates. The loading cycle is now paused.

i. Allow driver to select additional gates and repeat the loading

operation described above with different (or the same) gates until the truck is full. Driver presses the Stop pushbutton to pause the loading cycle each time. Each time the cycle pauses, deactivate the “truck warning” interlock.

j. When the loading operation is complete and no other gates are

required to be operated, driver presses the “Finish” pushbutton. When the “Finish” pushbutton is pressed, terminate the loading cycle and deactivate the “Loading” indicator light. Configure the PLC to subtract the current hopper weight from the beginning weight and store the computed value as the current truck fill weight, along with time and date stamp. Transfer this information to the PICS system.

k. Since “truck warning” bit is deactivated, PICS turns the truck control

light box green indicating that it is now safe to exit.

l. Driver opens the exit overhead door, exits and closes the overhead door manually.

AARHIP 14550-21

8. The OIT touch screen panel is to be capable of displaying digital readouts

that show the amount of sludge in tons (total) in each hopper. 9. Main Control Panel OIT Displays

a. Storage Sub-System Manual/Off/Auto b. Loading Sub-system Manual/Off/Semi-Auto c. Sludge loading Loading status d. Hopper Screws On/Off status e. Hopper Screws Manual Start/Stop control f. Inlet Gates Open/Closed status g. Inlet Gates Manual Open/Close control h. Outlet Gates (live bottom) Open/Closed status i. Outlet Gates (live bottom) Manual Open/Close control j. Hopper sludge level Digital value and animated graphic k. Hopper sludge weight Digital value l. Alarm silence Touch Screen Push Button m. Last truck fill load Weight, date and time

10. Warning Alarms

a. High, high level in sludge hopper b. Bottom Screw fault(s) c. Air pressure – low psi d. Valve sequence failure

11. Communications:

a. Provide digital communications from each Main Control Panel PLC

with the plant PICS (SCADA) system. Provide communications link in accordance with the requirements specified in Sections 13400 and 13451.

b. Configure Ethernet data link coordinated with the plant PICS system

integrator to facilitate data transfer.

c. Signals to PICS: Provide the following signals as a minimum to PICS via the data link for status, alarm and control interface. Provide additional signals as deemed appropriate by the manufacturer for the sludge hopper system.

(1) Permissive to run in-feed conveyor. This permissive is to be

active whenever the sludge cake hopper is ready to accept sludge. This permissive is active MANUAL and AUTO modes when the sludge hopper is ready, not full and not in a fault

AARHIP 14550-22

condition. This permissive is to be removed whenever the sludge hopper system is full, in failure mode or otherwise unable to accept sludge.

(2) Sludge storage control sub-system MANUAL/OFF/AUTO mode status

(3) Sludge loading control sub-system MANUAL/OFF/SEMI-AUTO mode status

(4) Bottom Screws running status (5) Hopper Inlet Gates position status (6) Hopper Outlet (truck feed) gates position status (7) Bottom Screw Failure (8) Gate position sequence failure (9) Truck “Loading” status (10) Hopper level (11) Hopper sludge weight (12) Weight load of previous truck fill, with time and date stamp.

2.10 ELECTRICAL EQUIPMENT REQUIREMENTS

A. Conform all electrical equipment to applicable standard of the National Electrical Manufactures Association (NEMA) and the National Electrical Code (NEC). Insulate both power and control equipment for not less than 600 volts even though operating voltages may be lower.

B. Provide all motors of the totally enclosed, fan cooled (TEFC) type, designed in

accordance with the detailed motor specifications and suitable for operation with a 480 volt, 3 phase, 60 Hz. Power supply.

C. Power supply: Power supply to the equipment will be 460 volts, 60 Hz, 3-phase.

Power supply for electrical controls will be 120 volts, 60 Hz, single-phase.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install all shaftless screw conveyors and cake hoppers in accordance with manufacturer's recommendations and approved shop drawings and as specified in Division 1.


A. Manufacturer's Field Service: Furnish the services of a qualified representative of the conveyor and cake hopper equipment manufacturer to inspect the installation, supervise testing the equipment, make any necessary adjustments, supervise placing it in initial trouble-free operation, instruct the operating personnel in its operation, maintenance, testing, trouble-shooting, assembly and disassembly and

AARHIP 14550-23

as specified in Division 1. Provide such services for a period of ten (10) days in no more than five (5) trips to the project site.

Field services at the project site will be performed during normal daylight working hours from Monday through Friday, legal holidays excepted. The Contractor will coordinate the manufacturer’s technical services in a timely professional manner. At a minimum, two weeks notice must be given to the manufacturer for travel purposes unless previously agreed upon by the manufacturer. To avoid project delays, every effort should be made to coordinate inspection, training and start up of the equipment in one trip.

B. After inspection of the installed equipment the Supplier shall furnish a written report certifying that the equipment has been properly installed and lubricated, is in accurate alignment, is free from any undue stress imposed by connecting piping or anchorage, has been operated under full load conditions and that it operates satisfactorily. After inspection of the installed equipment the Supplier will furnish a written report certifying that the equipment has been properly installed and lubricated, is in accurate alignment, is free from any undue stress imposed by connecting piping or anchorage, has been operated under full load conditions and that it operates satisfactorily.


A. Fabrication: All welds to be continuous unless otherwise specified. Facing surfaces of field-welded components are to be beveled and match marked.

B. Edge Grinding: Sharp corners of all cut and sheared edges will be made smooth.

C. Fasteners: Provide all bolts, nuts, washers, and other fasteners made of stainless

steel.

D. Clean stainless steel 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.

E. Stainless steel surfaces do not require painting.

F. Furnish electric motors, gear reducers, electrical control panels, and other

purchased sub-components with the manufacturer’s standard finish.

G. Paint the shaftless screw conveyors as specified in Section 09900, the spiral shall be furnished with one coat of shop primer only.

H. All iron and mild steel surfaces to be painted are to be dry abrasive blasted in

accordance with SSPC-SP6, and in accordance with Specification Section 09900. Paint or hot dip galvanize all surfaces within 24 hours to prevent rusting and surface discoloration.

AARHIP 14550-24

I. After surface preparation, ferrous metal surfaces, if any, are to receive a minimum

of one (1) coat of epoxy primer except for the spiral flighting. Provide a total minimum dry film thickness of 3 mils prior to shipment to jobsite. Primer must be compatible with the paint system specified for the equipment in Specification Section 09900. All finish coats are to be applied at the project site by the Contractor.

3.4 MANUFACTURER’S WARRANTY

A. The Manufacturer will Warranty the equipment furnished under this section to be free from defects in workmanship and material for a period of twelve (12) months after the equipment has been placed into trouble free operation at the project site. Any warranted material defects found to exist will be repaired or replaced at no cost to the Owner.

AARHIP 14550-25

Shaftless Screw Conveyor Design Table

Conveyor Performance & Design Conveyor Designation SLC- 01, 02, 03 SLC- 04, 05 SLC-06, 07 1 Material conveyed Sludge Sludge Sludge 2 Density, average, lbs/cf 60 60 65 3 Volume, ft3/hr. 370 720 800 4 Max. Screw speed, rpm 22 22 18 5 Trough fill rate @ Design load, % 45 45 45 6 SYSTEM DESIGN 7 Length, approx. ft 20 105 65 8 Degrees Incline, approx. 10 0 0

9 Feed Inlet From CFG SLC- 01, 02, 03 Pug Mill SLC-

07

10 Discharge outlet to SLC- 04, 05 SLC- 04 or Pug

Mill Cake Hoppers 11 No. Discharges: 2 3 8 12 Discharge Type (axial or vertical) Vert Vert Vert 13 Conveyor size, U or OK trough U355 U420 U500 14 Trough width, ID inches, min. 14 16.5 19.7 15 Trough thickness, min. 11 ga. 11 ga. 11 ga. 16 Minimum lid thickness 11 ga. 11 ga. 11 ga. 17 Lid length, inches max. 60 60 60 18 Chute thickness, min. 11 ga. 11 ga. 11 ga. 19 Spiral OD, min. 12.4 14.4 15.9 20 Spiral, outer thickness, min. 1” 1 ¾” 2 ½” 21 Spiral pitch (full or 2/3) Full Full Full 22 Spiral insert Yes Yes Yes 23 Liner type SPX/BioWear SPX/BioWear SPX/BioWear 24 Liner length, ft, max 4' 4' 4' 25 Liner thickness, inch, min. ½” 9/16” 9/16

26 Conveyor-Reversing (Rev.)/Non-Reversing (NRev.) Rev. NRev. NRev.

27 Location of drives Pulling Pulling Pulling 28 Drive Hp, min. 5 40 20 29 Motion failure probes, # per conveyor 1 1 1 30 NEMA rating at probe 4 4 4 31 Control panel, number required - - - 32 NEMA rating of panel 4X 4X 4X 33 Materials of Construction 34 U Trough, lids, end plates & flanges 316 ss 316 ss 316 ss 35 Hardware 316 ss 316 ss 316 ss 36 supports, vertical, less than 6' 316 ss 316 ss 316 ss 37 drive shafts 1045 1045 1045 38 Bell-housings HDG HDG HDG

AARHIP 14550-26

Conveyor Performance & Design Conveyor Designation SLC- 01, 02, 03 SLC- 04, 05 SLC-06, 07 39 Liners UHMW UHMW UHMW 40 Spiral HTMAS HTMAS HTMAS

END OF SECTION

AARHIP 14551-1

SECTION 14551

TEMPORARY DEWATERED CAKE CONVEYOR EQUIPMENT

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing, installing, testing and placing in satisfactory operation, one temporary conveyor system, together with all accessories and appurtenances necessary for a complete installation. Locate conveyor system as shown in the Solids Handling Building. The work includes the conveyor, all conveyor supports, conveyor cover, drives, electrical controls, tests, and all accessories necessary for a complete installation.


Following:

1. Section 05500 - Metal Fabrications 2. Section 05085 - Galvanizing 3. Section 09900 - Painting 4. Section 16220 - Electric Motors

1.2 REFERENCES


1. GMA 420.04 -Practice for Enclosed Speed Reducers.

2. AWS D1.6:1999 - Structural Welding Code - Stainless Steel.

Where other listed Standards and Specifications differ in requirements and interpretations, they shall take precedence over CEMA Standards.

3. NEMA Latest Applicable Codes and Standards. 4. AFBMA Latest Applicable Codes and Standards.

5. ANSI Latest Applicable Codes and Standards

6. NFPA70 National Electrical Code

7. ASTM A36 - Specification for Structural Steel.

8. ASTM D412 -Standard Test Methods of Rubber.

AARHIP 14551-2

9. ASME B20.1-1987 - Safety Standard for Conveyors and Related

Equipment. 1.3 SYSTEM DESCRIPTION

A. General: Provide belt conveyors complete with cover, conveyor belt pans, tracks and supports, take-up and drive stations, controls and auxiliary equipment necessary for a complete installation.

B. Design Conditions: Provide belt conveyor as follows:

SCREENINGS CONVEYOR SCHEDULE

Item No.

Item

Description

1 Number required One (1) 2 Location Solids Handling Building 3 Conveyor configuration Flat w/transition to helical inclined section

(approx., see Drawings) 4 Belt type Modular, with molded clear like convolution 5 Belt width 26 inches (Belt pans) 6 Trough-belt profile 20° 7 Belt cleats Molded 8 Approx. conveyor length1 167’-3” feet 9 Approx. conveyor height Varies 10 Helical arc/radius1 90°/24'-0" 11 Belt speed normal/maximum 22 fpm 12 Average conveyor material density 65 pounds per cubic foot 13 Maximum conveyor capacity 5 tons per hour 14 Nameplate motor horsepower, HP 5.0 15 Electrical service 460V, 3φ, 60 Hz

1 Refer to the Contract Drawings.

1.4 SUBMITTALS


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B. Shop Drawings: Submit shop drawings, including arrangement and erection drawings of the equipment and control equipment, substantial templates, schematic control diagrams, electrical connection diagrams, and complete description of the control system.

C. Quality Control Submittals: Submit manufacturer's certified performance and

material records as required.

D. Operation and Maintenance: Submit an Operation and Maintenance manual in accordance with Division 1.

1.5 WARRANTY

A. General: Provide a guarantee that the system will operate at the design capacities specified in the conveyor schedule. Any adjustments or modifications necessary to attain design capacity will be made without any increase in Contract Price. Furnish all belt conveyors complete with installation instructions including allowable clearances and tolerances, and all start-up, check-out and operating procedures.

B. Design: Design all conveyor equipment as specified, to handle the materials

indicated at the capacities stated in the conveyor schedule. 1.6 ASSEMBLY REQUIREMENTS

A. General: Include all material and equipment necessary to provide a 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: Furnish 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. Provide equipment of such design that piping and electrical connections, ductwork and auxiliary equipment can be assembled and installed without causing major revisions to the location or arrangement of any of the facilities.

C. Fabricated Sections: Furnish all fabricated steel sections shop assembled into units

as large as practicable and as shipping regulations will permit and match marked for field assembly. Provide mechanical equipment and components shop mounted on the steel sections as much as practicable for shipment, in order to keep field assembly to a minimum. Furnish required lifting lugs.

D. Identification: Clearly identify all loose items by equipment number and erection

mark numbers to facilitate assembly.

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A. Deliver, store, and handle all products and materials as specified in Division 1 and as follows:

1. Major structural components shall be prepared for shipment in accordance with

the carriers' specifications. All other components, control panels, instruments and loose pieces shall be skidded, crated or palleted to the carriers' specifications. Further, all skids, carriers and pallets shall be enclosed in watertight plastic wrapping, 6 mil. minimum thickness.

2. Each box or package shall be properly marked to show its net weight in addition

to its contents.

3. Finished surfaces of all exposed equipment openings shall be protected by wooden blanks, strongly built and securely attached thereto.

4. Finished iron or steel surfaces not painted shall be properly protected to prevent

rust and corrosion.

5. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation.

6. Factory assembled parts and components shall not be dismantled for shipment

unless permission is received in writing from the Engineer.

7. Master shipping list shall be supplied showing the quantity of each section, subassembly, or piece, the piece number and the drawing on which each subassembly or piece is detailed.

8. All equipment shall be prominently marked for identification in assembly. The

area(s) in which the equipment is/are designated to be used shall be indicated on the shop drawings. The part identification shall be stenciled conspicuously on large pieces of equipment. Small parts shall have a metal tag wired in place with identification stamped or etched.

1.8 SPARE PARTS

A. One set of spare parts, consisting of 5 belt pans w/hardware, 10 guide blocks, 1 master link guide block assembly, 5 chain attachments, and 2 rubber scraper blades.

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PART 2 PRODUCT

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below.

1. Serpentix Conveyor Corporation 2.2 GENERAL

A. These Specifications shall be considered as minimum requirements.

1. Provide conveyor equipment consisting of conveyor belt pans, tracks and supports, take-up and drive stations. The centerline length of the conveyor(s) is to be approximately 167'-3", with 26 inch wide belt pans and travel at a speed of 22 FPM. Distribute evenly the load on the conveyor(s). Do not exceed the design capacity rating of 5 tons per hour. Provide conveyor(s) with watertight modular conveying surfaces with a 20 degree trough cross section at the outside of the belt width. Each modular conveying section is to have a convolution that permits the assembled belt to make continuous vertical, horizontal and helical turns that will flatten out as it goes over the drive station, and allows for continuous belt cleaning with a pretensioned scraper bar. Reinforce the modular belt pan section with non-metallic stiffeners molded into each modular belt section to achieve required toughing. Design the conveyor(s) in such a way that all moving parts of the system, except for the drive and tension station components, will pass a single designated point along the conveying path which may be used for maintenance and/or service of the conveyor(s).

2. The conveyor system shall be designed to operate in a hazardous, damp, wet

and corrosive atmosphere.

3. Shop Welding: Belt Conveyor manufacturer’s shop welding procedures, welders and welding operators shall be qualified and certified in accordance with the requirement of AWS D1.6. Shop Drawings shall clearly show complete information regarding location, type, size and length of all welds in accordance with AWS A2.1 “Welding Symbols Chart”. Special conditions shall be fully explained by notes and details.

B. Design Data

1. Sizes, quantities and pertinent design data shall be as shown on the

Drawings, specified herein and noted on the Belt Conveyor Schedule at the end of this Section.

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2. The conveyor will transport lime stabilized dewatered sludge cake with a solids content of approximately 30 percent and suspended solids (screenings).

2.3 MATERIALS

A. All parts of the equipment furnished shall be amply designed and constructed for the maximum stresses occurring during fabrication, erection and continuous operation. All materials shall be new. Both workmanship and materials shall be of the best quality, suitable for the services to which the units are to be subjected and shall conform to all applicable sections of these specifications. All parts of duplicate equipment shall be interchangeable without modification and all parts subject to wear shall be of standard pattern and easily replaceable without the necessity of special cutting and fitting.

2.4 COMPONENTS

A. Conveyor Belt and Chain

1. The conveying surface will consist of individually replaceable modular belt pan sections molded of moldable plastic rubber (MPR). Fasten the belt pans every eight (8) inches and it will be supported by a nylon attachment and two (2) durable enhanced, plastic guide (and wear) blocks bolted to a case hardened alloy steel chain. Provide chain with a minimum breaking strength of 35,000 pounds. Each modular belt pan section will have a cleat-like convolution at least 1 1/2 inches high, permanently molded into the rubber. The closed-link alloy steel chain, with alternating horizontal and vertical links will allow for movement in two or more directions. The 4" pitch chain will be guided by the guide blocks bolted bilaterally to each vertical chain link. The belt pan attachments and guide blocks shall be shipped assembled on the chain. The chain and guide blocks will operate in a UHMWPE track consisting of a base, two sides and two top containment angles.

B. Tracks and Supports

1. The fabricated I-beam is to be the structural frame of the conveyor system.

The top and bottom flanges of the I-beam will have the UHMWPE track, with bilaterally positioned angles to contain the guide blocks as they are pulled through the track system by the steel chain. The structural I-beam will be fabricated from 1/8-inch thick, A36 structural steel. The containment angles will be UHMWPE. The guide blocks will stabilize the belt pan surface in the event of unbalanced material loading. Factory fabricate and ready for job site assembly by splice bolting where indicated track sections of required length. The conveyor frame and the conveyor supports are to be structural steel conforming to ASTM A36. All shop welding will conform to the latest standards of the American Welding Society.

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C. Drive Unit

1. The fully assembled drive station is to consist of a 5 horsepower, 230/460v, 3 ph, 60 Hz, TEFC energy efficient motor, a durable corrosion resistant UHMW polyethylene sprocket, gear reducer, v-belt, sheaves, and steel sprockets which in combination give the proper belt speed for the load indicated. A single chain drive between the reducer and the steel sprocket shaft is to be provided for further power and speed reduction. The belt drive sheaves are to be interchangeable in order to provide a different speed by means of other size sheaves. Directly coupled drive motor-gear reducer combinations shall not be acceptable. Incorporate a mechanical ratcheting clutch into the drive design to prevent or mitigate damage to any of the drive clutch shall be incorporated into the drive design to prevent or mitigate damage to any of the drive conditions will cause the ratcheting clutch to release, isolating the power from the electric motor to the gearbox and other power transmission components. The torque setting is adjustable and will be properly set at the factory for each conveyor application.

D. Chain Tensioning Station

1. The fully assembled tension station will consist of a durable corrosion resistant UHMW polyethylene chain sprocket, a constant pressure spring-loaded chain tensioner adjustable by a single ratchet, and track all fabricated and assembled in a structural frame ready for installation.

E. Skirt Boards and Drip Pans

1. Provide conveyor skirt boards at each loading area per dimensions shown on

the drawings. Skirts are to be 3/8” thick HDPE and supported by brackets from the conveyor frame. Provide brackets that are A-36 steel, hot dipped galvanized.

2. Provide 16 gauge, galvanized steel sheet drip pans, with A36 steel support

brackets, below the conveyor and sloped to drain as indicated on the drawings.

F. Hardware

1. Provide all nuts, bolts and washers of Type 304 stainless steel.

G. Belt Scraper

1. Provide a pretensioned scraping mechanism, with a replaceable rubber blade

and UHMWPE backing plate to continuously remove most material from the conveying surface at the conveyor discharge.

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H. Safety Stop Switch

1. Flag arm safety pull-cord switches on each side of the conveyor with orange protective coated cable running the entire length of the conveyor. Nema 7 (Explosion Proof), 20 amps, 125, 250 or 480 VAC, single pole, double throw circuit.

I. Discharge Chute

1. Fabricate the discharge chute of 3/16-inch steel sheets and A36 steel support

members. Provide the chute which will prevent spillage and splash in the area of transfer. No side angles are to be more than 25 degrees off vertical, 30 degrees if Trivar-100 UHMW plastic sheets are provided on sliding surfaces.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install all belt conveyors in accordance with manufacturer's recommendations and approved shop drawings and as specified in Division 1.


A. Manufacturer's Field Service: Furnish the services of a qualified representative of the conveyor equipment and scale equipment manufacturers to inspect the installation, supervise testing the equipment, make any necessary adjustments, supervise placing it in initial trouble-free operation, instruct the operating personnel in its operation, maintenance, testing, trouble-shooting, assembly and disassembly and as specified in Division 1.


A. The conveyor is to be hot dipped galvanized to ASTM 123-892 specifications. All OEM supplied equipment will be furnished with their factory finish.

3.4 MANUFACTURER’S AGREED PRICES

In consideration of the City of Ann Arbor inserting in the proposed contract to be entered into between the City and the successful Bidder for the construction of the Residuals Handling Improvements Project, a requirement for the Bidder to offer in the base bid for temporary dewatered cake conveyor equipment manufactured by the Sepentix Conveyor Corporation. The Sepentix Conveyor Corporation has submitted a Proposal to the City to furnish such equipment, appurtenances and devices as described in this Section to each Bidder at an agreed price as listed in the attached proposal included herewith and made part of this Section. The

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Contractor shall review the proposal and be responsible for providing any additional components required for a complete installation but not included in the attached proposal.

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ANN ARBOR, MI P2 PATHWINDER CONVEYOR CONFIGURATION &

APPLICATION DATA

Date Issued: July 16, 2008

Telephone: 303-430-8427 www.serpentix.comFax: 303-430-7337 9085 Marshall Ct. • Westminster, CO • 80031-2920 [email protected]

P2 PATHWINDER CONVEYOR QUOTATION NO. RDN4832

Components not specifically included below are to be provided by the purchaser. SCOPE OF SUPPLY

for

In general accordance with our quotation drawing #4832 Rev. B

CONVEYING SURFACE Modular MPR belt pans, with 1½" high convolutions, and 20 degree trough at edges of the belt.

CONVEYOR CHAIN Closed-link, hardened alloy steel chain, 4-inch pitch.

CONVEYOR TRACK I-beam, 1/8" minimum thickness, A36 steel structure with UHMWPE containment channel.

DRIVE STATION Fully assembled, with a 5 Hp, 460Volt, 3 Phase, 60 Hertz, TEFC, standard efficiency motor. Includes a mechanical clutch to prevent over-torque conditions.

TENSION STATION Fully assembled, with a constant pressure chain tensioner, adjustable by a single ratchet.

SUPPORT STRUCTURES As generally indicated on quotation drawing; A36 structural steel.

HARDWARE Nuts and bolts assembly hardware shall be type 304 stainless steel.

DRIP PANS Located under the conveyor on the inclined section as shown on the quote drawing, 16 gauge galvanized steel, with A36 steel brackets, hot dipped galvanized

Centerline Length: 167'-3” Belt Width: 26 Inches Belt Speed: 22 ft./min. Elevation Change: 6'-7" Incline Angle: 17 º Material: Sludge Density: 65 lbs./ft3

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QUOTATION NO. RDN4832 Page 2 of 3

SKIRT BOARDS At material loading area as shown on the quote drawing, 3/8” thick HDPE, with A36 steel brackets.

COVERS Located as shown on the quotation drawing, 22 gauge galvanized steel, with A36 steel brackets. Covers are shipped flat, to be bowed and fastened into position by the installing contractor. Some cutting and fitting may be required onsite by the installing contractor.

SAFETY STOP SWITCH Nema 7 (Explosion Proof), 20 Amp, flag arm safety pull-cord switches on each side of the conveyor with protective coated orange cable running the entire length of the conveyor.

SPARE PARTS 5 belt pans, 10 guide blocks, 1 master link assembly, 5 intermediate chain attachments and 2 scraper blades.

BELT CLEANER A pretensioned single-bar scraper located at discharge to remove most material.

MANUALS Standard assembly, operating and maintenance instruction manuals. Electronic O&M manuals, if required, are only available in a .pdf format.

SHOP FINISH Hot dipped galvanized to ASTM 123-892 specification. All OEM supplied equipment incorporated into the conveyor design, e.g. motor, gear reducer, bearings, will be furnished with their factory-applied finish. Any additional coatings by purchaser.

FIELD SERVICES 1 trip(s), not to exceed 1 day(s) for equipment startup & O&M training. NOTE: Once travel arrangements are confirmed, additional travel cost, if any, incurred due to requested advancement or postponement of agreed upon scheduled trips(s), shall, with the submittal of applicable documentation, be accepted and paid for by the purchaser of the equipment. Unused services will not be credited.

EXCEPTIONS & CLARIFICATIONS TO THE SPECIFICATIONS • All OEM supplied equipment incorporated into the conveyor design, e.g. motor, gear reducer, bearings, will be furnished with their factory-applied finish. Any additional coatings by purchaser. • Controls, control panels and motor starters are not included. • Anchor bolts for equipment installation are not included. • The discharge chute that is directing material onto the conveyor system at the tension station is not included in this quotation and should be provided by others. • Special insurance requirements such as being added as an additional insured to our policy is subject to additional costs and is not included in this quotation. • See Typical "Purchaser to Furnish" Items in Attachment A.

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QUOTATION NO. RDN4832 Page 3 of 3

INSTALLATION/ASSEMBLY MAN HOUR ESTIMATE • Conveyor(s) are shipped unassembled. Field assembly is required. Minimum estimated installation/assembly time is 2 man-hours per linear foot. Actual time will vary with field conditions, equipment used, installation experience and methods used by the installation contractor.

EQUIPMENT APPROVAL & SHIP DATE • Allow 2 to 3 weeks to submit approval drawings after our receipt of a formal purchase order. • Allow at least 2 to 3 weeks for purchaser review and the return of the approval drawings. • Upon our receipt of all drawings and submittal data approved by the purchaser, this equipment will be shipped in 10 to12 weeks.

PAYMENT TERMS AND CONDITIONS • Quoted prices are firm for acceptance up to June 30, 2009. • Delivery must be taken before Dec 31, 2009. • Ninety percent (90%) net 30 days from the equipment ship date. • Ten percent (10%) retainage, with final payment due within 180 days of the equipment ship date. • These payment terms are independent of those the purchaser may have with the owner, and are subject to the purchaser’s credit approval. Other payment terms may apply. • Enclosed forms TC1, TC2 & Attachment A are part of this quotation.

TOTAL PRICE……………………………………………………………………………..$140,000.00 • Federal, state, local or other taxes are not included. • FOB Westminster, CO, FFA Jobsite

Please refer all questions concerning this quotation to our representative listed below, or to this office.

Very Truly Yours,

Sales and Marketing Manager

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REGIONAL REPRESENTATIVE Mr. Dale Storm Peterson & Matz, Inc. 2250 Point Blvd, Suite 300 Elgin, IL 60123 TEL: 847-844-4405 FAX: 847-844-4409 Email/: [email protected]

Enclosures: Quotation Dwg. #4832 Rev. B Attachment A (Standard Purchaser to Furnish Items) TC1 (Standard Terms and Conditions) TC2 (Standard Terms and Conditions)

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END OF SECTION

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SECTION 14620

MONORAIL SYSTEMS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing one (1) trolley-monorail system with its controls, together with all accessories and appurtenances necessary for a complete installation. Locate the hoisting equipment as shown.


Following:

1. Section 05085 - Galvanizing 2. Section 09900 - Painting 3. Section 16055 - Electrical Requirements for Shop-Assembled Equipment 4. Section 16220 - Electric Motors

1.2 REFERENCES


1. ANSI B30.11, B30.16, B30.17, B30.2 2. ANSI/ASME HST-4M 3. CMAA Spec Nos. 70 and 74 4. NACM No. 6001 5. OSHA 1910.179


A. Type and Capacity: Provide the following equipment:

Unit A. One 20-ton monorail trolley hoist with motor-operated trolley and motor-operated wire rope hoist, located in the Centrifuge Area of the Solids Handling Building.

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B. Performance Requirements: Provide the equipment meeting the following performance requirements:

UNIT

Items "A" Capacity – tons 20 Elev. of bottom of monorail girder 809’-6” Elev. of hook in highest position - not lower than 801’-11” Elev. of hook in lowest position - not higher than 736’-0” Elev. of operating floor 787’-0” Trolley travel speed ft/min (approx.) 25 Trolley horsepower 0.75 Hoisting speed (approx.) ft/min 13 Hoist horsepower 20 Size of monorail girder 16” Distance centerline of monorail to end of trolley hoist - maximum (perpendicular to monorail)

20”

Distance centerline to end of trolley hoist - maximum (parallel to monorail)

4’-1/4”

Radius of monorail curvature 8’ Minimum expansion joint expansion 2-1/2”

1.4 SUBMITTALS


B. Product Data and Information: Submit catalog data and information for each unit.

C. Shop Drawings: Submit shop drawings, including arrangement and erection

drawings of the equipment and control equipment, templates, schematic control diagrams, electrical connection diagrams, and complete description of the control system.

D. Quality Control: Submit the following documents:

1. Manufacturer's certified performance and material records

2. Manufacturer's certified copies of Field Test Reports

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E. Operation and Maintenance Manuals: Submit operation and maintenance manuals for the hoisting equipment.


A. Qualifications: Provide hoisting equipment of complete assembled units of standard manufacture made by a company which has had equipment of equivalent capacity and design giving satisfactory service in similar installations, and which can furnish replacement parts which are completely interchangeable within the original hoist assembly.

B. Regulatory Requirements: Provide hoisting equipment meeting the requirements

of the following specifications except as modified:

1. ANSI Safety Standards: B30.2, B30.11, B30.16, and B30.17

2. Crane Manufacturers Association Inc.

a. CMAA Specification No. 74 for top running and under running single girder electric overhead traveling cranes

3. ANSI/HST Hoist Performance Standard: ANSI/ASME HST-4M for electric

wire rope hoists 1.6 DELIVERY, STORAGE AND HANDLING

A. Deliver, store and handle all products and materials as specified in Division 1 and as follows:

1. Protect all electrical equipment from the weather during transit and storage

by suitable means, including shrink wrapping or hand wrapping and taping. 1.7 SPARE PARTS

A. Furnish the following spare parts:

1. One set of trolley truck bearing assemblies

2. One contactor assembly of each type

3. One push button assembly for pendant push button control station

4. One year supply of lubricants

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PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Trolley Monorail Systems

a. Cleveland Tramrail Division

2.2 MATERIALS

A. General: Design monorail structures in accordance with AISC Standards. Design all load bearing parts with a safety factor of at least five at rated capacity loads, based on the ultimate strength of the materials used. Arrange the equipment to operate within the space shown with adequate clearances, with minimum clearance to the nearest obstruction not less than 3 inches vertical and 2 inches horizontal.

1. Arrange all working parts for convenient inspection, lubrication, adjustment,

repair, or replacement. Assemble paint, test, and adjust the equipment, in the shop as far as practicable before shipment.

2. House the operating machinery and other exposed parts suitably, fabricate

the exterior of the unit to have smooth surfaces of pleasing appearance.

3. Design the hoist with an overload limit device to prevent damage to the equipment or structure if loads in excess of the specified capacity of the hoist are applied.

4. Place an inscription, easily readable from the operating floor on each trolley

monorail unit showing the rated capacity of the equipment and control identification. Provide all appurtenances, caution markers, and appliances necessary to comply with applicable safety laws and codes.

5. Unless otherwise specified, provide all hoisting equipment suitable for

normal indoor and outdoor service as shown, designed for the following service classification:

a. Motorized hoist Class H-3 of Hoist Manufacturers Institute HMI-100

6. Provide all hoisting equipment components designed for outside service

suitable for operation at a range of temperature 5 degrees F to 110 degrees F, and subject to moderate dust and corrosion conditions.

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7. Provide monorail track constructed of high carbon steel with raised tread fabricated using continuous welding. Provide track with standardized rail width of 4 ½ inches.

8. Provide single girder crossover with expansion joint and discharge points at

locations where monorail track crosses a building expansion joint. Provide crossover with expansion length as listed in Section 1.3.B. Coordinate all other monorail system components with the crossover to provide a complete, properly operating system.

9. Provide 30-dgree Type “ST-3A” sliding switches with motor actuators at

each monorail track curve.

B. Monorail Trolley With Wire Rope Hoist:

1. Trolley Frames: Provide trolley frames for the monorail hoists of welded rolled steel or cast steel construction, or a combination of both.

2. Trolley Wheels: Design trolley wheels to operate on the bottom flange of

the monorail beam. Manufacture wheels of forged steel with tapered, hardened treads, designed to carry the maximum wheel load under normal conditions without undue wear, with diameter no less than is shown in Table 4.1 of Hoist Manufacturers Institute - Standard Specifications HMI-100-74 for contour wheels with treads no less than 1-inch wide or 9-1/2”, whichever is greater. Machine the wheels to matched diameters with treads to match the rolling surface of the lower flange of the monorail beam. Provide wheels of the regreasable type.

3. Hoisting Drum: Fabricate the hoisting drum of high-grade cast iron or steel

to withstand the maximum bending and crushing loads. Design the drum so that not less than two complete wraps of hoisting rope will remain in the grooves when the hook is in the lowest position, and there will be no overlapping when the hook is in the highest position. Turn drum grooves from solid metal, grooved right- and left-hand for double reeving, and provide grooves of not less than one half the nominal wire rope diameter in depth. Provide the pitch diameter of the drum and running sheave not less than 24 times the nominal rope diameter. Equip the drum with shrouded flanges or the equivalent to prevent cable override. Install an adjustable geared limit switch at the upper and lower limits of the hook travel, and an overload cutoff to prevent application of forces greater than the specified capacity of the hoist.

4. Drives: Manufacture the trolley of the electric motor-operated type with

electric motor-operated wire rope hoist.

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5. Motor: Provide motor power supply of feed rail conductors type. Provide control from pendant controller push button station, cable supported from a swivel type cable reel mounted as shown.

C. Hoisting Wire Rope: Design hoisting rope specially for crane service and

consisting of 6 x 37 type preformed improved plow steel strands over a fiber core.

1. Wire Size: Size the hoisting wire rope in accordance with OSHA requirements and the Crane Manufacturer's recommendation, and provide the rated load plus block weight divided by the number of parts of rope not to exceed 20 percent of the nominal breaking strength of the rope.

D. Bearings: Provide all bearings of the ball or roller type, conforming to the

standards of the Anti-friction Bearing Manufacturers Association. Provide bearing housings that are split or designed to permit easy removal of the shafts. Prelubricate and seal all bearings for life.

1. Design all bearings in the crane wheels, drive shaft bearings and gear

reduction shaft bearings for a minimum B10 bearing life of 5,000 hours.

E. Hoisting Blocks: Provide hoisting blocks of enclosed steel construction with forged steel hooks with spring-operated safety latches supported on ball or roller bearings. Design hooks to rotate freely 360 degrees on the bearing support.

F. Gears: Design all gearing to meet the requirements of Section 4.2 of CMMA

Specification No. 74 and AGMA Standards, and of helical or spur type constructed of heat treated steel. Provide worm gears of bronze and with precision machined cut teeth. Provide all pinions of heat treated alloy steel. Enclose or guard gearing and provide either oil bath or splash lubrication.

1. Design the gear reducer or gear motor specifically for crane service with

minimum classification of Moderate Shock service and with minimum service factor of 1.0.

G. Brakes: Equip each hand-operated hoist with a Weston or multiple disc type

mechanical brake which will automatically hold the load indefinitely in any position and permit it to be lowered without acceleration under full control when the chain is pulled in the lowering direction.

1. Provide each electrically-operated hoist with a mechanical load brake as

specified above and, in addition, a dc magnetic brake, spring set and magnetically released or solenoid- operated shoe type motor brake acting directly on the motor pinion shaft the instant power is shut off, equally effective in both directions. Provide brakes which are adequate to sustain the capacity load, capable of at least fifteen operations per minute, and permit smooth operation for inching.

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2.3 ELECTRIC MOTORS

A. Provide motors meeting the requirements of Section 16220 except as modified below.

1. Design hoisting equipment drive motors specifically for hoist service,

conforming to NEMA STANDARDS Part 18 - Subsection "Integral-horsepower AC Crane Motors". Provide horizontal shaft, totally enclosed nonventilated, Class B insulated, 30 minute duty rated, high torque, high slip, induction motors, 1800 rpm maximum speed, suitable for operation at 460 volts, 3-phase, 60 hertz. Provide motors with lifetime lubricated ball bearings. Design motor and gear assembly for the crane application and provide Type D motors flange mounted to the gear reducer or integral motor and gear reducer. Provide motors whose maximum noise level measured 5 feet from each motor does not exceed 90 dBa.

2.4 OPERATION AND CONTROLS

A. General: Provide operation and control equipment meeting the requirements of Section 16055.

B. Starters: Provide each electrically-operated hoist and trolley motor with integral

reversing starters, complete with manual reset overload relays in NEMA 4 enclosure. Arrange all components for positive starting in each direction.

C. Standards: Provide all components complying with the NEMA Standards for

Industrial Control for Cranes and Hoists, NEC, ANSI B30.11 and ANSI B30.16.

D. Limit Switches: Provide hoisting controls which include an adjustable limit switch to limit the normal up and down travel of the hook with a second factory set fixed switch operated by the hook or block to stop the hoist when the highest safe point is reached. Furnish adjustable limit switches of the heavy duty control circuit or power circuit type and factory set fixed limit switches of the power circuit type. Connect limit switches to open the motor circuit and apply the brake, but not to prevent lowering by operation of the appropriate push button. Provide switches in enclosures of the same NEMA rating as the associated motor starter, and designed and installed so that they will not be damaged by swinging of the hook.

E. Pendant Push Button Control Station: Support pendant push button control

stations by a cadmium plated steel or Type 304 stainless steel cable or chain paralleling the control cable sized to withstand any effort to pull the hoist with the cable. Provide control transformers for operating the pendant controller at 115 volts ac. Provide each control cable of NEC Type S0 and to include the required number of flexible No. 14 AWG copper conductors, all cabled with necessary fillers and tape, and a tough polyvinyl chloride sheath of at least 45 mils thickness. Provide one piece cables, without flaws, and supported by a Kellems type safety grip.

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1. Locate the pendant push button controller approximately three feet six

inches above the operating floor similar to No. 2 of Figure 4 of Recommended Arrangement of Controllers, ANSI B30.2 Section 2-1.10.3 Controller (k), except where otherwise specified. Provide an indicating light to show that power is available. Furnish two push buttons for each motor, one for each direction of travel. For two speed trolleys or hoists, provide controlling push buttons of two position type for slow and fast speeds. Provide all push buttons of the momentary contact maintained pressure type, automatically de-energizing when the contact pressure is relieved. Enclose pendant controllers in the same type of NEMA enclosures as specified for the associated motor starters. Manufacture the pendant controller push button station of weatherproof nitrile-vinyl rubber or light-weight resilient molded Lexan for nonexplosion-proof enclosures and cast aluminum for explosion-proof enclosures.

2.5 POWER SUPPLY

A. General: Provide all electric power supply equipment suitable for 480-volt, 3-phase, 60-hertz electric service. Provide all hoisting equipment with suitable junction boxes for connection of field services and complete with a ground pad. Locate connections as shown.

B. Conductor Bar Type: Provide power supply consisting of the single conductor

bottom entry electrification type to include a system of safety shielded covered conductors extending the length of the monorail, as shown.

1. Provide conductors of galvanized steel construction with rigid

polyvinyl-chloride covers, rated at minimum of 75 amperes continuous rating. Securely support conductors hanger clamps and end covers, with pickups firmly held by collector arms. Provide the power supply originating at a junction box located as shown.

C. Cable Reel Type: Provide power supply of the reel type to include a payout reel

with a 4-conductor, heavy duty cable of adequate length to reach any point of trolley travel. Provide conductors of extra flexible stranded copper and of NEC Type S0 supported from the hoist by a Kellems type safety grip.

1. Spring-load the reel to prevent a cable sag of more than 3 feet at the limit of

travel. Bracket-mount the reel from the wall on a suitable swivel or from the structural beams as shown. Locate the reel at the center of travel at a location necessary for the cable to clear (columns).

AARHIP 14620-9

PART 3 EXECUTION

3.1 INSTALLATION

A. Install all trolley-monorail systems in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.


A. Manufacturer's Field Service: Furnish the services of a qualified representative of the manufacturer to provide instruction on the proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the field testing of the equipment and place it in initial trouble-free operation, as specified in Division 1.

B. Tests: After installation of the trolley-monorail systems, control equipment and all

appurtenances, subject the units to a field running test, as specified in Division 1, under actual operating conditions. Test all trolley-monorails in accordance with ANSI B30.16. Operate hoist through a complete lift and lowering cycle and through complete travel of the trolley to determine that the equipment will perform the function of hoisting, braking and traveling quietly, smoothly and safely without failure of any parts. Test the hoisting equipment to as near capacity as possible with available loading facilities such as material or equipment which is readily available within the area served that can be used for producing the loads. Promptly correct defects in the equipment indicated by the tests.


A. Paint the trolley-monorails meeting the requirements of Section 09900, using colors conforming to applicable safety laws and codes. Paint the trolley beams in accordance with the Structural Steel (Interior) class of work. Paint the motors, hoists, trolleys and blocks in accordance with the Machinery (Interior) class of work. Do not paint hoist wire ropes.

END OF SECTION

AARHIP 14620-10


AARHIP 14650-1

SECTION 14650

JIB CRANES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing two (2) jib cranes with all accessories and appurtenances necessary for a complete installation. Locate jib cranes as shown.

B. Related Work Specified in Other Sections Includes:

1. Section 05085 - Galvanizing 2. Section 09900 - Painting

1.2 REFERENCES


1. ASME B30.11-Safety Standards for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings - Monorails and Underhung Cranes (Includes Revision Service)

2. ASME B30.16-Overhead Hoists (Underhung) 3. NACM-Single Loop Chain


A. Type and Capacity: Provide the following equipment:

Two 1-ton, free-standing, base plate mounted jib cranes with manually-operated geared army style trolley operating on the bottom flange of the boom girder, and manually-operated chain hoist. Locate the jib cranes as shown at Blend Tank Nos. 1 and 2.

AARHIP 14650-2

B. Performance Requirements: Provide jib crane meeting the following limiting conditions:

Item Condition Capacity - tons 1 Elev. of bottom of jib boom girder 764’-3” Elev. of hook in highest position - not lower than 763’-2” Elev. of hook in lowest position - not higher than 737’-2” Max. pull on hoist operating chain to lift capacity load (lbs) 83 Max. chain overhaul to lift load one foot (ft.) 52 Jib crane span (ft.) 20

1.4 SUBMITTALS


B. Product Data and Information: Submit catalog data and information for the jib

crane, trolley and hoist.

C. Shop Drawings: Submit shop drawings, including arrangement and erection drawings of the equipment and templates.

D. Quality Control: Submit the following:

1. Manufacturer's certified performance and material record

2. Manufacturer's certified copies of Field Test Reports

E. Operation and Maintenance Manuals: Submit operation and maintenance manuals

for the jib crane, trolley and hoist. 1.5 QUALITY ASSURANCE

A. Qualifications: Provide completely assembled jib crane unit of standard manufacture made by a company which has had equipment of equivalent capacity and design giving satisfactory service in similar installations, and which can furnish replacement parts which are completely interchangeable within the original assembly.

AARHIP 14650-3

B. Regulatory Requirements: Provide jib crane meeting the requirements of the following specification except as modified:

1. ASME Safety Standards: B30.2, B30.11, and B30.16


A. Deliver, store and handle all products and materials as specified in Division 1. 1.7 SPARE PARTS


1. One year supply of lubricants.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Spanco

2.2 MATERIALS

A. General: Design structural components in accordance with AISC Standards. Design all load bearing parts with a safety factor of at least five at rated capacity loads, based on the ultimate strength of the materials used. Arrange jib crane to operate within the space shown with adequate clearances, with minimum clearance to the nearest obstruction not less than 3 inches vertical and 2 inches horizontal.

1. Arrange all working parts for convenient inspection, lubrication, adjustment,

repair, or replacement. Assemble, test and adjust the equipment in the shop as far as practicable before shipment.

2. House the operating machinery and other exposed parts suitably for outdoor

service. Fabricate the exterior of the unit to have smooth surfaces of pleasing appearance.

3. Design the hoist with an overload limit device to prevent damage to the

equipment or structure if loads in excess of the specified capacity of the hoist are applied.

AARHIP 14650-4

4. Place an inscription, easily readable from the operating floor, on jib crane unit showing the rated capacity of the equipment and control identification. Provide all appurtenances, caution markers, and appliances necessary to comply with applicable safety laws and codes.

5. Coating any portion of the jib crane, trolley or hoist using electroplating

with zinc is not acceptable.

B. Jib Crane: Provide jib crane of the base plate mounted free standing pillar type with manually-rotated monorail boom designed to operate through an arc of 360 degrees.

1. Coat the crane by hot dip galvanizing meeting the requirements of Section

05085. 2. Provide jib crane with an underhung manually-operated geared army style

trolley with manually-operated geared chain hoists rated for outdoor installation and service.

3. Appurtenances: Provide the jib crane complete with all appurtenances

including structural sub base plate with anchors pillar base anchors, pillar bearings, pillar-mast, monorail boom, chain trolley hoist, block, swivel safety latch lift-hook. Provide all appurtenances rated for outdoor installation and service.

4. Bearings: Arrange the monorail boom to revolve on thrust bearings and

guide roller bearings or with an upper pintle bearing and lower roller type bearings. Provide the upper thrust or pintle bearings of with provision for Alemite type grease lubrication. Provide the lower bearings with provision for Alemite type grease lubrication.

5. Support or Anchor: Design the crane base at the center of rotation to be

supported and anchored at the bottom on a concrete foundation to sustain the crane under all conditions of normal operations.

6. Stress: Construct the jib crane of welded steel with weathertight

compartments, removable inspection and service ports. Design the pillar-mast, jib boom and bracing to keep the crane in proper alignment such that stresses in structural members do not exceed 10,000 psi in compression and 12,000 psi in tension under capacity load plus dead load plus an impact allowance equal to 15 percent of the capacity load, limit jib boom sag to not more than 1/450 of the span with full load at the outer limit of trolley travel.

7. Track: Provide a jib boom consisting of a horizontal steel beam, the lower

flanges of which serve as a track for the trolley. Rigidly attach the boom to

AARHIP 14650-5

the upper rotating part of the pillar-mast structure and adequately brace boom in a level position, provided with trolley stops.

C. Hoisting Chain - (Load Chain): Provide hoisting or load chain of welded link type,

accurately pitched to pass smoothly over all load sprockets without binding. Manufacture chain of stainless steel. Use welded link chain meeting the requirements of the National Association of Chain Manufacturers (NACM) Grade 28 or single loop weldless chain meeting the requirements of NACM No. 6001. Remove excess metal at welded chain joints for proper fit into the chainwheel pockets. Remove burrs and sharp edges. Use chain that is suitable for bare hand operation.

1. Proof Test: Provide load chains which have been proof tested by the chain

or hoist manufacturer with a load equivalent to at least one and one half times the hoists rated load divided by the number of chain parts supporting the load.

D. Operating Wheels and Chains: Equip operating wheels with swinging chain

guides to permit rapid handling of the operating chain without gagging the wheel and permit a reasonable side pull on the chain. Provide operating chains which hang to approximately 3 feet above the sidewalk at Blend Tank No. 1 and approximately 3 feet above the lowest elevation (grade) within the crane rotation at Blend Tank No. 2. Provide hooks on which to hang the operating chains when not in use.

E. Bearings: Provide all bearings of the ball or roller type, conforming to the

standards of the Anti-friction Bearing Manufacturers Association. Provide bearing housings that are split or designed to permit easy removal of the shafts. Prelubricate and seal all bearings for life.

1. Design all bearings in the crane wheels, drive shaft bearings and gear

reduction shaft bearings for a minimum B-10 bearing life of 5,000 hours.

F. Hoisting Blocks: Provide hoisting blocks of enclosed steel construction with forged steel hooks with spring-operated safety latches, supported on ball or roller bearings. Design hooks to rotate freely 360 degrees on the bearing support.

G. Gears: Design all gearing to meet the requirements of Section 4.2 of CMMA

Specification No. 74 and AGMA Standards, and of helical or of spur type constructed of heat treated steel. Provide worm gears of bronze and with precision machined cut teeth. Provide all pinions of heat treated alloy steel. Enclose or guard gearing and provide either oil bath or splash lubrication.

1. Design the gear reducer or gear motor specifically for crane service with

minimum classification of Moderate Shock service and with minimum service factor of 1.0.

AARHIP 14650-6

H. Brakes: Equip each hand-operated hoist with a Weston or multiple disc type

mechanical brake which will automatically hold the load indefinitely in any position and permit it to be lowered without acceleration under full control when the chain is pulled in the lowering direction.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install jib crane in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.


A. Manufacturer's Field Service: Furnish the services of a qualified representative of the manufacturer to provide instruction of the proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the field testing of the equipment and place the equipment in initial trouble-free operation, as specified in Division 1.

B. Tests: After installation of the jib crane, and all appurtenances, subject the units to

a field running test, as specified in Division 1, under actual operating conditions. Test jib crane in accordance with ASME B30.16. Operate each hoist through a complete lift and lowering cycle to determine that the equipment will perform the function of hoisting, braking quietly, smoothly and safely without failure of any parts. Test the hoisting equipment to as near capacity as possible with available loading facilities such as material or equipment which is readily available within the area served that can be used for producing the loads. Promptly correct defects in the equipment indicated by the tests.


A. Paint the jib crane appurtenances meeting the requirements of Section 09900 using colors conforming to applicable safety laws and codes. Paint the trolley beams in accordance with the Structural Steel class of work. Paint the motors, hoists, trolleys and blocks in accordance with the Machinery class of work. Do not paint mast, boom, hand chains or any portions of the jib crane, trolley or hoist constructed of stainless steel or galvanized steel.

END OF SECTION

AARHIP 15060-1

SECTION 15060

SUPPORTS AND ANCHORS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing all hanging and supporting devices of construction shown, specified, or required for pipelines, apparatus, and equipment other than electrical equipment.


Following:

1. Section 05085 - Galvanizing 2. Section 05120 - Structural Steel 3. Section 05560 - Metal Castings 4. Section 09900 - Painting 5. Section 15106 - Ductile Iron Pipe and Fittings 6. Section 15107 - Steel Pipe and Fittings 7. Section 15109 - Erecting and Jointing Interior Piping

1.2 REFERENCES


1. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, 800

2. ASME B31.1 - Power Piping (Includes Revision Service)

3. ASTM A 307 - Specification for Carbon Steel Bolts and Studs,

60,000 PSI Tensile Strength

4. MSS SP-58 - Pipe Hangers and Supports - Materials, Design and Manufacture

5. MSS SP-69 - Pipe Hangers and Supports - Selection and

Application

6. MSS SP-89 - Pipe Hangers and Supports - Fabrication and Installation Practices

AARHIP 15060-2

7. MSS SP-90 - Guidelines on Terminology for Pipe Hangers and Supports

1.3 SUBMITTALS


B. Shop Drawings: Submit shop drawings to show the quantity, type, design and

location of all supports, hangers and anchors required.

C. Submit a CERTIFICATE (ONLY), signed and sealed by a Licensed Professional Engineer experienced in structural Engineering and registered in the State where the construction will be performed, that certifies that the Licensed Professional Engineer has evaluated and approved the CONTRACTOR’s supports and anchors as detailed on the submittal drawings and has prepared complete design calculations confirming the adequacy of all supports, hangers, anchors and expansion compensating devices used. Provide a separate CERTIFICATE for each piping system before starting the installation.


A. General: System includes supporting devices adequate to maintain the pipelines, apparatus, and equipment in proper position and alignment under all operating and testing conditions with due allowance for expansion and contraction.

B. Design Requirements: Design supporting devices in accordance with the best

practice and provide supporting devices that are not unnecessarily heavy. Design supporting devices to accommodate loads imposed during leakage tests for the test pressures specified. Base the required strength of supporting devices on the combined weight of the piping and connected equipment, the weight of the denser of the fluids used in operations or testing and the weight of insulation where applicable. Install supports with a working safety factor of not less than 5, and conform installation to requirements of Section 05120.

C. Provide springs where necessary. Make hangers and supports of standard design

where possible and best suited for the service required. Include proper pipe protection saddles for hangers and supports on pipes which are covered with insulation. Where required, make supports screw adjustable after installation unless approved otherwise.

D. Interference: Design all supporting devices so as to minimize interference with

access and movement. Eliminate the potential for injuries due to protruding supporting devices.

AARHIP 15060-3

E. Sizing: Provide base piping support, hanger rod size, brackets and spacing meeting the requirements of ASME B31.1, MSS SP-58, SP-69, SP-89 and SP-90 except as modified herein.

1. Modify hangers for plastic pipes to increase the bearing area by inserting a

protective sleeve of medium-gauge aluminum sheet metal between the pipe and the hanger.

a. Align hangers such that no sharp edges come in contact with the pipe.

b. Provide a wooden or thermoplastic pad between the plastic pipe and

any concrete or masonry surface.

c. Use supports for vertical lines of a type which do not exert a compressive strain on the pipe. Riser-type clamps that squeeze the pipe will not be permitted.


A. Deliver, store and handle all products and materials as specified in Division 1.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Pipe hangers and supports

a. Grinnell Corporation, Cranston, RI b. Globe Pipe Hanger Products, Inc., Cleveland, OH

2. Sheet metal shield

a. "Thermal-Hanger Shields" by Pipe Shields Incorporated, Vacaville,

CA 2.2 MATERIALS

A. Use structural and miscellaneous steel, metal castings, ductile iron pipe and fittings, steel pipe and fittings, and supports meeting the requirements of Sections 05120.

B. Support overhead hangers using threaded rods properly fastened in place by

suitable screws, clamps, inserts, or bolts, or by welding. Subject hangers to tensile

AARHIP 15060-4

loading only. Where lateral or axial movement may occur, provide suitable linkage to permit sway.

C. Suspended Piping: Support suspended piping by adjustable ring or clevis hangers

and threaded rods from heavy duty concrete inserts or other fastening devices, except as otherwise specified or noted.

D. Brackets: Make brackets of welded steel and designed for the following load

classifications.

Load Classification Maximum Load

per Bracket

Light 750 pounds

Medium 1,500 pounds

Heavy 3,000 pounds

1. When medium or heavy brackets are bolted to vertical surfaces, furnish and install backplates of adequate size and thickness to distribute the load against the vertical surfaces.

2. When the use of backplates is not practicable, fasten the brackets to the

vertical surfaces in such a manner that the safe bearing strength of the vertical surfaces will not be exceeded.

E. Chairs and Pipe Rolls: Use cast-iron pipe rolls or chairs. Provide pipe rolls with

threaded nuts or with sockets to take threaded rods.

F. Saddle Stands: Use adjustable saddle stands.

1. Provide each stand with a length of steel pipe fitted at the base with standard threaded cast-iron flange or steel base plate and at the top with an adjustable saddle or roll. Bolt the base flange or plate to the floor, foundation or concrete base.

2. Use stanchions of construction similar to the saddle stand, except fit them at

the top with cast-iron pipe saddle supports or with pipe stanchion saddles with yokes and nuts.

G. Insulation Support Requirements: At support points, protect insulated pipes by a

360 degree insert of high density, 100 psi, waterproofed calcium silicate encased in a 360 degree sheet metal shield.

1. Make inserts of the same thickness as the adjoining pipe insulation.

AARHIP 15060-5

2. Provide the shield length, minimum galvanized sheet metal gauge and installation procedure in accordance with the manufacturer's recommendations.

3. Extend insulation inserts one inch beyond the sheet metal shields on cold

water lines, and jacket and vapor seal as required when the abutting insulation is installed.

H. Expansion: Connect, support and guide piping to permit and control pipe

expansion and contraction and to accommodate building expansion, contraction and settling without damage to the piping or support system.

1. Furnish and install anchors when specified, shown, or required for holding

the pipelines and equipment in position or alignment. Design anchors for rigid fastening to the structures, either directly or through brackets.

2. Provide cast-iron chair type anchors for piping with steel straps, except

where anchors form an integral part of pipe fittings or where an anchor of special design is required.

3. Inserts: Provide galvanized concrete inserts.

a. Design inserts to permit the rods to be adjusted horizontally in one

plane and to lock the rod nut or head automatically.

b. Recess inserts near the upper flange to receive reinforcing rods.

c. Design inserts so that they may be held in position during concrete placing operations. Design inserts to carry safely the maximum load that can be imposed by the rod which they engage.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install hanger and supports in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1 and Section 15109.

3.2 GALVANIZING AND PAINTING

A. Galvanizing: When specified, galvanize hangers and supports as specified in Section 05085.

B. Painting: Paint hangers, supports, anchors, and similar devices as specified in

Section 09900.

AARHIP 15060-6

C. Touch-Up Painting: Clean and touch-up painting of field welds, bolted

connections and abraded areas as specified in Section 09900.

END OF SECTION

AARHIP 15072-1

SECTION 15072

VIBRATION ISOLATION

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installation of vibration isolators for mechanical equipment, piping and ductwork and all other appurtenances for a complete installation.


1. Section 15183 - Hydronic Piping Valves and Specialties 2. Section 15184 - Refrigeration Piping and Specialties 3. Section 15190 - Natural Gas System 4. Section 15450 - Plumbing Equipment 5. Section 15510 - Boilers and Boiler Room Equipment 6. Section 15670 - Condensing Units 7. Section 15720 - Air Handling Units 8. Section 15740 - Heating, Ventilating and Air Conditioning Pumps 9. Section 15765 - Terminal Heat Transfer Units 10. Section 15810 - Ductwork 11. Section 15830 - Fans

1.2 REFERENCES


1. ASTM A 36/A36M - Specification for Structural Steel. 2. NFPA 90A - Installation of Air Conditioning and Ventilating Systems

1.3 SUBMITTALS


B. Shop Drawings: Submit shop drawings showing structural design and details of

vibration isolators, steel beam bases and other custom-fabricated work not covered by the manufacturer's submitted data.

1. Furnish templates to fabricators of equipment bases, and other support

systems, as needed for coordination of vibration isolation units with the supported equipment.

AARHIP 15072-2

2. Submit shop drawings indicating locations of units and flexible connections.

Include support isolation points for piping and ductwork including risers.

3. Include a schedule of the units, showing size or manufacturer's part number, and weight supported and resulting deflection of each unit.

4. Submit catalog data for each type of vibration isolation including materials,

dimensions, application and performance characteristics. 1.4 QUALITY ASSURANCE

A. Product Qualification: Provide each type of vibration isolation unit produced by specialized manufacturer and as follows:

1. Except otherwise indicated, obtain vibration isolation units from a single

manufacturer.

2. Engage the manufacturer to provide technical support in selection and supervision of installation of vibration isolation units.

B. Performance: Comply with the minimum static deflections recommended by the

American Society of Heating, Refrigerating and Air-Conditioning Engineers, including definitions of critical and noncritical locations, for selection and application of vibration isolation materials and units as indicated.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Vibration Isolators.

a. Consolidated Kinetics Corp. b. Korfund Dynamics Corp. c. Mason Industries, Inc. d. Vibration Eliminator Co., Inc. e. Vibration Mountings and Controls, Inc.

2. Flexible Duct Connectors.

a. Vent Products Co. Inc. b. Ventfabrics Inc. c. Holtz Rubber Co.

AARHIP 15072-3

3. Flexible Pipe Connectors.

a. Flow Flex Engr. Co. b. Flexonic Inc. c. Metraflex Co. Inc.

2.2 PAD-TYPE ISOLATORS

A. General: Except as otherwise indicated, provide a manufacturer's standard pad-type isolation unit, color coded to indicate load capacity:

1. Neoprene pads.

B. Neoprene Pads: Use oil-resistant neoprene sheets, of the manufacturer's standard

hardness and cross-ribbed pattern, designed for neoprene-in-shear-type vibration isolation, and of the thicknesses required.

2.3 SPRING ISOLATORS

A. Spring Isolators, Free-Standing: Except as otherwise indicated, provide vibration isolation springs between top and bottom loading plates, and with pad-type isolators bonded to the bottom of the bottom loading plate. Include studs or cups to provide for centering of the springs on the plates. Include leveling bolts with lock nuts and washers, centered in the top plate, arranged for leveling and anchoring the supported equipment. Include holes in the bottom plate for bolting the unit to the substrate.

B. Vibration Isolation Springs: Use wound-steel compression springs, of high-

strength, heat-treated, spring alloy steel, with an outside diameter of not less than 0.8 times the operating height, with a lateral stiffness not less than vertical stiffness, and designed to reach solid height before exceeding the rated fatigue point of the steel.

2.4 RAILS

A. Equipment Rails: Where rails or beams are indicated for use with isolator units to support equipment, provide steel beams complying with ASTM A 36/A36M, with a minimum depth of 6 inches or 0.08 times the span of beam between isolators (whichever is greater). Provide welded brackets at the ends of each beam, and anchor each end to the spring isolator unit. Provide bolt holes in beams matching anchor bolt holes in equipment. Provide beams of the section modulus indicated, or, if not indicated, selected for normal-weight equipment loading to limit static load stress to 16,000 psi. Except as otherwise indicated, position equipment on equipment rails so that the load will be equally supported by the isolator units.

AARHIP 15072-4

2.5 BASES AND FRAMES

A. Fabricated Equipment Bases: Where supplementary bases are required for use with isolator units to support equipment (base not integral with equipment), provide welded units, fabricated of structural steel shapes, plates and bars complying with ASTM A 36/A36M, as shown. Provide welded support brackets at points as required, and anchor the base to spring isolator units. Except as otherwise indicated, arrange brackets to result in the lowest possible mounting height for the equipment. Provide bolt holes in bases to match mounting anchor bolt holes in the equipment. Fabricate the bases with the depth of the structure not less than 0.10 times the longest span of the base, rigidly braced to support the equipment without deflections or distortions which would be detrimental to the equipment or equipment performance.

2.6 HANGERS AND RISERS

A. Isolation Hangers: Provide hanger units formed with brackets and including the manufacturer's standard compression isolators of the type indicated. Design brackets for 5 times the rated loading of units. Fabricate units to accept misalignment of suspension members, and for use with either rod or strap type members, including acoustical washers to prevent metal-to-metal contacts.

1. Provide a vibration isolation spring with a cap and pad-type isolators,

securely retained in the unit.

2. Provide a neoprene pad, securely retained in the unit.

3. Provide a fiberglass pad or shape, securely retained in the unit, with a threaded metal top plate.

4. Install a removable spacer in each unit, to limit the deflection during

installation to the rated-load deflection.

B. Riser Isolators: Provide the manufacturer's standard pad-type isolator bonded to steel plates, formed for welding to the pipe sleeve extension.

C. Riser Support Isolators: Provide the manufacturer's standard pad-type isolator

laminated between 2 formed steel plate members, one for welding to the pipe sleeve extension and other for welding to the pipe riser.

2.7 DUCT AND PIPE CONNECTORS

A. Flexible Duct Connectors: Provide flexible connections made from prefabricated Type 316 L stainless steel, and laminated flexible sheets of cotton duct and sheet elastomer (butyl, neoprene or vinyl), reinforced with steel wire mesh where required for strength to withstand the duct pressure indicated. Form connectors with full-faced flanges and accordion bellows to perform as a flexible isolation

AARHIP 15072-5

unit, and of the manufacturer's standard length for each size unless otherwise indicated. Provide adequate joint flexibility to allow for thermal, axial, transverse, and torsional movement, and capable of absorbing vibration of connected equipment. Equip each unit with galvanized steel retaining rings for airtight connections with ductwork. Provide products approved by NFPA for vibration isolation connectors in duct systems as covered by NFPA Bulletin 90A.

1. Provide U-type configurations, asbestos free of 2 ply, vulcanized EPDM

elastomer fabric flexible connectors, with a 9-inch minimum width, and molded flanges and corners. Design the flexible connectors for no less than 2 psi, temperature no greater than 200 degrees F, and to accept the system movements without imposing any significant forces on the ductwork. Provide flexible connectors resistant to all chemicals and reaction byproducts they are exposed to. Use shop painted retaining bars to back up flanges.

B. Flexible Pipe Connectors: For ferrous piping, provide stainless steel hose covered

with stainless steel wired braid with NPT steel nipples or 150 psi ANSI flanges, welded to the hose.

PART 3 EXECUTION

3.1 APPLICATIONS

A. General: Apply types of vibration isolation materials and units indicated at locations shown or otherwise required. Selection is at the CONTRACTOR's option where more than one type is indicated.

B. Pad-Type Isolators: Install pad type isolators at the following equipment:

1. Boilers. 2. Condensing Units. 3. Air Handling Units. 4. Base Mounted Pumps.

C. Equipment Rails or Fabricated Equipment Bases and Spring Isolators: Install

equipment rails or fabricated equipment bases and spring isolators where the following floor-mounted equipment is indicated:

1. Air handling units. 2. Centrifugal fans. 3. Base mounted pumps. 4. Condensing Units.

AARHIP 15072-6

D. Isolation Hangers: Install isolation hangers where the following suspended equipment is indicated:

1. In-Line Fans.

2. Unit Heaters.

3. Pipe over 1-inch pipe size, located in mechanical equipment rooms, and

each run connected to vibration-isolation-mounted equipment for a distance of 100 diameters but not less than 50 feet.

4. Ductwork located in mechanical equipment rooms, and each run connected

to vibration-isolation-mounted equipment for a distance of 50 feet.

E. Riser Isolators: Install riser isolators where the following risers pass through floors; provide support-type where riser support is required:

1. Pipe risers.

2. Pipe risers, within 50 feet 0 inches of a connection with vibration-isolation-

mounted equipment for a distance of 50 feet.

3. Pipe risers in critical locations.

F. Flexible Duct Connectors: Install flexible duct connectors at the following ductwork connections:

1. Connections with air handling equipment. 2. Connections with all fans. 3. Building expansion joints.

G. Flexible Pipe Connectors: Install flexible pipe connectors in piping systems at the

following locations:

1. Hydronic and refrigerant pipes.

2. Pumps.

3. Air handling units.

4. Condensing units - refrigerant pipes. 3.2 INSTALLATION

A. General: Except as otherwise indicated, comply with the manufacturer's instructions for installation and load application to vibration isolation materials and units. Make adjustment so that the units do not exceed the rated operating

AARHIP 15072-7

deflections or bottom out under loading, and are not short-circuited by other contacts or bearing points. Remove space blocks and similar devices (if any) intended for temporary protection against overloading during installation.

B. Other Requirements: Meet the following installation requirements.

1. Anchor and attach units to substrate and equipment as required for a secure

operation and to prevent displacement by normal forces, and as indicated.

2. Adjust leveling devices as required to distribute this loading uniformly onto isolators. Shim units as required where leveling devices cannot be used to distribute loading properly.

3. Locate isolation hangers as near overhead support structure as possible.

4. Weld riser isolator units in place as required to prevent displacement from

loading and operations.

5. Bond flanges of flexible duct connectors to ducts and housings to provide airtight connections. Seal seams and penetrations to prevent air leakage.

6. Install flexible pipe connectors on the equipment side of shutoff valves,

horizontally and parallel to equipment shafts wherever possible. 3.3 EXAMINATION OF RELATED WORK

A. Coordination: Examine the installation of equipment, piping, ducts and conduits related to vibration isolation, including items connected to vibration isolators, and after completion of other related work but before equipment startup, furnish a written report listing any observed inadequacies for proper operation and performance of the vibration isolators. Have the report cover, but not necessarily be limited to the following:

1. Equipment installations on vibration isolators.

2. Piping connections including flexible connections.

3. Ductwork connections including provisions for flexible connections.

4. Passage of piping and ductwork which is to be isolated through walls and

floors.

B. Equipment Start-Up: Do not start-up equipment until inadequacies have been corrected in an acceptable manner.

AARHIP 15072-8

3.4 DEFLECTION MEASUREMENTS

A. Measurement Report: Upon completion of the vibration isolation Work, prepare a report showing measured equipment deflections for each major item of equipment as indicated.

1. Base mounted pumps 2. Air handlings 3. Boilers 4. Fans

END OF SECTION

AARHIP 15080-1

SECTION 15080

MECHANICAL INSULATION

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Mechanical insulation for piping, ductwork and equipment.


1. Section 09900 - Painting 2. Section 15183 - Hydronic Piping, Valves and Specialties 3. Section 15184 - Refrigeration Piping and Specialties 4. Section 15405 - Plumbing Piping and Valves 5. Section 15720 - Air Handling Units 6. Section 15810 - Ductwork

1.2 REFERENCES


1. ASTM C 195- - Mineral Fiber Thermal Insulation Cement

2. ASTM C 533 - Calcium Silicate Block and Pipe Thermal Insulation

3. ASTM C 552 - Cellular Glass Block and Pipe Thermal Insulation

4. ASTM C 547 - Mineral Fiber Pipe Insulation

5. ASTM C 612 - Mineral Fiber Block and Board Thermal Insulation

6. ASTM C 921 - Practice for Determining the Properties of Jacketing Materials for Thermal Insulation

7. ASTM E 84 - Test Method for Surface Burning Characteristics of

Building Materials

8. NFPA 255 - Surface Burning Characteristics of Building Materials

9. UL 723 - Surface Burning Characteristics of Building Materials

AARHIP 15080-2

1.3 SUBMITTALS


B. Product Data: Submit the manufacturer's technical product data, insulation

materials, fire ratings, material safety data sheets and installation instructions for each type of mechanical insulation. Submit a schedule showing the manufacturer's product number, k-value, thickness, density, and furnished accessories for each mechanical system requiring insulation.

C. Maintenance Data: Submit maintenance data and replacement material lists for

each type of mechanical insulation. Include this data and product data in the maintenance manual.


A. Manufacturer's Qualifications: Provide insulation from firms regularly engaged in manufacture of mechanical insulation products, of the types and sizes required, whose products have been in satisfactory use in similar services for not less than 5 years.

B. Installer's Qualifications: Use firm with at least 5 years successful installation

experience on projects with mechanical insulations similar to that required for this project.

C. Flame/Smoke Ratings: Provide composite mechanical insulation (insulation,

jackets, coverings, sealers, mastics and adhesives) with flame-spread index of 25 or less, and smoke-developed index of 50 or less, as tested by ASTM E 84 method.


A. General: Deliver, store and handle all products and materials as specified in Division 1 and as follows.

B. Labeling: Deliver the insulation, coverings, cements, adhesives, and coatings to

the site in containers with the manufacturer's stamp or label, affixed showing the fire hazard indexes of products.

C. Protection: Protect the insulation against dirt, water, and chemical and mechanical

damage. Do not install damaged or wet insulation and remove damaged materials from the project site.

AARHIP 15080-3

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. General: Acceptable manufacturers are listed below. Other manufacturers of equivalent products may be submitted.

1. Armstrong World Industries, Inc. 2. Babcock and Wilcox; Insulating Products Div. 3. Certainteed Corp. 4. Knauf Fiber Glass GmbH. 5. Manville Products Corp. 6. Owens-Corning Fiberglas Corp. 7. Pittsburgh Corning Corp. 8. Rubatex Corp. 9. Pipe Shields Inc. - "Thermal-Hanger Shields" 10. IMCOA (Refrigerant Piping)

2.2 MATERIALS

A. Piping Insulation: Provide fiberglass piping insulation meeting ASTM C 547, Class 1 unless otherwise indicated.

1. Hot pipe insulation: Provide heavy duty bonded fibrous glass sectional pipe

insulation with a thermal conductivity not exceeding 0.3 BTU per hour per square foot per degree F per inch thickness at 200 degrees F mean temperature.

2. Cold pipe insulation: Provide heavy duty bonded fibrous glass sectional

pipe insulation with a thermal conductivity not exceeding 0.26 BTU per hour per square foot per degree F per inch thickness at 50 degrees F mean temperature.

3. Jackets for Piping Insulation: Provide jackets meeting the requirements of

ASTM C 921, Type I for piping with temperatures below ambient, and Type II for piping with temperatures above ambient.

a. Encase pipe fitting insulation with one-piece premolded PVC fitting

covers, fastened as per the manufacturer's recommendations.

b. Encase exterior piping insulation with stainless steel jacket which is of weather-proof construction.

4. Refrigerant Pipe Insulation: Provide refrigerant pipe insulation of the

waterproof closed cell type with a zero water vapor transmission rate, temperature range of -10 degree F to +200 degree F and which do not contain corrosive constituents associated with stress corrosion failure of

AARHIP 15080-4

copper tube. Provide insulation which has excellent resistance to chemicals, ozone and solvents. Provide seam joining to be moisture proof using non-toxic sealant.

5. Accessories: Provide the following accessories:

a. Provide staples, bands, wires and cement as recommended by the

insulation manufacturer for the applications indicated.

b. Provide adhesives, sealers, and protective finishes as recommended by the insulation manufacturer for the applications indicated.

B. Ductwork Insulation: Provide rigid fiberglass ductwork insulation meeting ASTM

C 612, Class 1, with "K" value of 0.24 at 75 degrees F, and 3 lb/cu.ft. minimum density.

1. Jackets for Ductwork Insulation: Provide jackets that meet ASTM C 921,

Type I for ductwork with temperatures below ambient, and Type II for ductwork with temperatures above ambient.


a. Provide staples, bands, wires, tape, anchors, corner angles and similar

accessories as recommended by the insulation manufacturer for the applications indicated.

b. Provide cements, adhesives, coatings, sealers, protective finishes and

similar compounds as recommended by the insulation manufacturer for the applications indicated.

C. Equipment Insulation

1. Rigid Fiberglass Equipment Insulation: Provide insulation that meets

ASTM C 612, Class 2, with "K" value of 0.24 at 75 degrees F, and 3 lb/cu.ft. density.

2. Jacketing Material for Equipment Insulation: Provide pre-sized glass cloth

jacketing material, not less than 7.8 ounces per square yard, or metal jacket at the CONTRACTOR's option, except as otherwise indicated.


a. Provide adhesives, cements, sealers, mastics and protective finishes as

recommended by the insulation manufacturer for the applications indicated.

AARHIP 15080-5

b. Provide staples, bands, wire, wire netting, tape, corner angles, anchors and stud pins as recommended by the insulation manufacturer for the applications indicated.

D. Thermal Hanger Shields: Provide insulated pipe protectors consisting of a 360-

degree high density, 100 psi, waterproofed calcium silicate inserts encased in 360-degree sheet metal shields. On cold water pipes provide protectors with insulation extended 1-inch beyond the sheet metal shield.

1. Provide the thickness of the insulation insert to be the same as the adjoining

pipe insulation, and sheet metal gauge in accordance with the manufacturer's recommendations.

PART 3 EXECUTION

3.1 INSPECTION

A. General: Examine areas and conditions under which mechanical insulation is to be installed. Do not proceed with Work until unsatisfactory conditions have been corrected in manner acceptable for insulation installation.

3.2 PLUMBING PIPING SYSTEM INSULATION

A. Insulation Omitted: Omit the insulation on chrome-plated exposed piping (except for handicapped fixtures), air chambers, unions, strainers, check valves, balance cocks, flow regulators, buried piping, and preinsulated equipment.

B. Cold Piping Application Requirements: Insulate the following cold plumbing

piping systems:

1. Potable cold water piping.

2. Plumbing vents within 6 lineal feet of a roof outlet.

3. Drain piping from drip pans.

4. Insulate each piping system specified above with the following type and thickness of insulation:

a. Fiberglass: 1-inch thickness.

C. Hot Piping Application Requirements: Insulate the following hot plumbing piping

systems:

1. Potable hot water piping.

AARHIP 15080-6

2. Potable hot water recirculating piping.

3. Hot drain piping.

4. Insulate each piping system specified above with the following type and thicknesses of insulation:

a. Fiberglass: 1-inch thickness.

D. Jackets for Piping Insulation: Install jacketing on all piping insulation.

E. Thermal Hanger Shields: Provide insulated pipe protectors at all support points.

3.3 HVAC PIPING SYSTEM INSULATION

A. Insulation Omitted: Omit insulation on hot piping within radiation enclosures or unit cabinets, on cold piping within unit cabinets provided that the piping is located over a drain pan and on heating piping beyond a control valve, located within heated space.

B. Sub-Freezing Piping Application Requirements: Insulate the following sub-

freezing HVAC piping systems:

1. Refrigerant liquid and suction lines between evaporators and compressors.

2. Insulate each piping system specified above with the following type and thicknesses of insulation:

a. Closed Cell: 1-inch thick for pipe sizes up to and including 1-inch, 1-

1/2 inch thick for pipe sizes over 1-inch.

C. Cold Piping Application Requirements: Insulate the following cold HVAC piping systems:

1. HVAC make-up water piping.

2. Air conditioner condensate drain piping.

3. Insulate each piping system specified above with the following type and

thicknesses of insulation:

a. Fiberglass: 1-inch thick for pipe sizes up to and including 4 inches, 1-1/2-inch thick for pipe sizes over 4 inches.

D. Hot Piping Application Requirements: Insulate the following hot HVAC piping.

1. HVAC hot water (glycol solution) supply and return piping.

AARHIP 15080-7

2. Hot gas refrigerant piping.

3. Insulate each piping system specified above with the following type and

thicknesses of insulation:

a. Fiberglass: 1-inch thick for pipe sizes up to and including 1-inch, 1-1/2-inch thick for pipe sizes 1-1/4-inch through 2 inches, 2-inch thick for pipe over 2-1/2 inches, 2-1/2-inch thick for steam pipes 4 inches and larger.

E. Jackets for Piping Insulation: Install jacketing on all piping insulation materials.

F. Insulation of Piping Exposed to Weather: Protect outdoor insulation from weather

by installing an stainless steel jacket. Place jacket to shed water from the insulation.

G. Thermal Hanger Shields: Provide insulated pipe protectors at all support points.

3.4 DUCTWORK SYSTEM INSULATION

A. Hot Ductwork Application Requirements: Insulate the following hot ductwork:

1. Hot supply and return ductwork between fan discharge, or heating unit discharge, and room terminal outlet, except omit insulation on return ductwork located in conditioned spaces.

2. Heating plenums and unit housings not pre-insulated at the factory.

3. Insulate each ductwork system specified above with one of the following

types and thicknesses of insulation:

a. Rigid Fiberglass: 2 inches thick.

B. Dual Temperature Ductwork Application Requirements: Insulate the following dual temperature ductwork:

1. Hot/cold supply and return ductwork between the fan discharge or HVAC

unit discharge, and room terminal outlets, except omit insulation on return air ductwork located in conditioned spaces.

2. Outdoor air plenums.

3. Insulate each ductwork system specified above with one of the following


a. Rigid Fiberglass: 2 inches thick.

AARHIP 15080-8

C. Jackets for Ductwork Insulation: Jacket ductwork insulation.

3.5 EQUIPMENT INSULATION

A. Cold Equipment Application Requirements: Insulate the following cold equipment:

1. Drip pans under cooling equipment.

2. Glycol solution tank.

3. Insulate each item of equipment specified above with one of the following


a. Fiberglass: 2 inches thick for cold surfaces above 35 degrees F and 3 inches thick for surfaces 35 degrees F and lower.

B. Hot Equipment Application Requirements: Insulate the following hot equipment:

1. Hot water expansion tanks.

2. Hot water pumps.

3. Hot water air separators.

4. Blow down separator.

5. Insulate each item of equipment specified above with the following type and

thickness of insulation:

a. Fiberglass: 2 inches thick.

C. Jackets for Equipment Insulation: Jacket equipment insulation. 3.6 INSTALLATION

A. General: Install piping, ductwork and equipment thermal insulation in accordance with the manufacturer's recommendations and approved shop drawings, and as specified in Division 1. Install all products in accordance with the recognized industry practices so that insulation serves its intended purpose.

B. Piping Insulation

1. Order of Installation: Install insulation on pipe systems subsequent to the

testing and acceptance tests.

AARHIP 15080-9

2. Insulation Surfaces: Install the insulation materials with smooth and even surfaces. Insulate each continuous run of piping with full-length units of insulation, with a single cut piece to complete the run. Do not use cut pieces or scraps abutting each other.

3. Cleaning and Drying: Clean and dry pipe surfaces prior to insulating. Butt

insulation joints firmly together to form a complete and tight fit over the surfaces to be covered.

4. Integrity: Maintain integrity of the vapor-barrier jackets on pipe insulation,

and protect to prevent puncture or other damage.

5. Insulating Fittings: Cover valves, fittings and similar items in each piping system with an equivalent thickness and composition of insulation as applied to the adjoining pipe run. Install factory molded, precut or job fabricated units except where a specific form or type is indicated.

6. Penetrations: Extend piping insulation without interruption through walls,

floors and similar piping penetrations, except where otherwise indicated.

7. Pipe Hangers: Butt pipe insulation against pipe hanger insulation inserts. For hot pipes, apply a 3 inch wide vapor barrier tape or band over the butt joints. For cold piping apply a wet coat of the vapor barrier lap cement on butt joints and seal the joints with a 3 inch wide vapor barrier tape or band.

8. Pipe exposed to weather: Provide water tight stainless steel jackets to

protect piping located outside.

C. Ductwork Insulation

1. Insulation Surfaces: Install the insulation materials with smooth and even surfaces.

2. Cleaning and Drying: Clean and dry ductwork prior to insulating. Butt

insulation joints firmly together to form a complete and tight fit over the surfaces to be covered.

3. Integrity: Maintain the integrity of the vapor-barrier on ductwork insulation,

and protect it to prevent puncture and other damage.

4. Penetrations: Extend ductwork insulation without interruption through walls, floors and similar ductwork penetrations, except where otherwise indicated.

5. Corner Angles: Except for oven and hood exhaust duct insulation, install

corner angles on external corners of insulation on ductwork in exposed finished spaces before covering with the jacketing.

AARHIP 15080-10

D. Equipment Insulation:

1. Insulation Surfaces: Install the insulation materials with smooth and even

surfaces and on clean and dry surfaces. Redo poorly fitted joints. Do not use mastic or joint sealer as a filler for gapping joints and excessive voids resulting from poor workmanship.

2. Integrity: Maintain the integrity of the vapor-barrier on equipment

insulation and protect it to prevent puncture and other damage.

3. Hot Equipment: Do not apply insulation to equipment while they are hot.

4. Staggered Joint Method: Apply the insulation using the staggered joint method for both single and double layer construction, where feasible. Apply each layer of insulation separately.

5. Coating: Coat insulated surfaces with a layer of insulating cement, troweled

in a workmanlike manner, leaving a smooth continuous surface. Fill in scored block, seams, chipped edges and depressions, and cover over wire netting and joints with cement of sufficient thickness to remove surface irregularities.

6. Jackets: Cover the insulated surfaces with all-service jacketing neatly fitted

and firmly secured. Lap the seams at least 2 inches. Apply over vapor barrier where applicable.

7. Insulations Omitted: Do not insulate boiler manholes, handholes, cleanouts,

the ASME stamp, and the manufacturer's nameplate. Provide a neatly beveled edge at interruptions of insulation.

8. Removable Insulation: Provide removable insulation sections to cover parts

of equipment which must be opened periodically for maintenance, including metal vessel covers, fasteners, flanges, frames and accessories.

3.7 EXISTING INSULATION REPAIR

A. Repair: Repair damaged sections of existing mechanical insulation, both previously damaged or damaged during construction. Use insulation of same thickness as the existing insulation. Install a new jacket lapping and sealer over the existing insulation and paint to match the existing surface color.

3.8 PROTECTION AND REPLACEMENT

A. Replacement: Replace damaged insulation which cannot be satisfactorily repaired, including units with vapor barrier damage and moisture saturated units.

AARHIP 15080-11

B. Protection: Follow methods which are required for protection of the insulation Work during the remainder of construction period, to avoid damage and deterioration.

END OF SECTION

AARHIP 15080-12


AARHIP 15106-1

SECTION 15106

DUCTILE-IRON PIPE AND FITTINGS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing ductile-iron pipe, fittings and appurtenances, except soil pipe.

1. Provide ductile-iron pipe and fittings complete with all necessary jointing

facilities and materials, specials, adapters and other appurtenances required for installation in and completion of the pipelines to be constructed.

2. Provide flanged, plain end, rubber gasket, mechanical joint, or grooved-type

pipe joints of the types, sizes and classes shown or specified.

B. Related Work Specified In Other Sections Includes, But is Not Limited to, the Following:

1. Section 02512 - Disinfection 2. Section 02516 - Leakage Test 3. Section 15109 - Erecting and Jointing Interior Piping 4. Section 09900 - Painting

1.2 REFERENCES


1. AWWA C104/A21.4 - Cement-Mortar Lining for Ductile-Iron and Gray-Iron Pipe and Fittings for Water AWWA C104/A21.4

2. AWWA C105/A21.5 - Polyethylene Encasement for Ductile-Iron Piping

for Water and Other Liquids AWWA C105/A21.5

3. AWWA C110/A21.10 - Ductile-Iron and Gray-Iron Fittings 3 inches through 48 inches, for Water and Other Liquids AWWA C110/A21.10

4. AWWA C111/A21.11 - Rubber-Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings AWWA C111/A21.11

AARHIP 15106-2

5. AWWA C115/A21.15 - Flanged Ductile-Iron and Gray-Iron Pipe with Threaded Flanges AWWA C115/A21.15

6. AWWA C151/A 21.51 - Ductile-Iron Pipe, Centrifugally Cast in Metal

Molds or Sand-Lined Molds, for Water and Other Liquids AWWA C151/A21.51

7. AWWA C153/A21.53 - Ductile-Iron Compact Fittings, 3 inches through

12 inches, for Water and Other Liquids AWWA C153/A21.53

8. AWWA C606 - Grooved and Shouldered Type Joints AWWA

C606

9. ASTM A 307 - Specification for Carbon Steel bolts and Studs 1.3 SYSTEM DESCRIPTION

A. Design Standards: Provide ductile-iron pipe meeting the requirements of AWWA C 151/A21.51.

1. Place pipe in structures using a minimum wall thickness of Thickness

Class 52 for sizes up to and including 12-inch diameter and Thickness Class 51 for larger sizes, except provide Thickness Class 53 for pipe with threaded flanges or grooved-type joints.

2. Construct concrete encasement where shown.

1.4 SUBMITTALS


B. Submit the following shop drawings:

1. Pipe joints and fittings, sleeves, cleanouts and couplings. Where special

designs or fittings are required, show the Work in large detail and completely describe and dimension all items.

2. Fully dimensioned layout of pipes, fittings, couplings, sleeves, cleanouts,

expansion joints, harnessing, valves, supports, anchors and equipment. Label pipe size, materials, type, and class on drawings and include schedule.

3. Cross sections showing elevations of cleanouts, pipes, fittings, couplings,

sleeves, valves, supports, anchors and equipment.

4. Catalog data for pipe, fittings, couplings, sleeves, harnessing and cleanouts.

AARHIP 15106-3

C. Quality Controls: Submit certificates of compliance for pipe, fittings, gaskets,

lining, polyethylene encasement, coatings, specials, couplings, sleeves and cleanouts in accordance with this Section.


A. Deliver, store and handle all pipe, fittings and couplings as specified in Division 1 and Section 15109.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below. Manufacturers of equivalent product may be submitted.

1. Ductile-iron pipe and fittings.

a. American Cast Iron Pipe Company b. McWane Incorporated c. United States Pipe and Foundry

2. Ductile-iron retainer glands.

a. 3-inch through 24-inch diameter

(1) Nappco, Inc. Series 1246 (2) Ebba Iron, Inc., Series 100

b. larger than 24-inch diameter

(1) Ebba Iron, Inc., Megalug

3. Sleeve-type couplings.

a. 12-inches in diameter and smaller (1) Dresser Industries, Style 153 (2) Smith-Blair, Type 441 Omni Coupling System

b. larger than 12-inches in diameter

(1) Dresser Industries, Style 38 (2) Smith-Blair, Type 411

c. Gaskets.

(1) Dresser Plain Grade 27 (2) Smith-Blair 003

AARHIP 15106-4

4. Restrained push-on joints.

a. U.S. Pipe, TR Flex b. McWane Incorporated, Super-Lock c. American Cast Iron Pipe Company, Lok-Ring or Flex-Ring

5. Gaskets.

a. John Crane, Inc. b. Garlock Packing Company c. U.S. Rubber Company d. American Cast Iron Pipe Company e. United States Pipe and Foundry f. McWane Incorporated

6. Coatings and Linings

a. Kop-coat b. Tnemec c. American Cast Iron Pipe Company d. United States Pipe and Foundry

7. Grooved-type Couplings.

a. Victualic

2.2 MATERIALS

A. Fittings:

1. General: Provide all fittings meeting the requirements of ANSI A21.10, unless shown or specified otherwise. Fittings 14 inches and larger require a pressure rating of 150 psi, or as specified, whichever is greater.

2. Flanged: Where long radius flanged fittings and other flanged fittings not

covered in ANSI A21.10 are shown or indicated, provide items meeting the requirements of ANSI A21.10 and having laying lengths conforming to ANSI B16.1 for 125 pound American Standard fittings.

3. Nonflange: Where compact mechanical joint or rubber gasket joint fittings

are shown or indicated, provide items meeting the requirements of AWWA C153/A21.53.

AARHIP 15106-5

B. Grooved-Type Coupling Joints

1. General: Groove-type coupling joints consist of elements that remain jointed under pressure with no restraint from buttresses when the pipe is subjected to axial tension.

2. Requirements: Provide groove dimensions, couplings, gaskets, and bolts for

grooved-type joints meeting the requirements of AWWA C606.

3. Dimensional Characteristics: Provide pipe for grooved-type coupling joints which has radius cut grooves in accordance with Table 5(5a) of AWWA C606.

a. Provide the outside surface of the pipe between the groove and the

pipe free from deep pits or swells.

4. Working Pressure: Provide joints where the maximum joint working pressure of the coupling as specified by the manufacturer is not more than the test pressure of the pipeline and is not more than one-third of the ultimate strength of the coupling joint.

5. Unacceptable Joints: Do not accept the following:

a. Accept no grooved-type coupling joint unless it can be readily

disassembled after it is made up.

b. Accept no joints depending on stud bearing or friction to remain tight under tension.

C. Flanged Joints

1. Threaded Flanges: Provide threaded, ductile-iron, long hub flanges meeting

the requirements of AWWA C115/A21.15.

a. Screw flanges pipe on the threaded end of the pipe in the shop.

b. Reface the face of the flange and the end of the pipe together.

c. Design the flanges to prevent corrosion of the threads from the outside and to prevent leakage through the pipe threads.

2. Facing and Drilling: Provide flanges faced and drilled to the requirements

of AWWA C115/A21.15, unless special drilling is called for or required. Face flange accurately at right angles to the pipe axis. Drill flanges smooth and true, and cover machined faces with zinc dust and tallow or equivalent material.

AARHIP 15106-6

3. Taps: Tap flanges where tap or stud bolts are required.

4. Fasteners: Provide bolts, stud bolts, and nuts meeting the requirements of ASTM A 307, Grade B.

5. Gaskets: Provide full-face gaskets for flanged joints on 12-inch diameter

and smaller pipe and gaskets of the ring type for flanged joints on larger pipe. Provide flange gaskets meeting the requirements of AWWA C115/A21.15 except make gaskets for gas lines with neoprene and aramid.

D. Rubber Gasket Joints

1. Provide mechanical joints and push-on type joints meeting the requirements

of AWWA C111/A21.11.

E. Harnessing

1. General: For ductile-iron pipe and fittings with mechanical joints that require harnessing, provide ductile-iron mechanical joint retainer glands.

2. Joint Assemblies: Design the joint assemblies to resist pullout of the joints

at the test pressures specified.

F. Wall Pipes and Sleeves

1. Wall Pipes

a. Where wall pipes are shown or specified, provide ductile iron wall pipes that meet the requirements of AWWA C110/A21.10 with end connections that are 1) of the types shown and 2) flush with the surfaces of the walls or floors. Unless otherwise shown or specified, provide wall pipes with intermediate collars located at the centers of the walls or floors.

2. Sleeves

a. Where pipes pass through exterior walls or floors or wetted interior

walls or floors of structures and where wall pipes are not to be provided, provide ductile-iron sleeves meeting the requirements of AWWA C110/A21.10, with ends that are flush with the wall or floor surfaces and with intermediate collars located at the centers of the walls or floors.

b. Where pipes pass through non-wetted interior walls or floors and

where wall pipes are not to be provided, provide ductile-iron sleeves meeting the requirements of AWWA C110/A21.10; steel pipe sleeves meeting the requirements of Section 15107 or as shown or specified

AARHIP 15106-7

otherwise. Provide sleeves with ends that are flush with the wall or floor surfaces. Where shown or specified, provide intermediate collars located at the centers of the walls or floors.

c. Provide sleeves having large enough diameters to accommodate the

passage of pipe joints, if required.

d. Where shown or specified, provide modular, mechanical sleeve seals, meeting the requirements in Section 15108, in the annular spaces between pipes and sleeves. In all other locations, caulk the annular spaces between pipes and sleeves with caulk meeting the requirements in Section 07900.

G. Sleeve-Type Couplings

1. General: Manufacture middle rings to the following sizes.

a. At least 1/4 inch thick and 5 inches wide for 8-inch diameter and

smaller pipe.

b. 3/8 inch thick and 7 inches wide for 10- through 30-inch diameter pipe.

c. 1/2 inch thick and 10 inches wide for 36-inch diameter and larger

pipe.

2. Design: Manufacture middle rings without a pipe stop. Provide follower rings of proper thickness. Provide molded rubber gaskets.

H. Cleanouts

1. General: Provide cleanouts where shown or specified.

2. Size: Provide not less than 6 inch diameter cleanout openings for pipe 8

inches in diameter or larger. Provide cleanout openings for pipe 6 inches in diameter or smaller of the same diameter as the pipe.

3. Cleanout Covers: Provide cleanout covers which are blind flanges meeting

the requirements of AWWA C110/A21.10, except where conformation is required with the inside curvature of the pipeline, in which case the covers are flanged plugs of proper shape with American Standard flange drilling.

a. Fasten covers by means of steel studs and bronze nuts. Drill and tap

covers for a 1-1/2-inch diameter pipe connection.

4. Plugs: Equip the flange of conformed plugs with a dowel or other suitable means to provide proper setting.

AARHIP 15106-8

I. Connecting Pieces, and Special Fittings

1. Connecting Pieces: Provide connecting pieces, such as bell and bell, bell

and spigot, bell and flange, flange and flange, flange and spigot, and flange and flare, meeting the requirements of AWWA C110/A21.10.

2. Special Fittings : Provide special fittings, where required, of an approved

design that have the same diameters and thicknesses as standard fittings, unless otherwise required, but their laying lengths and other functional dimensions are determined by their positions in the pipeline and by the particular piping materials to which they connect.

J. Temporary Bulkheads: Provide temporary bulkheads at the ends of pipeline sections where adjoining pipelines have not been completed and are not ready to connect.

1. Removal: Remove all temporary bulkheads when they are no longer

needed.

K. Coatings and Linings

1. Cement Lining: Provide all ductile-iron pipe and fittings having a cement-mortar lining not less than standard thickness meeting the requirements of ANSI A21.4, unless shown or specified otherwise.

2. Exterior Primer: Shop coat ductile-iron pipe and fittings on the outside with

one coat of Kop-Coat 340 Gold Primer, 2.0 mils minimum dry thickness, for use in exposed locations, such as inside buildings, where finish painting or insulating is required.

3. Asphaltic Coating: Coat pipe for use not exposed to view with the standard

asphaltic outside coating specified in AWWA C151/A21.51.

4. Encased Pipe: Do not coat or paint the outside of fittings and pipe which are to be encased in concrete where watertightness is to be obtained.

5. Labels: Paint the weight and class designation conspicuously in white on

the outside of each pipe, fitting, and special casting after the shop coat has hardened.

6. Grooved-type Couplings: Shop coat couplings with Kop-Coat 340 Gold

Primer, 2.0 mils minimum dry thickness.

AARHIP 15106-9

7. Flange Joints: Immediately after facing and drilling, coat the back of the flanges and bolt holes with asphaltic coating meeting the requirements of AWWA C151/A21.51, Section 51-8.1.

8. Sleeve-type Couplings:

a. Shop coat couplings with Dresser Industries Red D or Smith-Blair

Standard Blue shop coat.

b. Provide an additional shop coat of Kop-Coat Hi-Guard epoxy or Tnemec Pota-pox on the interior of the middle ring.

c. Finish coat exterior of sleeve-type coupling after installation with the

same coating specified in Section 09900 for the pipeline of which it is a part.

d. Ensure shop coats and finish coats are compatible.

L. Drip Pans: Provide drip pans constructed of 16-gauge Type 304 stainless steel.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all ductile-iron pipe and fittings in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1 and Section 15109.

B. Insulation: Where shown or specified provide insulation, as specified in Section

15080, for pipes and fittings that are exposed to atmosphere after installation.

C. Drip Pans: Provide drip pans under all ductile-iron pipelines installed over electrical equipment and motors and properly connect to the drainage system with 3/4-inch red brass pipe. Make leak tight connection between the drip pan and the drain pipe. Pitch pans uniformly toward the drain pipe not less than 1/8-inch per lineal foot.

3.2 LEAKAGE TESTING

A. Cleaning: Flush clean and test all pipes after installation.

B. Testing: Test pipes for leaks and repair or tighten as required.

C. Procedures: Conduct tests in accordance with Section 02516.

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3.3 DISINFECTION

A. Disinfect all pipelines that are to carry potable water before they are placed into service as specified in Section 02512.

3.4 SCHEDULES

A. Refer to the Schedule contained in Section 15109 Erecting and Jointing Interior Pipe for information on the piping that is to be constructed using the pipe materials and methods specified herein.

END OF SECTION

AARHIP 15107-1

SECTION 15107

STEEL PIPE AND FITTINGS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing steel pipe and fittings, except for steel pipe in buried applications, as follows:

1. Steel pipe and fittings include all fabricated and wrought steel pipe fittings.

Use steel pipe only where specifically shown or specified. Provide pipe of the flanged, screwed, welded, grooved-type coupling joint or plain end type of the sizes and thicknesses as shown or specified.


Following:

1. Section 02512 - Disinfection 2. Section 02516 - Leakage Test 3. Section 09900 - Painting 4. Section 15080 - Mechanical Insulation 5. Section 15106 - Ductile Iron Pipe and Fittings 6. Section 15108 - Miscellaneous Pipe and Fittings 7. Section 15109 - Erecting and Jointing Interior Piping

1.2 REFERENCES


1. AWWA C200 - Steel Water Pipe 6 In. and Larger

2. AWWA C205 - Cement-Mortar Protective Lining and Coating for Steel Water Pipe - 4 In. and Larger - Shop Applied

3. AWWA C207 - Steel Pipe Flanges for Waterworks Service - Sizes 4

In. Through 144 In.

4. AWWA C208 - Dimensions for Fabricated Steel Water Pipe Fittings

5. AWWA C210 - Liquid Epoxy Coating Systems for Interior and Exterior of Steel Water Pipelines

AARHIP 15107-2

6. AWWA M11 - Steel Water Pipe: A Guide for Design and Installation

7. ASTM A 47 - Specification for Ferritic Malleable Iron Castings

8. ASTM A 53 - Specification for Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless

9. ASTM A 181/A181M - Specification for Carbon Steel Forgings, for General Purpose Piping

10. ASTM A 197 - Specification for Cupola Malleable Iron

11. ASTM A 283/A283M - Specification for Low and Intermediate Tensile

Strength Carbon Steel Plates, Shapes and Bars

12. ASTM A 307 - Specification for Carbon Steel Bolts and Studs, 50,000 psi Tensile

13. ASTM A 536 - Specification for Ductile-Iron Castings

14. ASTM D 2000 - Classification System for Rubber Products in

Automotive Applications

15. ASME B16.1 - Cast Iron Flanges and Flanged Fittings

16. ASME B16.21 - Non-metallic Gaskets for Pipe Flanges

17. ASME B16.3 - Malleable Iron Threaded Fittings

18. ASME B16.5 - Steel Pipe Flanges and Flanged Fittings: NPS 1/2 through 24 with Appendixes

19. ASME B16.9 - Factory-Made Wrought Steel Butt welding Fittings

20. ASME B36.10 - Welded and Seamless Wrought Steel Pipe


A. Design Standards: Use dimensions for steel pipe in accordance with ASME B36.10, unless specified otherwise.

1. Provide pipe of 6-inch diameter and smaller not less than Schedule 40.

2. Provide pipe of 8- through 16-inch diameter not less than Schedule 30.

AARHIP 15107-3

3. Provide pipe 18- through 30-inch diameter with a wall thickness of not less than 3/8 inch.

4. Provide pipe 36 inches in diameter and larger with a wall thickness of not

less than 1/2 inch.

B. Small Steel Pipe: Provide steel pipe less than 30 inches in diameter meeting the requirements of ASTM A 53.

C. Large Steel Pipe: Provide steel pipe 30 inches in diameter and larger meeting the

requirements of AWWA C200 and fabricated of plates meeting the requirements of ASTM A 283/A283 Grade D.

1. Fabricate pipe with straight-seam welds or spiral-seam welds.

2. Provide welds with a smooth uniform cross section to provide pipe with a

neat external appearance.

3. Fabricate the pipe with not more than two longitudinal seams and with girth seams not less than 7 feet apart.

4. The pipe and fitting diameters of 30 inches and larger, as shown or

specified, are inside diameters. 1.4 SUBMITTALS


B. Submit the following shop drawings:

1. Flanged, screwed, welding and mechanical coupling fittings and pipe,

couplings, harnessing and special fittings. When special designs or fittings are required, show the Work in large detail and completely describe and dimension the special or fitting.

2. Fully Dimensioned layout of pipe, fittings, couplings, sleeves, expansion

joints, supports, anchors, harnessing, valves and equipment. Label pipe size, type and materials on drawing and include schedule.

3. Cross sections showing elevation of pipe, fittings, sleeves, couplings,

supports, anchors, harnessing, valves and equipment.

4. Catalog data for pipe, couplings, harnessing and fittings.

AARHIP 15107-4

C. Quality Control: Submit the following certifications:

1. Certificate of compliance for pipe, fittings, couplings, sleeves, cleanouts and harnessing.

2. Welders' certifications.


A. Utilize certified welders, having current certificates conforming to the requirements of the ASME code to perform all welding on steel pipelines.


A. Deliver, store and handle pipe, fittings and couplings as specified in Division 1 and Section 15109.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Steel pipe and fittings

a. U.S. Steel b. L.B. Foster c. Northwest Pipe Company

2. Dielectric insulating fitting

a. Walter Vallett Company b. EPCO Inc.

3. Seamless steel welded fittings

a. Taylor Forge and Pipe Works b. Tube-Turns c. Walworth

4. Gaskets for flanged joints

a. Garlock Packing Company b. Crane Company c. U.S. Rubber Company

AARHIP 15107-5

5. Sleeve-Type Couplings

a. Dresser, Style 38 with Grade 27 gasket b. Smith-Blair, Inc., Type 411 with Type 003 gasket

6. Grooved-Type Couplings

a. Victaulic

7. Weldolets and Threadolets

a. Bonney Forge and Tool Works

8. Expansion Joints (Short Type)

a. Anamet, Inc.

9. Coatings

a. Kop-Coat b. Tnemec

2.2 MATERIALS

A. Fittings

1. Manufacture fittings for steel pipe to standard dimensions, suitable for the pressures specified. Provide steel fittings of the same or heavier wall thickness as the pipe of which they are a part.

a. Provide fittings used in pipelines 2-inch diameter or smaller of the

screwed pattern.

b. Provide fittings used in pipelines 2.5-inch diameter or larger of the seamless steel welded type or flanged type, except as shown or specified otherwise.

2. Unions: Use screwed unions on all steel pipelines 2-inch diameter and

smaller and flanged unions on pipelines 2.5-inch diameter and larger.

a. Provide an adequate number of unions of the screwed or flanged type in each main pipeline and each branch to facilitate the dismantling or removal of any branch line or any part thereof or the section of the main pipe to which it connects, without disturbing adjacent branch lines or their related main pipeline.

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3. Screwed Fittings: Provide malleable iron ASME B16.3 screwed fittings where shown or specified for steel pipelines meeting the requirements of ASTM A 197. Provide unions with brass or iron seats.

4. Welding Fittings: Provide butt welding fittings meeting the requirements of

ASME B16.9.

a. Provide outlets for welded connections that are made with Weldolets of the butt welding type.

b. Provide outlets for threaded connections that are made with

Threadolets.

5. Fabricated Steel Fittings: Unless otherwise shown, provide steel flange fittings meeting the requirements of ASME B16.5 for 150-pound standard, except provide flanges that are plain faced.

a. Fabricate steel fittings from the same plates as the pipeline of which

they are a part and meet the requirements of AWWA C208, unless otherwise shown or specified.

b. Provide fittings and elbows that are made of pipe segments or

preformed plates.

c. Provide reducers and increasers with the same laying length as American Standard Class 125.

d. Provide fabricated steel fittings with plain ends or welded flanges.

e. Provide tees, wyes, laterals and outlets reinforced in accordance with

AWWA M11.

B. Flanges and Flanged Joints

1. Flanges: Unless otherwise shown, provide all flanges for steel pipe, except blind flanges, of the slip-on welding type with hubs meeting the requirements of AWWA C207 Class D and made of metal meeting the requirements of ASTM A 181 Class 60

a. Attach the flanges to the barrel of the pipe with two continuous fillet

welds.

b. Provide plain faced blind flanges in accordance with ASME B16.5 Class 150.

AARHIP 15107-7

2. Flanged Joints: Make flanged joints with bolts or bolt studs with a nut on each end.

a. Provide bolts, stud bolts, and nuts meeting the requirements of ASTM

A 307 Grade B and ASME B16.1.

b. Provide bolts which have a 1/4-inch projection beyond the nut when joint with gasket is assembled.

3. Gaskets: Provide rubber gaskets for flanged joints meeting the requirements

of AWWA C207 as modified and supplemented herein. Provide 1/8-inch thick gaskets. Provide full face gaskets for pipe sizes 12 inches in diameter and smaller. Provide ring type gaskets for pipe larger than 12 inches in diameter.

4. Insulation: Provide insulated flanged joints as required. Provide flange

insulation kits to include flange insulating gasket, flange bolt insulating sleeves, and flange bolt insulating washers.

C. Sleeve-Type Coupling

1. General: Provide couplings with rolled steel followers, steel sleeves, rubber

compound gasket and high strength bolts and nuts.

2. Gasket Material: Use gaskets that are not affected by the fluid service of the pipeline.

3. Pressure Rating: Provide couplings with a minimum pressure rating equal to

the test pressure of the pipeline.

4. Middle Rings: Provide middle rings without a pipe stop, and at least 1/4-inch thick and 5 inches wide for 8-inch and smaller pipe, 3/8-inch thick and 7 inches wide for 10-inch through 30-inch pipe, and 1/2 inch thick and 10 inches wide for 36-inch and larger pipe, with follower rings of the proper thickness.

5. Harnessing: Unless shown or specified otherwise, design, furnish and install

harnessing for sleeve-type couplings in accordance with the applicable portions of AWWA Manual M11, Chapter 13 -Supplementary Design Data and Details, Section 13.10 - Joint Harnesses. Furnish harnessing having a design pressure equal to or greater than the test pressure of the pipeline on which it is installed.

D. Grooved-Type Coupling Joints

1. General: Where grooved-type coupling joints are shown or specified,

provide a system consisting of elements that remain jointed under pressure

AARHIP 15107-8

with no restraint from buttresses when the pipe is subjected to axial tension. Do not provide systems which cannot be readily disassembled after make up or which depend on stud bearing or friction to remain tight under tension.

2. Construction: Manufacture pipe for grooved-type coupling joints with

square cut grooves in accordance with the coupling manufacturer's specification. Provide couplings of the grooved mechanical type which engages the grooved pipe ends and encases a rubber gasket which bridges the pipe ends to create a seal. Provide couplings that are cast in two or more parts secured together when assembled with nuts and bolts. Provide coupling segments of malleable iron conforming to ASTM A 47 or ductile iron conforming to ASTM A 536.

3. Joint Pressure: Do not exceed the maximum joint working pressure of the

coupling as specified by the manufacturer nor allow it to be more than one-third of the ultimate strength of the coupling joint.

4. Gasket: Provide a rubber compound gasket not affected by the fluid service

of the pipeline and with properties conforming to ASTM D 2000.

5. Upon completion of work, the Contractor shall provide to the City one new grooving tool with all necessary accessories.

E. Expansion

1. General: Make ample provisions for flexibility in all pipelines to

compensate for expansion.

2. Expansion Device: Provide adequate expansion devices to allow the lines to expand and contract freely without damage to any part of the piping system.

a. Provide expansion devices in the form of expansion joints, expansion

couplings, swivel or swing joints or pipe bends, and include such anchors as may be shown, specified or required to make the devices effective.

b. If expansion devices are not required, fabricate all runs of pipe subject

to expansion shorter than their theoretical length to the extent that there is freedom to expand without increasing the stresses imposed when cold.

3. Expansion Joints: Provide expansion joints that are of the single short type

and are designed for the specified test pressures. Provide expansion joints with adequate tie rods to limit the axial movement at the specified test pressures, except where noted or specified otherwise.

AARHIP 15107-9

F. Wall Pipes and Sleeves

1. Wall Pipes

a. Where wall pipes are shown or specified, provide ductile iron wall pipes that meet the requirements of AWWA C110/A21.10 with end connections that are 1) of the type shown and 2) flush with the surfaces of the walls or floors. Unless otherwise shown or specified, provide wall pipes with intermediate collars located at the centers of the walls or floors.

2. Sleeves


walls or floors of structures and where wall pipes are not to be provided, provide ductile-iron sleeves meeting the requirements of AWWA C110/A21.10 with ends that are flush with the wall or floor surfaces and with intermediate collars located at the centers of the walls or floors.


where wall pipes are not to be provided, provide ductile-iron sleeves meeting the requirements of AWWA C110/A21.10; steel pipe sleeves meeting the requirements of this Section or as shown or specified otherwise. Provide sleeves with ends that are flush with the wall or floor surfaces. Where shown or specified, provide intermediate collars located at the centers of the walls or floors.

c. Provide sleeves having large enough diameters to accommodate the

passage of pipe joints, if required.

d. Provide steel sleeves 12 inches in diameter and larger with a minimum wall thickness of 0.375 inch. For steel sleeves that are smaller than 12 inches in diameter provide Schedule 40 or thicker sleeves. Where shown or specified, provide steel sleeves with intermediate collars located at the centers of the walls or floors. Provide collars having outside diameters four inches greater than the outside diameters of the sleeves, fabricated from steel plates having minimum thickness equal to the sleeve thickness and double welded to the sleeves.

e. Where shown or specified, provide modular, mechanical sleeve seals,

meeting the requirements in Section 15108, in the annular spaces between pipes and sleeves. In all other locations, caulk the annular spaces between pipes and sleeve with caulk meeting the requirements in Section 07900.

AARHIP 15107-10

G. Cleanouts

1. Where shown or specified provide cleanouts as specified in Section 15106.

H. Coatings and Linings

1. General: Line and coat steel pipelines in accordance with the piping schedule.

a. Coat all bolts, nuts, couplings and the like after the joint has been

made.

b. Paint in accordance with Section 09900.

c. Do not paint the outside of pipe and fittings that are to be concrete encased.

2. Liquid Epoxy: Where liquid epoxy lining and coating is shown, specified or

required, line and coat in accordance with the requirements of AWWA C210.

3. Cement-Mortar Lining: Provide cement and mortar lining in accordance

with the requirements of AWWA C205 where shown or specified.

4. Galvanizing: Provide galvanizing in accordance with ASTM A 53 where shown or specified.

5. Sleeve-type Couplings: Shop coat all surfaces with Dresser Red D, Smith-

Blair Standard Blue Shop-coat, or equal nontoxic material compatible with the finish coatings specified. Give the inside coating of the middle ring an additional shop coat of Kop-Coat Hi-Guard epoxy or Tnemec Pota-pox. Finish coat as specified in Section 09900 for the pipeline of which it is a part.

6. Groove-type Couplings: Shop coat couplings as specified in Section 09900

for the pipelines of which the coupling is a part.

I. Dielectric Insulation

1. Provide dielectric insulating joints or fittings at connections between exterior piping and interior piping.

J. Drip Pans: Provide drip pans constructed of 16-gauge Type 304 stainless steel

AARHIP 15107-11

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all steel pipe and fittings in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1 and Section 15109.

B. Insulation: Where shown or specified provide insulation, as specified in Section

15080, for pipes and fittings that are exposed to atmosphere after installation.

C. Reducing Fittings: Use ample fittings for all changes in pipe size. Do not use bushings.

D. Drip Pans: Provide drip pans under all steel pipelines installed over electrical

equipment and motors and properly connect to the drainage system with 3/4-inch red brass pipe. Make leak tight connection between the drip pan and the drain pipe. Pitch pans uniformly toward the drain pipe not less than 1/8-inch per lineal foot.

3.2 LEAKAGE TESTING

A. Cleaning: Flush clean and test all pipes after installation.

B. Testing: Test pipes for leaks and repair or tighten as required.

C. Procedures: Conduct tests in accordance with Section 02516. 3.3 DISINFECTION

A. Disinfect all pipelines that are to carry potable water before they are placed into service as specified in Section 02512.

3.4 SCHEDULES

A. Refer to the Schedule contained in Section 15109 Erecting and Jointing Interior Pipe for information on the piping that is to be constructed using the pipe materials and methods specified herein.

END OF SECTION

AARHIP 15107-12

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AARHIP 15108-1

SECTION 15108

MISCELLANEOUS PIPE AND FITTINGS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing miscellaneous pipe and fittings as indicated. Miscellaneous pipe and fittings include all aluminum, copper, brass, plastic, cast-iron soil and lined steel pipe and fittings.


Following:

1. Section 02500 - Laying and Jointing Buried Pipelines 2. Section 02512 - Disinfection 3. Section 02516 - Leakage Tests 4. Section 09900 - Painting 5. Section 15106 - Ductile Iron Pipe and Fittings 6. Section 15107 - Steel Pipe and Fittings 7. Section 15109 - Erecting and Jointing Interior Piping 8. Section 15183 - Hydronic Piping Valves and Specialties 9. Section 15184 - Refrigeration Piping and Specialties 10. Section 15405 - Plumbing Piping and Fittings

1.2 REFERENCES


1. ASTM A 74 - Specification for Cast Iron Soil Pipe and Fittings

2. ASTM B 26/B26M - Aluminum Alloy Sand Castings

3. ASTM B 32 - Specification for Solder Metal

4. ASTM B 42 - Specification for Seamless Copper Pipe, Standard Sizes

5. ASTM B 43 - Specification for Seamless Red Brass Pipe,

Standard Sizes

6. ASTM B 108 - Specification for Aluminum Alloy Permanent Mold Castings

AARHIP 15108-2

7. ASTM B 241 - Specification for Aluminum and Aluminum Alloy Seamless Pipe and Seamless Extruded Tube

8. ASTM C 564 - Specification for Rubber Gaskets for Cast Iron

Soil Pipe and Fittings

9. ASTM D 1784 - Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds

10. ASTM D 1785 - Specification for Poly (Vinyl Chloride) (PVC)

Plastic Pipe, Schedules 40, 80, and 120

11. ASTM D 2464 - Specification for Threaded Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80

12. ASTM D 2564 - Specification for Solvent Cements for Poly

(Vinyl Chloride) (PVC) Plastic Piping Systems

13. ASTM D 2855 - Recommended Practice for Making Solvent-Cemented Joints with Poly (Vinyl Chloride) (PVC) Pipe and Fittings

14. ASTM F 491 - Specification for Poly (Vinylidene Fluoride)

(PVDF) Plastic-Lined Ferrous Metal Pipe and Fittings

15. ASTM F 492 - Specification for Propylene and Polypropylene

(PP) Plastic-Lined Ferrous Metal Pipe and Fittings

16. ASTM F 599 - Specification for Poly (Vinylidene Chloride)

(PVDC) Plastic-Lined Ferrous Metal Pipe and Fittings

17. ASME B1.20.1 - Screw Threads - Pipe Threads, General Purpose

(Inch)

18. ASME B16.15 - Cast Bronze Threaded Fittings, Classes 125 and 250 (Includes Revisions Service)

19. ASME B16.18 - Cast Copper Alloy Solder Joint Pressure Fittings

(Includes Revision Service)

AARHIP 15108-3

20. ASME B16.22 - Wrought Copper and Copper Alloy Solder-Joint Pressure Fitting (Includes Revision Service)

21. ASME - Boiler and Pressure Vessel Codes, Section IX -

Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators.

22. AWWA C151/A21.51 - Ductile-Iron Pipe Centrifugally Cast in Metal

Molds or Sand-Lined Molds, for Water or Other Liquids

23. CISPI 301 - Hubless Cast Iron Sanitary System

24. CISPI 310 - Hubless Cast Iron Soil Pipe and Fittings for

Sanitary and Storm Drain, Waste, and Vent Piping Applications

25. AWS A5.8 - Brazing Filler Metal

1.3 SUBMITTALS


B. Shop Drawings: Submit the following Shop Drawings.

1. Submit complete detailed shop drawings in conformance with the specified

requirements.

2. Include drawings that show the piping layouts and schedules of all pipe, fittings, valves, expansion joints, flexible couplings, hangers, supports and other appurtenances.

3. When any work is of special design show in large detail and completely

describe and dimension.

4. Welders Certificate: Include welders’ certification with ASME/Section IX. 1.4 DELIVERY, STORAGE AND HANDLING

A. Deliver, store and handle all products and materials as specified in Division 1 (and as follows :)

AARHIP 15108-4

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Pipe and Fittings:

a. Aluminum Pipe and Fittings

(1) ALCOA, Pittsburgh, PA (2) ALCAN Aluminum Corp., Cleveland, OH

b. Brass Pipe and Fittings

(1) Metalloy Industries, Inc., Ft. Lauderdale, FL (2) Nibco, Elkhart, IN

c. Cast-Iron Soil Pipe and Fittings

(1) U.S. Pipe and Foundry Co., Birmingham, AL (2) Tyler Pipe Industries, Tyler, TX (3) Charlotte Pipe and Foundry, Charlotte, NC

d. Copper pipe and Fittings

(1) Mueller Industries, Inc., Wichita, KS (2) Nibco, Elkhart, IN

e. PVC and CPVC Pipe and Fittings

(1) United States Plastic Corp., Lima, Ohio (2) Harvel Plastics Inc., Easton, Pennsylvania (3) Spears Manufacturing Company, Sylmar, California

f. Lined Steel Pipe and Fittings

(1) Polyvinylidene Chloride (PVDC) lined pipe and fittings

(a) Ameriform Manufacturing, Inc., Milton, KY

(2) Polypropylene-lined pipe and fittings

(a) Performance Plastics Products, Houston, TX (b) Crane Resistoflex Co., Bay City, MI

AARHIP 15108-5

(3) Polyvinylidene fluoride (PVDF or Kynar®) lined pipe and fittings

(a) Performance Plastics Products, Houston, TX (b) Crane Resistoflex Co., Bay City, MI

g. Wall Sleeve Annular Seals

(1) Thunderline Corp. (Link-Seal), Belleville, MI

2. Dielectric Insulating Fittings:

a. Walter Vallett Co., Detroit, MI b. EPCO, Inc., Cleveland, OH

2.2 MATERIALS

A. Brass Pipe and Fittings

1. Pipe: Provide red brass pipe that meets the requirements of ASTM B 43.

a. Provide pipe sizes, wall thicknesses and dimensions that meet the ASTM B 43 Table 2 requirements for regular pipe.

2. Fittings: Provide brass pipe fittings that meet the ASME B16.15

requirements.

a. Provide fittings rated for steam working pressures up to 125 psig.

b. Provide unions made entirely of brass or bronze.

c. Provide screwed type joints with clean cut, tapered and smooth threads that meet ASME B1.20.1 requirements.

3. Finish: Provide piping with a rough finish, unless otherwise specified.

B. Cast-Iron Soil Pipe and Fittings

1. Pipe and Fittings: Provide service weight, hub and spigot, cast-iron soil pipe

and fittings meeting the requirements of ASTM A 74 or hubless cast iron soil pipe and fittings meeting the requirements of CISPI 301. Do not use hubless pipe and joints for buried pipe.

2. Protective Coatings: Provide interior protective coatings (linings) and

exterior protective coatings for pipe and fittings in the finished work as follows and as indicated in the piping schedules:

AARHIP 15108-6

a. For pipe and fittings not exposed in the finished work, provide an interior bituminous lining and an exterior bituminous coating that meet AWWA C151/A21.51 requirements.

b. For pipe and fittings exposed in the finished work, provide an interior

bituminous lining that meets AWWA C151/A21.51 requirements.

(1) If the pipe schedules indicate that the pipe exterior is to be painted, paint in accordance with the requirements in Section 09900.

(2) If the pipe schedules indicate that the pipe exterior is to have a

bituminous coating, coat the pipe in accordance with the requirements in AWWA C151/A21.51.

3. Joints: Provide lead and oakum joints or neoprene gasket, compression type

joints in accordance with ASTM C 564 for hub and spigot pipe. Consult the piping schedules. Provide hubless couplings for hubless pipe. Compose hubless couplings of a stainless steel shield, clamp assembly and an elastomeric sealing sleeve conforming to CISPI 310.

4. Cleanouts: Provide cleanouts where shown or specified, and meeting the

requirements of Section 15405, unless otherwise specified.

C. Copper Pipe and Fittings

1. Small Copper Piping: For copper pipe 3 inches in diameter and smaller, provide Type K hard drawn copper tubing that meets ASTM B 88 requirements.

a. Fittings: Provide ASME B16.18, cast copper alloy or ASME B16.22

wrought copper and copper alloy fittings.

b. Joints: Threaded or ASTM B 32 lead-free soldered joints.

c. Joints: Brazed joints, AWS A5.8 BCUP silver/phosphorus/copper alloy with melting range 1190-1480 degrees F.

2. Large Copper Piping: For copper pipe larger than 3 inches in diameter,

provide regular seamless copper pipe that meets the ASTM B 42 requirements.

a. Fittings: Provide solder type fittings of the same material as the pipe.

b. Joints: Use threaded or brazed joints.

AARHIP 15108-7

3. Potable Water Piping: Use ASTM B 32 alloy Grade 95TA (95 percent tin and 5 percent antimony) solder for piping carrying potable water.

4. Unacceptable Uses: Do not use copper pipe with soldered joints for

transporting fuel oil or other flammable or toxic liquids inside buildings.

D. Polyvinyl Chloride (PVC) and Chlorinated Polyvinyl Chloride (CPVC) Pipe and Fittings

1. Pipe and Fittings: Provide PVC pipe and fittings that are Schedule 80 and

meet the requirements of ASTM D 1784 Class 12454-B and ASTM D 1785 unless otherwise shown or specified. Provide CPVC pipe and fittings that are Schedule 80 and meet the requirements of ASTM D 1784 Class 23447-B and ASTM D 1785, unless otherwise shown.

2. Joints: Provide ASTM D 2855 solvent welded joints utilizing ASTM D

2564 solvent cement or ASTM D 2464 threaded joints, as indicated in the piping schedules.

E. Wall Pipes and Sleeves for Miscellaneous Pipe and Fittings

1. Wall Pipes

a. Where wall pipes are shown or specified, provide ductile iron wall

pipes that meet the requirements of AWWA C110/A21.10 with end connections that are 1) of the types shown and 2) flush with the surfaces of the walls or floors. Unless otherwise shown or specified, provide wall pipes with intermediate collars located at the centers of the walls or floors.

2. Sleeves


walls or floors of structures and where wall pipes are not to be provided, provide ductile-iron sleeves meeting the requirements of AWWA C110/A21.10 with ends that are flush with the wall or floor surfaces and with intermediate collars located at the centers of the walls or floors.


where wall pipes are not to be provided, provide ductile-iron sleeves meeting the requirements of AWWA C110/A21.10; steel pipe sleeves meeting the requirements of Section 15107 or as shown or specified otherwise. Provide sleeves with ends flush with the wall or floor surfaces. Where shown or specified, provide intermediate collars located at the centers of the walls or floors.

AARHIP 15108-8

c. Provide sleeves having large enough diameters to accommodate the passage of pipe joints, if required.

d. HDPE Sleeves: Where shown or specified, provide molded HDPE

sleeves as manufactured by the Thunderline Corporation, or approved equal, with integrally formed intermediate collars or water stops.

e. Where shown or specified, provide modular, mechanical sleeve seals,

meeting the requirements of this Section, in the annular spaces between pipes and sleeves. In all other locations, caulk the annular spaces between pipes and sleeves with caulk meeting the requirements in Section 07900.

F. Modular, Mechanical Sleeve Seals: Provide modular, mechanical type seals

consisting of interlocking, synthetic-rubber links shaped to continuously fill the annular space between the pipe and the sleeve. Provide an elastomeric sealing element that is of the size, quantity, type and material that the manufacturer recommends for the intended service and that will provide an effective hydraulic seal. Provide stainless steel bolts and nuts.

G. Supports and Anchors: Provide all pipelines with supporting and anchoring

devices as specified in Section 15109. Provide drip pan hangers and supports as specified for sheet metal ductwork in Section 15810.

H. Drip Pans: Provide drip pans constructed of 16-gauge Type 304 stainless steel.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all miscellaneous pipe and fittings in accordance with the specifications contained herein and in Sections 02500 and 15109 and in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Connections Between Dissimilar Metals: Where connections are to be made

between pipelines or equipment of corrosion causing dissimilar metals make the connections using dielectric insulating couplings, unions or other approved dielectric insulating devices.

C. Couplings: Only use couplings to join standard lengths of pipe and as required to

complete a straight run of pipe. Do not use couplings to join random lengths of pipe and cuttings from standard lengths.

D. Reducing Fittings: Use reducing fittings for all changes in pipe size. Do not use

bushings.

AARHIP 15108-9

E. Pipe Flexibility: Make ample provisions for flexibility in all pipelines in

accordance with Section 02500 for buried pipelines and Section 15109 for interior pipelines.

F. Drip Pans: Provide drip pans under all metallic pipelines installed over electrical

equipment and motors and properly connect to the drainage system with 3/4-inch red brass pipe. Make leaktight connection between the drip pan and the drain pipe. Pitch pans uniformly toward the drain pipe not less than 1/8-inch per lineal foot.


A. Cleaning: Flush all process and potable water pipelines with clean water.

B. Leakage: Test pipes at the pressures specified in the piping schedules located in Section 02500 and Section 15109.

C. Paint in accordance with Section 09900, unless otherwise specified.

3.3 DISINFECTION

A. Disinfect all potable water pipelines in accordance with Section 02512. 3.4 SCHEDULES

A. Refer to the schedules contained in Section 02500 Laying and Jointing Buried Pipelines and Section 15109 Erecting and Jointing Interior Piping for information on the piping that is to be constructed using the pipe materials and methods specified herein.

END OF SECTION

AARHIP 15108-10


AARHIP 15109-1

SECTION 15109

ERECTING AND JOINTING INTERIOR AND EXPOSED EXTERIOR PIPING

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Furnishing of supports and hangers and installation of all interior and exposed exterior piping and supports.

1. Furnish, support, hang and install piping of the materials, coatings and

linings shown or specified at locations as specified or where shown.

B. Related Work Specified In Other Sections Includes, But is Not Limited to, the Following:

1. Section 02512 - Disinfection 2. Section 02516 - Leakage Tests 3. Section 05085 - Galvanizing 4. Section 07900 - Joint Sealers 5. Section 09900 - Painting 6. Section 15060 - Supports and Anchors

1.2 REFERENCES


1. ASME B1.20.1 - Pipe Threads, General Purpose, Inch

2. ASME B31.1 - Power Piping with Addenda

3. AWWA C600 - Installation of Ductile-Iron Water Mains and Their Appurtenances



1. Take extreme care in loading and unloading the pipe and fittings. Do the

work slowly using skids or suitable power equipment, and keep the pipe under control at all times.

AARHIP 15109-2

2. Handling Procedures: Under no condition is the pipe to be dropped, bumped, dragged, pushed or moved in any way which will cause damage to the pipe, lining or coating.

3. Use of Slings: When handling the pipe with a crane, use a suitable pipe

hook or sling around the pipe. Under no condition is the sling to be allowed to pass through the pipe unless adequate measures are taken to prevent damage to the pipe ends, lining and coating.

4. Damage: If any piping or fittings are damaged in the process of delivery,

storing, handling, or laying, replace or repair such piping or fittings as approved.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Pipe Dope for Threaded Joints

a. Masters Metallic Compound by Harbinseal Corporation

2.2 MATERIALS

A. Provide hangers and supports and all necessary appurtenances as specified in Section 15060.

2.3 FABRICATION

A. Coating: Provide all threads coated with a suitable pipe dope, Masters Metallic Compound, graphite and engine oil, or equal, before jointing.

PART 3 EXECUTION

3.1 PREPARATION

A. Galvanizing and Painting: Galvanize as specified, in accordance with Section 05085.

1. Paint hangers, supports, anchors, and similar devices as specified in Section

09900.

AARHIP 15109-3

3.2 INSTALLATION

A. General: Install all piping in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

1. Install exposed piping at right angles or parallel to building walls. Diagonal

runs are not permitted, unless expressly indicated.

2. Install piping free of sags or bends and with ample space between piping to permit proper insulation applications, with 1-inch clearance outside the insulation.

3. Place pipe runs to minimize obstruction to other work.

4. Install piping to allow for expansion and contraction without stressing pipe,

joints or connected equipment.

5. Slope piping as shown and arrange systems to drain at low points.

6. Do not penetrate building structural members unless shown.

7. Locate groups of piping parallel to each other and at common elevations whenever practical, spaced to permit applying insulation and servicing of valves.

8. Fire Barrier Penetrations: Where pipes pass through fire rated walls,

partitions, ceilings, and floors, maintain the fire rated integrity. Refer to Section 07900 for special sealers and materials.

9. Arrange miscellaneous pipelines, which are shown in diagram form on the

Plans, clear of other pipelines and equipment.

10. Fit and install pipelines in a neat and workmanlike manner in accordance with approved shop drawings.

11. Provide an adequate number of unions in main pipe and branch pipe runs to

facilitate dismantling or removal of pipeline sections without disturbing adjacent branch or connecting lines.

12. Install suitable sleeves at all points where pipes pass through walls or floors

of structures and where wall castings are not provided.

13. Include proper pipe protection saddles on pipes which are covered with insulation.

AARHIP 15109-4

B. Flanged Joints: Make flanged joints with bolts or bolt studs with a nut on each end.

1. Field Flanges: Shop screw threaded flanges to pipe unless threading in the

field is permitted with prior approval.

2. Flange to Pipe Assembly: Assemble pipe to be fitted with threaded flanges as follows:

a. Accurately thread pipe and flanges to the appropriate gauge, screw

flanges on by heavy machinery until the end of the pipe projects beyond the face of the flange and a tight metal-to-metal joint is produced without evidence of heat in the threaded portion.

b. Cut the projecting end of the pipe off flush with the face of the flange.

c. Make a light refacing cut across both the end of the pipe and the face

of the flange at right angles to the center line of the pipe and then ream the pipe.

d. Flanged to Flange Assembly: Align flange surfaces parallel.

Assemble joints by sequencing bolt tightening to make initial contact of flanges and gaskets as flat and parallel as possible. Use suitable lubricants on bolt threads. Tighten bolts gradually and uniformly to appropriate torque specified by bolt manufacturer.

C. Threaded Joints: Conform threaded joints to ASME B1.20.1, tapered pipe threads

for field cut threads unless otherwise specified. Join pipe, fittings, and valves as follows:

1. Note internal length of threads in fittings or valve ends, and proximity of

internal seat or wall, to determine how far pipe should be threaded into joint.

2. Align threads at point of assembly.

3. Apply appropriate tape or thread compound to the external pipe threads.

4. Assemble joint to appropriate thread depth. Assemble joint to produce a tight joint without evidence of heat in the threaded portion. When using a pipe wrench on valves, place wrench on valve end into which pipe is being threaded.

5. Damaged Threads: Do not use pipe with threads which are corroded, or

damaged. If weld opens during cutting or threading operations, do not use that portion of pipe.

AARHIP 15109-5

6. Retightening: Once a threaded joint has been assembled, it is not to be backed off unless the threads are recleaned and new compound or tape applied before rejointing.

D. Mechanical Joints: In making up mechanical joints, center the spigot in the bell.

1. Thoroughly brush the surfaces with which the rubber gasket comes in

contact, with a wire brush just prior to assembly of the joint.

2. Brush pipe manufacturers recommended lubricant over the gasket just prior to installation.

3. Place the gasket and gland in position, insert bolts, and fingertighten nuts.

4. Tighten the nuts with a torque wrench to bring the gland up toward the pipe

evenly.

5. Torques: Apply bolt torques complying with AWWA C600.

6. Effective Sealing: If effective sealing is not obtained at the maximum torque listed, disassemble and reassemble the joint after thorough cleaning.

E. Sleeve Type Couplings: For sleeve type couplings, equally tighten diametrically

opposite bolts on the coupling to bring the gaskets up evenly all around the pipe.

1. Torque Wrenches: Do final tightening with torque wrenches set for the torque recommended by the coupling manufacturer.

F. Welding: Comply welding of pipe joints with the requirements of ASME B31.1

unless otherwise specified. Do all off site welding of steel pipe conforming to the appropriate requirements.

1. Procedures: Confirm that pipe and fittings with wall thickness of 3/16-inch

and larger have ends beveled for welding, and that the parts to be welded are securely held in place and are in proper alignment during welding.

a. Separate the abutting pipe ends before welding to permit complete

fusion to the inside wall of the pipe without overlapping.

b. Provide welding continuous around the joint and completed without interruption.

c. Provide welds of the single vee butt type, of sound weld metal

thoroughly fused into the ends of the pipe and into the bottom of the vee.

AARHIP 15109-6

d. Provide welds free from cold shuts, pinholes, oxide inclusions or other defects.

G. Anchors and Stands: Furnish and install anchors and stands when specified,

shown, or required for holding the pipelines and equipment in position or alignment.

1. Small Piping Supports: Where adjustable supporting devices are not

required, support pipelines 3 inches in diameter and smaller on cast-iron, malleable iron, or steel hooks, hook plates, rings or ring plates.

H. Hangers and Supports

1. Direction Changes: Provide pipe hangers at each change in pipe direction,

on both sides of pipe mounted valves and equipment and on both sides of pipe loops and expansion absorbing devices.

2. Brackets: Use brackets for the support of piping from vertical surfaces.

3. Anchors: Furnish and install anchors when specified, shown, or required for

holding the pipelines and equipment in position or alignment.

4. Inserts: Install galvanized inserts in concrete structures where required for fastening supporting devices.

5. Fire Protection System Piping: Support fire protection system piping

independently from other piping systems.

6. Controlled Movements: Install hangers and supports to allow controlled movement of piping systems, to permit freedom of movement between pipe anchors, and to facilitate action of expansion joints, expansion loops, expansion bends and similar units.

7. Load Distribution: Adjust hangers to distribute loads equally on the

attachment and to achieve any indicated slope of the pipe.

I. Cast Iron Soil Pipe and Fittings

1. Joints: Provide joints of neoprene gasket compression type or lead and oakum.

a. Thoroughly caulk leaded joints with picked oakum and molten lead.

b. Use twelve ounces of soft pig or bar lead in each joint for each 1-inch

of pipe diameter.

c. Pour all lead in at one time.

AARHIP 15109-7

d. Finish the face of lead joints with the face of the hub and leave

without putty, paint or cement.

e. Extend gasket on rubber gasket joints the full depth of the bell and overlap the face of the bell

2. Connection: Provide all joints to be leakproof and gastight.


A. Tests: After installation of the interior and exposed exterior piping and supports, control equipment and all appurtenances, subject the units to a field running test, as specified in Division 1, under actual operating conditions. Where field welding of pipe joints shown, specified, permitted, or required meet the requirements of ASME B31.1 -Power Piping, Chapter VI (Section 136.4.2 Visual Examination) (Section 137.4 Hydrostatic Testing) or (Section 137.5 Pneumatic Testing).

1. Perform testing of pipelines in accordance with the requirements of Section

02516. 3.4 CLEANING

A. General: Clean the interior of pipelines of all dirt and superfluous material of every description in an approved manner.

B. Thoroughly clean threads for threaded joints after reaming.

C. Disinfection: Disinfect pipelines carrying potable water in accordance with

requirements of Section 02512. 3.5 SCHEDULE

A. Definitions: Abbreviations used in the schedule are as follows:

1. Pipe Materials:

a. Al Aluminum b. Br Brass c. C Concrete d. CI Cast-iron e. CISP Cast-iron soil pipe f. Cl Clay g. CPVC Chlorinated Polyvinyl Chloride h. CU Copper i. DI Ductile Iron j. PCCP Prestressed Concrete Cylinder Pipe

AARHIP 15109-8

k. PE Polyethylene l. PVC Polyvinyl Chloride m. RCP Reinforced Concrete Pipe n. RCPP Reinforced Concrete Pressure Pipe o. SS Stainless Steel p. St Steel

2. Joints:

a. B Bituminous b. B&S Bell and Spigot c. F Flanged d. G Grooved End e. H Harnessed f. HC Hubless Coupling g. HSC Hub and Spigot - Compression Gasket h. HSL Hub and Spigot - Lead and Oakum i. MJ Mechanical Joint j. PO Push-on Joint k. RRG Restrained Retainer Gland l. RS Rubber and Steel m. Sd Soldered n. SF Socket Fusion o. Sl Sleeve Type Coupling p. SW Solvent Welded q. W Welded

3. Coatings and Linings:

a. BC Bituminous - Cold Application b. CE Concrete Encased c. CL Cement-Mortar Lined d. E Epoxy e. G Galvanized f. GL Glass Lined g. I Insulated h. KL Polyvinylidene Fluoride (PVDF or KYNAR®) Lined i. P Painted j. PCL Polyvinylidene Chloride (PVDC) Lined k. PEW Polyethylene Wrapped l. PPL Polypropylene Lined m. RC Rubber Coated n. RL Rubber Lined o. W Wrapped

AARHIP 15109-9

B. Schedule: Provide products as listed in the following schedule.

END OF SECTION

AARHIP 15109-10

INSIDE PIPING SCHEDULE

Protective Coatings

Service Size

(Inches) Pipe

Material Int. Ext.2 Joints Class of Schedule

Test Pressure (psig)1 Remarks

Gravity Thickener Building TWAS 4 DI CL P F 52 100 Sludge Transfer 6 DI CL P F 52 100 Sludge 6 DI CL P F 52 100 Thickened Sludge 6 DI CL P F 52 100 Centrifuge Feed 6 DI CL P F 52 100 Pump Discharge 6 DI CL P F 52 100 Air 6 St --- P, I F --- 100 Schedule 80 Solids Handling Building WAS Suction Header 6, 8 DI CL P F 52 100 GBTFP Discharge Header 4, 6, 8 DI CL P F 52 100 TWAS Suction Header 6 DI CL P F 52 100 TWASP Discharge Header 4, 6 DI CL P F 52 100 West Plant WAS 6, 10 DI CL P F 52 100 East Plant WAS 8, 10 DI CL P F 52 100 Centrifuge Feed 4, 6 DI CL P F 52 100 STP Suction 6, 8 DI CL P F 52 100 STP Discharge 8 DI CL P F 52 100 Sludge Transfer 6 DI CL P F 52 100 Recirculated Sludge 4, 6 DI CL P F 52 100 Blended Sludge 6 DI CL P F 52 100 Air 4, 6 St --- P, I Sc, F, W --- 100 Schedule 80 WAS Storage Tank Vents 8 DI CL P F 52 100 Inclined Screw Conveyor 16 DI CL P F 52 100

AARHIP 15109-11


Protective Coatings

Service Size

(Inches) Pipe



Drain WAS Tank EMO 8 DI CL P F 52 100 Centrate Vent 8 DI CL P F 52 100 Solids Vent 8 DI CL P F 52 100 Centrifuge Centrate 8, 12 DI CL P F 52 100 Lime Slurry Suction 3 DI CL P F 52 100 LSFP Discharge 2 1/2, 3 DI CL P F 52 100 Sump Pump Discharge 2 DI CL P F 52 100 Lime Slurry Tank Overflow 4 DI CL P F 52 100 Lime Slurry Tank Drain 3 DI CL P F 52 100 GBT Filtrate 10 DI CL P F 52 100 GBT Drain 12 DI CL P F 52 100 Sludge to Truck Loading Station

6 DI CL P F 52 100

Sample Sink Discharge 4 DI CL P F 52 100 Truck Loading Header 8, 6 DI CL P F 52 100 Plant Effluent Water 3, 4, 6, 10, 14 St --- P, I G --- 50 Schedule 40 Plant Effluent Water 1, 1 1/2, 2 CU --- P, I Sd --- 100 Type K Seal Water 1/2 St --- P Sc Main Building Drain 16 DI CL P MJ 52 100 Polymer System Vent 4 PVC --- --- SW --- --- Schedule 80 Polymer Fill Line 4 PVC --- --- SW --- --- Schedule 80 Polymer Storage Tank Overflow

4 PVC --- --- SW --- --- Schedule 80

Polymer Storage Tank Drain 4 PVC --- --- SW --- --- Schedule 80 Polymer Recirculation Line 2 PVC --- --- SW --- --- Schedule 80 Polymer Pump Suction 2 PVC --- --- SW --- --- Schedule 80

AARHIP 15109-12


Protective Coatings

Service Size

(Inches) Pipe



Polymer Dilution Water 1 Cu --- --- Sd --- 100 Type K Polymer Day Tank Drain 2 PVC --- --- SW --- --- Schedule 80 Polymer Day Tank Overflow 2 PVC --- --- SW --- --- Schedule 80 Polymer Dilution Unit Suction

2 PVC --- --- SW --- --- Schedule 80

Polymer Solution 2 PVC --- --- SW --- --- Schedule 80 Polymer Pump Discharge 2 PVC --- --- SW --- --- Schedule 80 Sludge Sample Line 2 DI CL P F 52 100 Truck Loading Facility Truck Liquid 8 DI CL P F 52 100 Liquid Loading Arm 6 DI CL P F 52 100 Lime Silo Fill Pipe 4 DI CL P F 52 100 Plant Effluent Water 2, 3 St --- P, I Sc, F --- 100 Schedule 80 Blend Tanks Air 4, 6 St --- P, I Sc, F, W --- 100 Schedule 80 Mixing Pipe 12, 16 DI CL P F 52 100 HVAC and Plumbing Cooling Coil Condensate Drain

2-1/2 and Less CU --- P, I Sd --- 100 Type K

AARHIP 15109-13


Protective Coatings

Service Size

(Inches) Pipe



Natural Gas 2 and Less St --- P Sc --- 50 Schedule 40 2-1/2 and

Larger St --- P W, F --- 50 Schedule 40

Glycol Fill 2-1/2 and Less St --- P Sc --- 100 Schedule 40 Refrigerant All CU --- P, I Sd --- 250 Type K Waste, Drain, Vent and Storm

3 and Larger CSIP BC P B&S --- 3

Less then 3 St G G, P Sc --- 3 Schedule 40 Potable Water, Cold and Hot All CU --- P, I Sd --- 100 Type K Sump Pump Discharge All DI CL BH F --- 30 Class 53

1 Measure the test pressure shown in the schedule at the centerline of the pipe’s low point. Adjust test pressures measured at other locations accordingly. 2 Do not insulate sections of pipe that pass through or are within structures containing water. 3 Test by Filling with water to top of system or with 5 psi compressed air.

AARHIP 15109-14


AARHIP 15110-1

SECTION 15110

VALVES AND VALVE OPERATORS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing all valves and operators, except special regulating valves, telescopic valves, flap valves and valves specified in Section 15405 - Plumbing Piping and Valves.

1. Provide valve operators complete, including a suitable enclosure, with all

appurtenances necessary for the operator to perform its intended function. Such appurtenances include, but are not limited to, anchor bolts and other mounting hardware, control switches, limit switches, pressure switches, torque switches, gauges, control valves, electrical supply connections, internal electric wiring and controls, terminal blocks, air supply piping, solenoid valves, miscellaneous valves, regulating controls, push button controls, miscellaneous controls, extension stems, local and remote indicators, operating nuts, purge water service with all associated piping, indicating lights, floor boxes, direct burial valve boxes and other such items.

2. For each valve, provide the type of operator specified for the valve in the

Valve Schedule.


1. Section 05085 - Galvanizing 2. Section 09900 - Painting 3. Section 15108 - Miscellaneous Pipe and Fittings 4. Section 16121 - Wires and Cables - 600 Volts and Below 5. Section 16140 - Wiring Devices 6. Section 16055 - Electrical Requirements for Shop-Assembled Equipment 7. Section 16220 - Electric Motors 8. Section 16413 - Disconnect Circuit Breakers

AARHIP 15110-2

1.2 REFERENCES


1. ASME B1.20.1 - Pipe Threads, General Purpose

2. ASME B1.20.7 - Hose Coupling Screw Treads

3. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings

4. ASTM A 27/A27M - Specification for Steel Castings, Carbon, for General Application

5. ASTM A 29/A29M - Specification for Steel Bars, Carbon and Alloy,

Hot Wrought and Cold-Finished, General Requirements

6. ASTM A 48 - Specifications for Gray Cast Iron Castings

7. ASTM A 126 - Specification for Gray Iron Castings for Valves,

Flanges, and Pipe Fittings

8. ASTM A 197 - Specification for Cupola Malleable Iron

9. ASTM A 276 - Specification for Stainless and Heat-Resisting Steel Bars and Shapes

10. ASTM A 278 - Specification for Gray Iron Castings for Pressure-

Containing Parts for Temperatures Up to 650 F

11. ASTM A 395 - Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures

12. ASTM A 436 - Specification for Austenitic Gray Iron Castings

13. ASTM A 479/A479M - Specification for Stainless and Heat Resisting

Steel Wire Bars, and Shapes for Use in Boilers and Other Pressure Vessels

14. ASTM A 536 - Specification for Ductile Iron Castings

15. ASTM A 564/A564M - Hot Rolled and Cold Finished Age Hardening

Stainless and Heat Resisting Steel Bars and Shapes

AARHIP 15110-3

16. ASTM A 572/A572M - Specification for High Strength Low Alloy Columbium Vanadium Steels of Structural Quality

17. ASTM A 743/A743M - Specifications for Castings, Iron-Chromium, Iron-

Chromium - Nickel, and Nickel-Base Corrosion-Resistant for General Application

18. ASTM A 744/A744M - Specification for Castings, Iron-Chromium-

Nickel, Corrosion-Resistant, for Severe Service

19. ASTM B 30 - Specification for Copper Base Alloys in Ingot Form

20. ASTM B 62 - Specification for Composition Bronze or Ounce

Metal Castings

21. ASTM B 148 - Specification for Aluminum-Bronze Castings

22. ASTM B 584 - Specification for Copper Alloy Sand Castings for General Applications

23. AWWA C500 - Metal Seated Gate Valves for Water and Sewerage

Systems

24. AWWA C502 - Dry-Barrel Fire Hydrants

25. AWWA C504 - Rubber-Seated Butterfly Valves

26. AWWA C508 - Swing Check Valves for Waterworks Service, 2 inch through 24 inch NPS

27. AWWA C509 - Resilient-Seated Gate Valves for Water Supply

Service

28. AWWA C540 - Power-Actuating Devices for Valves and Sluice Gates

29. MSS SP-70 - Cast Iron Gate Valves, Flanged and Threaded

Ends

30. MSS SP-71 - Cast Iron Swing Check Valves, Flanged and Threaded Ends

31. MSS SP-80 - Bronze, Globe, Angle and Check Valves

32. NACM - Welded and Weldless Chain Specifications

AARHIP 15110-4

33. SAE J356 - Welded Flash Controlled Low-Carbon Steel

Tubing Normalized for Bending, Double Flaring, and Beading

34. SAE J524 - Seamless Low-Carbon Steel Tubing Annealed for

Bending and Flaring

35. SAE J525 - Welded and Cold-Drawn Low-Carbon Steel Tubing Annealed for Bending and Flaring

1.3 SUBMITTALS


B. Shop Drawings: Submit the following:

1. Complete detailed drawings of all valves

2. Certified shop test report for the hydraulic power unit.

C. Quality Control Submittals: Submit the following:

1. If requested, manufacturer's certified performance and material records.

2. If requested, complete calculations for each size of motor operator indicating

the force required to operate the valve, the operator force provided, full load and locked rotor current, and horsepower.

D. Operation and Maintenance: Submit operation and maintenance manuals for the

valve operators. 1.4 QUALITY ASSURANCE

A. Furnish all valves of the same type from the same manufacturer. Provide parts that are interchangeable for all valves of the same type and size.


A. General: Deliver, store and handle all products as specified in Division 1 and as follows.

B. Historical Performance: Furnish and install eccentric plug valves of a type that has

shown successful performance for a minimum of ten years. If requested, submit documentation of successful installations in which eccentric plug valves of the proposed type have been in operation for at least ten years.

AARHIP 15110-5

C. Tests: Furnish a letter confirming that all plug valves have been satisfactorily

tested as specified, prior to shipment.

D. Storage and Erection: Pack and store all valves in satisfactory operating condition. Carefully erect all valves in their respective positions, free from all distortion and strain.

1.6 SPARE PARTS

A. For each size cylinder:

1. One set of packing 2. One set of cup leathers or O-rings 3. One needle valve (if used) 4. One check valve (if used) 5. One oil fog unit (if used) 6. One hose (for swiveling type cylinders) 7. One solenoid control valve

B. For electric motor operators:

1. One motor of each size 2. One torque switch of each size 3. One limit switch assembly of each size 4. Six push buttons 5. Six color caps of each color 6. Twenty indicating lamps 7. One reversing starter of each size 8. One overload relay of each size

PART 2 PRODUCT

2.1 MANUFACTURERS

A. Acceptable valve manufacturers are listed below. Other manufacturers of equivalent products may be submitted.

1. Gate Valves:

a. American Flow Control b. M&H Valve Company c. Mueller Company d. NIBCO, Inc. e. Stockham f. United States Pipe and Foundry

AARHIP 15110-6

2. AWWA Butterfly Valves:

a. American Flow Control b. DeZurik c. Keystone d. Pratt

3. Knife Gate Valves:

a. DeZurik b. Keystone c. Technaflow

4. Eccentric Plug Valves:

a. DeZurik

5. Single Disc Swing Check Valves:

a. American Flow Control b. Clow Valve Company c. M&H Valve Company d. Mueller Company

6. Solenoid:

a. Automatic Switch Company b. Magnetrol

7. Globe and Angle Valves:

a. NIBCO, Inc. b. Stockham

8. Hose Bibbs (Ball Valves)

a. Apollo Ball Valves as manufactured by Conbraco .

9. Wall Hydrants

a. Josam - Series 71050 b. Wade - W-8620

AARHIP 15110-7

B. Acceptable actuator manufacturers are listed below

1. Electric Motor Operator - Nonmodulating:

a. Rotork, Inc. 2.2 MATERIALS

A. General:

1. Fabricate valves of materials resistant to corrosion for the required service.

2. Fabricate valves that are to be installed in metal pipelines and that are 2 inches in diameter and smaller of all brass or bronze, except fabricate the handwheel of ASTM A 197 malleable iron. Fabricate valves that are to be installed in metal pipelines and that are 2-1/2 inches in diameter and larger of the materials specified herein.

3. Fabricate gate, globe and angle valves with a minimum steam working

pressure rating of 125 psig and a minimum nonshock cold water, oil or gas pressure rating of 200 psig, unless otherwise specified.

4. Fabricate operators of materials resistant to corrosion for the required

services. Provide operator materials as specified.

5. Operator housings and pedestal handwheels:

a. Cast iron ASTM A 126, Class B ASTM A 48, Class 30 or 35 b. Ductile iron ASTM A 395 ASTM A 536, Grade 65-45-12 c. Cast steel ASTM A 27/A27M

6. Operator worms, steel ASTM A 29/A29M Grade

Designation 8620

7. Operator gears, steel (spur & helical) ASTM A 572/A572M

8. Worm gears, bronze ASTM B 148, Alloy C95400 or C95500

ASTM B 584, Alloy C86300

B. Valve Joints

1. Fabricate valves 2 inches in diameter and smaller of the threaded or solder end type for valves to be installed in copper pipelines, and of the threaded end type for valves to be installed in metal pipelines.

AARHIP 15110-8

2. Fabricate all valves 2-1/2 inches in diameter and larger, except bronze

valves 2-1/2 and 3 inches in diameter, with flanged ends, unless otherwise specified.

3. Fabricate bronze valves 2-1/2 and 3 inches in diameter with solder or

threaded type ends for valves installed in copper pipelines and threaded type ends for all other pipelines.

4. For metallic flanged joints, provide flanges that are faced accurately at right

angles to the axis of the casting. Face and drill flanges and shop coat with a rust-preventive compound before shipment.

5. For flanged joints, provide flanges whose dimensions and drillings meet the

requirements of ASME B16.1, 125 pounds as a minimum. For valves installed in pipelines with test pressure requirements higher than 125 psi, provide flanges whose pressure ratings equal or exceed the specified test pressure of the pipeline. Furnish special drillings where required. For valves having flanges that do not conform with the thickness requirements of ASME B16.1, test each valve in accordance with the hydrostatic shell test pressure requirements of ASME B16.1.

C. Operating Force: Fabricate valves to limit the maximum force required to operate

all manual valves, including but not limited to valves with wrench operated nuts, levers, handwheels and chainwheels, to 40 pounds. Limit the overall length of each wrench or single-arm lever to 18 inches. Limit the overall length of each dual-arm lever to 36 inches.

D. Handwheel: Mark each valve handwheel with an arrow and the word OPEN.

Mark each nut with an arrow.

E. Manually Operated Valves: Equip all manually operated valves that have operating nuts, levers or handwheels and that are more than 7 feet above the floor with chain operated levers or chainwheels. Extend chains to 7 feet above the floor.

2.3 GATE VALVES

A. Materials: Unless otherwise shown or specified, furnish and install gate valves meeting the following requirements:

Nominal Valve Size, Inches Standard Type

3 and smaller MSS SP-80 Solid wedge 4 thru 12 for HVAC Service MSS SP-70 Solid Wedge 4 thru 12, except for HVAC Service AWWA C509 Resilient seat 16 and larger, except for HVAC Service AWWA C500 Double disc

AARHIP 15110-9

B. Rising Stems: Manufacture all gate valves with rising stems, unless otherwise shown or specified. Design all gate valves to open when the nut or handwheel is turned counterclockwise.

C. Nonrising Stem: For buried service, furnish nonrising stem gate valves. Equip

nonrising stem valves, except for buried or submerged service, with externally visible indication of the disc position at all points of travel.

D. Stem Seals: Use the following types of stem seals:

Valve Type Stem Seal

Nonrising stem O-ring Rising stem (Outside stem and yoke) Stuffing box Geared Nonrising stem O-ring or stuffing box Rising stem (Outside stem and yoke) Stuffing box

E. Packing: Provide nonasbestos braided, twisted or formed ring type packing

suitable for the pressure-temperature ratings of the valve.

F. Bonnet: Provide 3-inch and smaller gate valves with threaded bonnets. Provide 4-inch and larger gate valves with outside screw and yoke bonnets.

G. Accessories: Provide zinc plated bonnet bolts, studs and nuts. except for

submerged service. Provide stainless bonnet bolts, studs and nuts for submerged service. Make wedging devices bronze to iron or bronze to bronze. Provide glands which are bronze or bronze bushed and bronze gland bolts and nuts.

2.4 BUTTERFLY VALVES

A. General:

1. Provide butterfly valves 4 inches and smaller of the full lug pattern with drilled and tapped bolt holes.

2. Provide butterfly valves 6 inches and larger of the full flanged pattern that

meet the requirements of AWWA C504.

3. Provide butterfly valves of the rubber-seated, tight-closing type.

4. For fluid temperatures equal to or less than 180 degrees F, provide Buna-N seats. For fluid temperatures greater than 180 degrees F, provide EPDM or Viton seats. For fluid temperatures exceeding the temperature ratings of EPDM and Viton, provide seats that are appropriate for the intended service.

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B. Materials:

1. For butterfly valves 4 inches and smaller, provide valve materials as specified below or as required for the service.

a. Valve bodies:

Cast iron ASTM A 126, Class B

b. Valve shafts: Stainless steel ASTM A 564, Type 630 (17-4 PH stainless

steel) ASTM A 276 Grade 316

c. Valve discs:

Aluminum Bronze ASTM B 148 Bronze ASTM B 30

d. Bearings: TFE coated stainless steel

2. For butterfly valves 6 inches and larger, provide valve materials as specified

below or as required for the service:

a. Valve bodies: Cast iron ASTM A 126, Class B ASTM A 48, Class 40

b. Valve shafts: ASTM A 276 or A 479/A479M, Type 304,

stainless steel or carbon steel with A 276 or A 479, Type 304 stainless steel journals

c. Valve discs:

Cast iron ASTM A 48, Class 40 Alloy cast iron ASTM A 436, Type 1 Ductile iron ASTM A 536, Grade 65-45-12 Bronze AWWA C504 Grade A, D or E

d. Mating seat surface:

Stainless steel (castings) ASTM A 743/A743M, A 744 Grade CF-8 or CF-8M

Stainless steel ASTM A 276 or A479,Type 304 Alloy cast iron ASTM A 436, Type 1

e. Seats: Buna-N (Wastewater)

New natural rubber or Buna-N (Water) EPDM (Air)

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C. General AWWA C504 Construction: For butterfly valves 6 inches and larger, manufacture valves and all accessories, including operators, to meet the requirements of AWWA C504, except as otherwise specified. Provide valve bodies of the short-body flanged type or mechanical joint-end type, as shown or specified. Wafer body type valves without lugs are not acceptable.

D. Pressure: Provide butterfly valves of pressure classes that are not less than Class

25B, that exceed the pipeline test pressure in which the valve is installed, or that are as specified, whichever is greater.

E. Shafts: If stub shafts are furnished, extend the shafts a minimum of 1-1/2

diameters into the discs and provide clearance between the shaft and discs not exceeding the following:

Shaft Diameter (Inches)___

Maximum Radial Clearance (Inches)

1/2 to 1-1/2 .002 2 to 4 .0025 5 .003 6 .004

F. Extended Necks: Provide butterfly valves in insulated lines with extended necks

to clear insulation. 2.5 KNIFE GATE VALVES

A. General: Provide valve of the resilient-seated, bonnet less knife gate type with wafer MSS SP-18 flanged connections. Provide gate with rounded bottom with a beveled knife edge and finish ground grate sides. Provide bronze yoke sleeve, stainless steel stem and carbon steel superstructure.

B. Seating: Provide seat ring with a molded resilient insert to the body and gate sides.

Provide valve body with guides to assist seating. Provide raised face seat with a relieved area around the seat to prevent jamming.

2.6 ECCENTRIC PLUG VALVES

A. General: Provide quarter turn valves having an eccentric action that causes the plug to rise off the seat contact during the opening movement rather than sliding from its seat.

B. Plugs: Provide plug valves with Neoprene or Buna-N faced plugs.

C. Materials: Construct plug valves of cast iron or semi-steel at least equal to ASTM

A 126, Class B. For valve sizes 3-inch and larger, construct the body seats with a welded-in overlay, of not less than 90 percent pure nickel, on all surfaces contacting the plug face. For valve sizes under 3-inch provide uncoated or epoxy

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coated body seats. Make the overlay a minimum of 1/16-inch thick for valve sizes 20-inch and smaller and a minimum of 1/8-inch thick for valve sizes 24-inch and larger. Provide zinc plated bonnet bolts, studs and nuts.

D. Seat Adjustment: Make the water-tightness or gas-tightness of the valve seating

adjustable. Provide a seating adjustment device that is external to the valve and that can be used without the need to remove the valve from the piping and with the valve under pressure.

E. Lubrication: Furnish plug valves with oil impregnated, permanently lubricated,

Type 316 stainless steel bearings in the upper and lower journals.

F. Stem Seal: Provide a stem seal consisting of multiple, self-adjusting and replaceable chevron type packing rings and a packing gland or provide two replaceable, self-adjusting, U-cup seals. Make the stem seal adjustable and replaceable without removing the valve from the piping and without the need to disassemble the valve and operator. For buried or submerged service, provide a sealed enclosure to keep the stem seal clean.

G. Valve Port: Unless otherwise specified, construct the valve with a minimum port

area of 100 percent of the full area of the pipe in which the valve is installed.

H. Multiport: Provide 3 and 4-way valve configuration when shown or specified.

I. Position Indicator: Equip plug valves, except for buried or submerged service, with external visible indication of the plug position.

J. Operators: Unless otherwise shown or specified, equip 4-inch and smaller valves

with wrench or lever operators and 6-inch and larger valves with gear operators. Equip all valves in low pressure gas service with gear operators. Furnish one wrench for each size valve in each individual room or space in which valves are located. House gear operators for submerged or buried service in a watertight enclosure. For buried or submerged service, equip valve operators with stainless steel external bolting.

2.7 SINGLE DISC SWING CHECK VALVES

A. General: Provide single disc swing check valves designed to allow a full diameter passage and to operate with a minimum loss of pressure. Provide 1/8 through 3 inch check valves that meet the requirements of MSS SP-80. Except as specified herein, provide 4 inch through 24 inch check valves that meet the requirements of AWWA C508. For heating, ventilating or air conditioning service, provide 4 inch through 24 inch check valves that meet the requirements of MSS SP-71.

B. Design: Equip check valves with bronze renewable seat rings, bronze discs or disc

rings and bronze disc hinge bushings and pins. Carefully mount discs and provide discs that swivel in disc hinges. Provide pins, discs and other parts that are

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noncorrosive, nonsticking and properly cured to operate satisfactorily within a temperature range of 34 to 100 degrees Fahrenheit and with the fluids or gases specified.

C. Levers and Weights: Equip 6 inch and larger check valves with outside levers and

weights. 2.8 SOLENOID VALVES

A. Provide solenoid valves of the direct acting, all electric, normally closed, packless type with full area ports, unless otherwise shown or specified. Design valves to not require a pressure assist from the process fluid to open or close. Size the solenoids in accordance with the pressure conditions in the pipeline in which valves are installed. Construct the valve body and bonnet of forged brass and construct the solenoid core of stainless steel. Design solenoid the coils for 115-volt, 60-hertz operation. Embed solenoid coils in molded plastic and install coils in NEMA Type 1 general purpose enclosures, except as shown or specified.

2.9 HYDRANTS

A. Provide fire hydrants meeting the requirements of AWWA C502 with two outlets for 2-1/2-inch hose, one of these outlets to be provided with a brass cap and 1-inch hose nipple. Provide nozzles with standard threads. Provide each hydrant with a gate valve and valve box. Furnish two hydrant wrenches.

2.10 AIR RELEASE VALVES

A. General: Provide air release valves that will automatically release air accumulations in process piping. Locate air release valve where shown. Provide isolation valves between the air release valves and process piping.

B. Materials: Fabricate the body of the valves of cast iron meeting the requirements

of ASTM A 126. Fabricate the float ball and lever of stainless steel meeting the requirements of ASTM A 276. Supply resilient, Buna-N seats.

C. Operation: Construct the air release valves to automatically release air

accumulations with the action of a float and lever mechanism. When the valve fills with air the float falls and, through the lever mechanism, causes the resilient seat to open an orifice allowing the air to escape t atmosphere. When the air has been exhausted from the valve, the float is buoyed up and, through the lever mechanism, causes the resilient seat to close the orifice, preventing water from being released from the valve.

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2.11 FLAP VALVES

Design flap valves for a standard 125-pound flange mounting. Furnish the flap valve complete with bronze bolts and neoprene gaskets having a thickness of 3/8-inch or more.

Construct the valves of cast iron, design for the heads specified or required and be sensitive and well balanced so as to operate automatically with a minimum of headloss. Furnish a ribbed frame and cover to provide adequate strength and rigidity. Provide seating surfaces that are bronzed faced and accurately machined to ensure practical water tightness. Furnish to hinge-links of the T-section type, bifurcated at the top to straddle the hinge posts and fit between paired ears on the cover at the bottom to provide double shear in the hinge pins. Furnish bronze hinge pins that can be locked into position and against turning. Provide provisions for valve lubrication.

2.12 TANK PRESSURE RELIEF VALVES

A. General: Provide tank pressure relief valves of the floor type with a collar sleeve, a cover and strainer made of gray iron and seats made of BUNA N synthetic rubber. Provide lugs in the body of the valve to retain the cover and strainer in the position against flow. Provide one cubic foot of 3/4-inch crushed stone below the strainer to convey groundwater to the valve.

2.13 PRESSURE REDUCING VALVES

A. Furnish direct acting, spring loaded, diaphragm operated, single seated pressure regulators designed for intermittent service with tight shutoff. The valves are to maintain the downstream pressure shown with inlet pressures up to 175 psig.

2.14 GLOBE AND ANGLE VALVES

A. General: Provide globe valves that meet the requirements of MSS SP-80.

B. Disc and Seats: Equip gate and globe valves with renewable bronze discs and renewable seats.

C. Bonnet: Equip globe and angle valves with threaded bonnets.

D. Packing: Provide nonasbestos braided, twisted or formed ring type packing

suitable for the pressure-temperature ratings of the valve. 2.15 MANUAL BUTTERFLY VALVE OPERATORS

A. General: Provide operators as an integral part of the valve. Manufacture manual operators of the enclosed, hand-lever, traveling-nut or worm-gear type, as shown or specified.

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B. Hand-Lever Type: Fabricate hand-lever type operators of cast-iron or steel

construction with a nonmetallic, nonslip handgrip. Equip the lever with a locking device to secure the valve disc in the fully open or fully closed position, or at a minimum of 5 intermediate positions at 1-degree intervals. Provide mechanical stop-limiting devices to prevent over travel of the disc in either direction. Permanently lubricate operators or provide operators with grease fittings.

C. Traveling-Nut Type: Fabricate traveling-nut type operators with a threaded steel

screw and a bronze nut. Provide a slotted-lever or link-lever system to transfer the applied torque to the disc shaft. Equip all rotating shafts, screws and links with separate bearings. Provide thrust bearings.

D. Worm-Gear Type: Fabricate worm-gear type operators with a worm gear and

matching drive worm. Provide bearings for each rotating member.

E. Stop-Limiting Devices: Provide stop-limiting devices on traveling-nut and worm-gear type operators to prevent over travel of the disc in either direction. Design the operator to hold the disc in any position without flutter or wear on the valve or operator. House the operator in a watertight enclosure. Pack operators with grease or with oil. For buried or submerged service, equip valve operators with stainless steel external bolting.

F. Position Indicators: For buried or submerged service, equip manually operated

butterfly valves, with externally visible indication of the disc position. 2.16 HOSE BIBBS VALVES

A. Provide hose bibs with either 3/4-inch or 1-1/2-inch hose thread outlet. 2.17 WALL HYDRANTS:

A. Provide wall hydrants of cast-bronze non-freeze type with 3/4-inch hose thread outlet, self-draining, integral vacuum breaker-backflow preventer, pressure relief valve, T-handle, polished face, bronze wall casing, bronze operating parts and 3/4-inch pipe thread inlet connection.

2.18 CHAINWHEEL OPERATORS

A. General: Manufacture chainwheels and chain guides of cast iron or ductile iron. Coat chainwheels and chain guides by hot dip galvanizing in accordance with the requirements of Section 05085.

B. Chains: Manufacture chain of steel. Use welded link chain meeting the

requirements of the National Association of Chain Manufacturers (NACM) Grade 28 or single loop weldless chain meeting the requirements of NACM No. 6001. Coat chain by hot dip galvanizing meeting the requirements of Section 05085.

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Remove excess metal at welded chain joints for proper fit into the chainwheel pockets. Remove burrs and sharp edges. Furnish chain that is suitable for bare hand operation.

2.19 FLOOR AND BENCH STANDS

A. General: Provide floor and bench stands for valves smaller than 12 inches of the wheel operated type without gears. Provide stands for 12- to 20-inch valves of single crank, single speed operated. Provide stands for 24-inch and larger valves of single crank, single speed or 2-speed operated as specified.

B. Materials: Use materials in floor and bench stands meeting the applicable

requirements of the "General" specifications subsection. Provide frames of cast iron or fabricated steel of heavy and substantial design with smooth exterior and neat appearance. Make adequate provision for lubrication and protect all operating parts.

C. Nameplate and OPEN Indication Marking: Equip each stand with a nameplate

stating the valve controlled by the stand and also stamp the operator with an arrow and the word OPEN to indicate the direction of rotation.

D. Rising Stems: Fit rising stem floor and bench stands with ball or roller bearings

designed to take the thrust. Equip rising stem stands with a transparent plastic cover to protect the stem. Provide the cover with labels and other attachments that will facilitate its use as an indicator of valve position.

E. Nonrising Stems: Fit nonrising stem floor and bench stands with thrust ball or

roller bearings. Provide an indicator to show the position of the valve.

F. Operating and Lift Nuts: Provide operating nuts or lift nuts of bronze meeting the requirements of ASTM B 62, finished all over, suitably splined to connect with the handwheel or gear and with threads which will engage smoothly with those of the lifting shaft.

G. Crank-Operated Stands: Provide crank-operated stands with a crank that will open

the valve when the crank is turned counterclockwise. Locate the center of the crank approximately 36 inches above the operating floor. Provide gears which are bevel or worm, of hardened steel or manganese bronze, with machine cut teeth and enclosed in a cast-iron body. Equip the crank with a brass or bronze sleeve-type handgrip rotating freely on the handle. Utilize a gear ratio that will enable the stand to operate the valve with a maximum force of 40 pounds on the crank at single or low speed.

H. Handwheel-Operated Stands: Provide handwheel-operated stands with

handwheels that open the valve when the wheel is turned counterclockwise. Locate the center of the handwheel approximately 36 inches above the operating

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floor. Provide a handwheel of sufficient diameter so that the stand will operate the valve with a maximum pull on the handwheel of 40 pounds.

I. Manually Operated Bench Stands: Equip manually operated bench stands located

more than 7 feet above the floor with chains and chainwheels that meet the requirements of the subsection headed "Chainwheel Operators".

2.20 ELECTRIC MOTOR OPERATORS - NONMODULATING

A. General: Provide nonmodulating electric motor operators of the close-coupled, electric motor-driven, worm gear type, complete with motor, gearing, limit switches and auxiliary contacts, torque switches, position indicator, handwheel, integral controller, and all required appurtenances. Design the operators to rotate valve discs through 90 degrees from the fully open to the fully closed position and back, as in butterfly, ball or plug valves, lift gate discs from the fully closed to the fully open position and back, as in gate valves. Provide operators that complete each operation in the time specified. Provide operators that hold the discs in any position from fully open to fully closed without vibration.

B. Operator Mounting: Design the operator to be mounted in the position shown or

specified.

C. Standard: Except as otherwise specified, provide operators meeting AWWA C540.

D. Open and Close Time Periods: Provide valve operators that fully open the valve

from the closed position in approximately 60 seconds and fully close it in approximately 60 seconds when the differential pressure and flow are at the values specified for the valve and the voltage at the terminals is within 15 percent of the nominal voltage. Design the operator to operate the valve through three consecutive opening and closing strokes or for a period of 15 minutes, whichever is longer, during every 60-minute period, at specified ambient temperature conditions under full differential pressure.

E. Temperature Range: Design the operator for indoor operation and for an ambient

temperature range of -20 to 140 degrees F.

F. Torque: Design the operator to exert an unseating torque of at least 50 percent in excess of the required disc seating torque at the specified voltage, neglecting hammer-blow effect.

G. Power Gearing: Provide power gearing consisting of helical or spur gears and

worming gearing. Fabricate helical and spur gears of accurately machined hardened alloy steel. Provide a hardened alloy steel worm with threads ground and polished after heat treating. Provide a nickel or manganese bronze worm gear. Use antifriction bearings throughout. Grease pack or oil bath lubricate the operator. Provide lubricants suitable for the ambient temperatures specified.

AARHIP 15110-18

H. Lost-Motion Device: Design operators for gate valves to include a lost-motion

device that will permit the motor to attain full speed, and then impart a hammer blow to the stem nut to start movement of the disc in both the opening and closing directions. Do not include this feature if the valve is for modulating service.

I. Handwheel - Manual Operation: Provide a handwheel for manual operation with a

maximum rim pull of 40 pounds. Design the handwheel so that it does not rotate during electrical operation and the motor does not rotate during manual handwheel operation. Provide an operator that is arranged so that motor or motor gearing failure does not prevent manual operation. Arrange the operator to automatically change from manual operation to electrical operation when its motor is energized and to continue electric operation until the operator is reset to manual operation. Provide a means for locking the drive in either manual or motor operation. Provide removable handwheels. Provide an adaptor key or drive nut to permit operation by a portable operator.

J. Declutching Mechanism: Provide a declutching mechanism to disengage the

motor mechanically but not electrically from motor to handwheel operation. If the clutch is of the external lever type, arrange it such that the lever does not move when the motor is energized.

K. Position Indication: Provide an operator-mounted disc position indicator of the

mechanical or indicating light type. For OPEN-CLOSED service, indicate the fully open, fully closed and intermediate disc position either mechanically or by lights. For modulating or throttling service, provide continuous disc position indication between the fully open and fully closed positions. Provide electrical contacts as required for remote indication of disc position.

L. Electric Motor Design: Provide an operator motor of the high torque, ball or roller

bearing, squirrel-cage type designed for continuous valve duty. Provide motor rated for 15 minute duty cycle or three complete opening and closing valve strokes, whichever is longer, during a 60 minute period under full differential pressure at 40 degrees C ambient. Design the motor for use on a nominal 480 volts, 3-phase, 60-hertz electrical service. Provide motor windings and leads with Class F or better insulation with built-in thermal overload protection. In other respects, provide motors meeting the requirements of Section 16220.

M. Housing: Provide housings for controls, gears, and motors with integrally cast

flanges. Fully machine and template drill the flanges and their mating surfaces. Provide joints which are metal-to-metal or gasket or O-ring sealed as required.

N. Control and Motor Enclosures: Provide NEMA 4 control and motor enclosures,

except as otherwise specified. Provide NEMA 7 enclosures where explosion-proof construction is shown or specified. Provide the controller with mechanical interlocks and mount as an integral part of the operator. For explosion-proof enclosures which are dependent upon metal-to-metal faces for weatherproofing,

AARHIP 15110-19

include explosion-proof breathers and drains with desiccant type dehumidification and with sufficient silica gel desiccant for 6 months service without requiring renewal. Include instructions for renewal of the desiccant. Provide a 2-year supply of desiccant.

O. Electrical Compartment Heater: Provide electrical compartment heaters, unless

other means can be proven effective for moisture elimination.

P. Electrical Requirements: Provide electrical controls for the operator as shown or specified. Design operators for 480-volt, 3-phase, 60-hertz service. Design all control circuits for 120- volt, single-phase, 60-hertz ac. Provide an integral 480/120-volt control transformer with fused secondary.

Provide the following:

• Automatic phase rotation to prevent reverse phasing.

• Single phasing protection to eliminate overheating.

• Instant motor reversal protection to remove shock loads through an

automatic time delay circuit.

• A logic circuit to protect the motor from overheating by tripping the contactor if the valve does not move within 7 to 15 seconds from start signal.

• Voltage spike protection by the inclusion of opto-isolators in the circuits,

which can be connected to remote control circuits.

• To prevent moisture ingress and minimize the need for extensive discrete wiring, duplex communication with actuators.

Q. Reversing Controller, Overload Protection and Internal Wiring: Provide a NEMA

rated reversing controller, or an approved special duty rated reversing controller, complete with mechanical interlocks and controls as an integral part of the operator. Provide adequate overload protection in the controller or embedded in the motor windings. Install an overload device in each phase. If overload devices are installed in the motor windings, provide devices of the bimetallic automatic reset type with the contacts in the control circuit. Arrange the internal wiring in the operator so that the opening and closing coils cannot be energized simultaneously at any time, regardless of external wiring conditions. Provide reversing controller suitable for 60 starts per hour at a rate of up to 600 starts per hour.

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R. Push Buttons and Selector Switches

1. Provide the operator with Local-Off-Remote mode selector. In Local, configure the valve to respond to only the Open/Stop/Close controls at the actuator. In Off, the actuator is not to respond to any control inputs. In Remote, configure the actuator to respond to both the remote contact Open/Close inputs and the commands issued over the “Two-Wire Control System” described below.

2. Where the operator is 7 feet or less from the floor and in an accessible

location, mount controls on the operator housing. Where the operators are located over 7 feet from the floor or in an inaccessible location, connect all internal control and indication wiring to a terminal block within the operator enclosure and provide a separate control station for remote mounting. Provide the remote control station with the same NEMA rating as the operator. Where remote control stations are required, provide the station with Local-Off-Computer mode selector, Open/Stop/Close pushbuttons and Open/Closed indicating lights. Contractor is to provide all required interconnecting cable and conduit as shown.

S. Two-Wire Control System: Provide operators configured for two-wire networked

control and monitoring as specified hereinafter in the section headed “Two-Wire Actuator Control System”.

T. Limit and Torque Switches: Provide the operator with limit and torque switches,

either direct or gear driven. Provide adjustable limit and torque switches with auxiliary contacts that are operative in either direction of travel. Provide limit switches that are "in step" with torque switches at all times, whether in motor or manual operation. Equip the operator with limit switches to stop movement in each direction and torque switches for protection against mechanical overload and to stop movement in either direction if an obstruction is encountered. Provide the number, function and arrangement of limit switches as shown, specified or required.

U. Additional Accessories: Provide additional limit switches, indicating lights,

position transmitters and remote position indicators, remote operating controls and other accessories and controls as shown, specified or required.

V. Control Components, Operator Housing and Operator Wiring: Provide control

components and operator housing that meets the requirements of Section 16055. Provide operator wiring that meets the requirements of Section 16121.

W. Submit the following information:

• Current at maximum load

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• Torque at maximum

• Flash test voltage

• Actuator output speed or operating time

Provide test certificates that provide a record of the details of the actuator’s specifications such as gear ratios for both manual and automatic drive, closing direction, and wiring code number.

X. Disconnect Switches: Provide a circuit breaker disconnect switch for each

operator as specified in Section 16413. 2.21 CONTROL VALVES

A. Manual Operated: For manually operated 4-way control valves associated with pneumatic and low pressure hydraulic cylinders, provide disc, packless type valve for valves 1-1/4 inches and less in size and eccentric plug valves that meet the requirements of Subsection headed "General" and "Eccentric Plug Valves" for valves larger than 1-1/4 inches in size.

B. Solenoid-Operated: Provide 4-way, differential-operated, packless, poppet seat

type solenoid-operated control valves with all parts rustproof and noncorrosive. Provide coils of the molded type, Class B insulated, in NEMA Type 4 Enclosure for nonhazardous areas and NEMA Type 7 for hazardous areas, designed for operation using 120-volt, 60-hertz current. Provide single-solenoid type valves. Arrange the solenoid such that when energized it positions the 4-way valve to open the cylinder-operated valve and when de-energized, it positions the 4-way valve to close the cylinder-operated valve. Arrange the 4-way valves for manual operation independent of and without disturbing the electrical control.

2.22 PORTABLE OPERATOR

A. Provide a portable operator of the electric drill type with a reversing switch and safety hold-down ON-OFF switch incorporated in the handle. Provide a heavy-duty electric drill that drives through an overload release clutch of the positive, spring loaded, hand type which instantly releases at a preset torque. Provide adaptors to fit the pinion shafts on the floor stands and other operators. Furnish a heavy-duty cord at least 30 feet long with an explosion-proof plug. Provide a plug that is compatible with the convenience outlets specified under Section 16140. Mount the unit on a tripod which has an adjustable height. Provide a unit that operates using 120-volt, 60-hertz current.

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2.23 EXTENSION STEMS, VALVE BOXES AND FLOOR BOXES

A. Equip all direct burial valves and valves in vaults or manholes with operating nuts and extended shafts to grade, unless otherwise shown or specified. Equip all direct burial valves with adjustable type, cast-iron, valve boxes and extended shafts to grade. Equip all valve boxes and floor boxes with ground level valve position indicators, unless otherwise shown or specified. Provide two tee wrenches for each size and type of operating nut.


A. Eccentric Plug Valve Leakage Test: Perform a plug leakage shop test on each eccentric plug valve with the plug in the closed position. Unless otherwise specified, perform the leakage test with a minimum pressure of 150 pounds per square inch (gauge) applied sequentially to both the upstream and downstream faces of the plug. Perform the test for a minimum duration of 15 seconds. Demonstrate that there is no leakage past the plug.

B. Eccentric Plug Valve Hydrostatic Test: Give each eccentric plug valve hydrostatic

shop pressure tests with the plug open and with the plug closed. Perform the hydrostatic tests with a minimum pressure that is at least equal to the test pressure specified for the pipeline in which the valve is installed. Perform the test for a minimum duration of 30 seconds. Demonstrate with the hydrostatic tests that the valve is structurally sound and that there are no leaks through the external surfaces of the valve.

C. Hydraulic Power Unit Shop Test: Prior to shipping the fluid power unit, conduct a

shop test that demonstrates that the unit fulfills the operating requirements of the Specifications.

2.25 TWO-WIRE ACTUATOR CONTROL SYSTEM

A. General:

1. The data monitoring and control system shall consist of a master station and field units. The master station shall perform the tasks of bus master, data collector, data concentrator, operator interface, protocol converter, sequencer, and be a slave to a host system.

2. The system shall be capable of operating with up to 240 field units as shown

on a two-wire shielded twisted pair data highway of length up to 20 kilometers (12.5 miles) without repeaters or other additional devices. The cable shall be connected from the master station to each field unit in turn and back to the master station.

3. The master station shall provide two communication ports with the

following modes of communication:

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a. Serial data communication with a host system such as a Distributed

Control System (DCS), PLC, RTU, or computer via data ports and the Modbus protocol.

b. Ethernet communication with support for Modbus TCP for data

exchange and TCP/IP for Web Server mode.

4. The master station and field units shall be protected against lightning by the provision of transient suppresser devices on all two-wire connection ports rated at 1.5k V for one millisecond. Opto-isolation shall be used within the field units and master station for enhanced noise protection.

5. Provide Rotork Pakscan IIE master station.

B. Master Station

1. General: The master station shall be of microprocessor type, suitable for

indoor mounting. All signals from the master station to the field units shall be suitable for transmission over a two-wire twisted pair cable with overall shield and shall use a current loop serial data communication. This cable shall be connected from the master station to each field unit in turn and then back to the master station.

2. The master station shall operate utilizing 90 to 264VAC, 43 to 440Hz, 1

amp

3. Enclosure: Provide the master station assembly housed in a wall mount, Nema 12 steel enclosure. Provide the enclosure door with a window kit to allow viewing the master station display status.

4. Display Panel and Keypad: The master station shall include a multi-line

LCD display panel and operator control keypad to allow it to be used as an operator interface. The display panel shall be capable of showing the status and tag number of every connected field unit, actuator, or other device associated with the field unit, the status of the master station, the system settings, the host protocol messages, the loop performance and any alarms present on the system.

The keypad shall permit viewing of any or all of the system data, including preset parameters in each field unit. It shall also allow the connected actuators or other devices to be operated. A security system shall be included to prevent access to control and setting of parameters. It shall be possible to set the highest address number of connected field units to minimize scanning times.

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5. Clock: A real time clock shall be included for alarm event time/date marking and it shall be possible to connect a serial alarm event printer to the RS232 port.

6. Backup Power Source: A long life battery shall be incorporated to retain the

parameter settings, clock and sequence programs in memory in the absence of a main power supply. Should the battery deteriorate, a warning indication shall be displayed on the master station's status screen. In the absence of both the battery and the main power supply, the memory must be maintained for at least an hour. Furthermore, basic setup data (such as port setups and addresses) must be held in a non-volatile EEPROM.

C. Host Communications

1. Host communications shall include both a serial port and an Ethernet port.

Configure the master station for data exchange via the serial port and for master station status and diagnostics via the Ethernet port.

2. Serial Port:

a. Serial host system communication shall be by either RS232 and/or

RS485. The Baud rate shall be adjustable from 2,400 to 96,000 with odd, even, always zero, or no parity.

b. The serial port host protocol shall be Modbus to minimize custom

software and programming.

3. Ethernet Port:

a. Ethernet communication shall be configurable for either (1) data exchange using Modbus TCP protocol or (2) for status information and diagnostics using an embedded web server.

b. Configure the Ethernet port for this project with the embedded web

server to allow the Owner to access the master station information over the plant’s Ethernet Local Area Network using a standard web browser. Allow the user to set up to three levels of password protection for access to the embedded web server.

c. Provide RJ-45, 10Base-T or 100Base-TX Ethernet port

D. Field Communications

1. The two-wire loop shall use a 20mA current for data transmission with a

maximum applied voltage of 15V. The current shall be modulated to enable messages to be transmitted. Full CRC and message framing checks must be included in the data protocol.

AARHIP 15110-25

2. The system shall continuously cyclically poll each connected field unit and

report any changes in status of the field unit or communication failure. On receipt of a command from the master station keypad or the host system, such as a PLC, the command shall take precedence over the data collection, polling shall cease, and the command shall be immediately transferred to the field unit. Provision shall be included to ensure the field unit has received the command correctly.

3. Failure or loss of power to any one or more connected field units on the

two-wire cable shall not cause loss of control or communication with the remaining devices connected on the cable. On restoration of power to a field unit, it shall be located and communicated with automatically.

4. The system shall tolerate a single open, short, or ground fault in the

two-wire cable without losing the ability to communicate and control any field unit remaining connected. An alarm shall be posted to indicate between which two field units the fault has occurred. Multiple faults shall result in the loss of communication with those field units which have become isolated and not the entire system. This cable security feature shall be inherent in the system and achieved using only a single cable without the need for duplicate or additional hardware.

E. Field Unit

1. Field units shall be plug-in cards, or easily added to existing valve actuators.

They shall also be available in a variety of enclosures suitable for location in the field or control room environment.

2. Parameter Settings: There shall be settings for the loop baud rate and unique

address (up to 32) for each field unit. These settings shall be made non-intrusively without the need to remove covers or gain access directly to the field unit itself. Where general purpose field units are required, it shall be possible to invert the reported input signal status.

3. Valve Actuator Field Units: When fitted to a suitable valve actuator, the

field unit shall require no additional power connection. The field unit shall form an integral part of the actuator assembly and it shall be an addition to the actuator control circuit and independent from that control circuit. It shall report the following signals to the master station:

Valve Opening, Valve Closing, Valve Open, Valve Closed, Valve Stationary in Mid-Position, Actuator Fault, Field Unit Fault, Cable Fault.

In addition, it shall also report some or all of the following signals:

AARHIP 15110-26

Continuous Valve Position, Monitor Relay Trip, Thermostat Trip, Local Stop Selected, Local Control Selected, Valve Obstructed, Valve Jammed, Four Additional Remote Digital Input Signals.

Remote control functions shall be provided to permit the actuator to Open Fully, Close Fully, Stop at Any Time, Assume an Intermediate Position, Assume Emergency Shut-Down (ESD) Position. It shall be possible to direct the actuator to position the valve to any desired intermediate position by entering a percentage open desired position. This applies to both modulating and non-modulating actuators.

Special Note: For actuators provided with remote mounted control stations (due to being inaccessible), program the field unit to monitor a contact on its ESD input from the remote control station’s Local-Off-Computer mode selector. Configure the wiring so that when the mode selector is in “Computer”, the ESD input is active. Program the field unit to only accept commands issued over the two-wire network when the ESD input is active (i.e. in Computer mode).

When forming an integral part of the actuator, the field unit must be located in a separate compartment from the field terminals. This compartment shall be double "O" ring sealed from the external environment. The whole enclosure shall be to IP68 (NEMA IV and NEMA VI).

When control room located, the field unit shall be 19" rack mounted and provided with a suitable 19" rack. All connections to the unit shall be to the front.

The actuator and field unit combination shall be suitable for an operating temperature of -30°C to +70°C and +80°C storage.

4. General Purpose Field Units: General Purpose Field Units shall be similar

to actuator field units with the same isolation and protection capabilities. They shall be capable of reporting the status of eight digital and two analog (for example, 4-20mA) inputs.

The field unit shall be capable of providing four digital outputs, each configurable for fleeting or maintained status and one analog (0-5V) output. All I/O shall have discrete address capability.

When field mounted, the field unit enclosure shall be to IP68 (NEMA IV and VI). In hazardous area applications, it shall be certified to a minimum of Eexd IIB T4. The field unit must be located in a separate "O" ring sealed compartment from the field terminals to preclude the ingress of moisture.

For control room location, the field unit shall be 19" rack mounted and provided with a suitable 19" rack. All connections to the unit shall be to the front.

AARHIP 15110-27

The General Purpose Field Unit shall be suitable for an operating temperature range of -30°C to +70°C, and +80°C storage.

F. Test Equipment

1. Provide hand-held test equipment to facilitate the testing of installed field

units and the setting of field unit parameters. Field unit testers shall be able to emulate master station communication on a two-wire loop terminals, as well as evaluate status and diagnostic information.

2. Master station test equipment shall be in addition to the master station

display and keypad. It shall connect to the RS232 host communication port and be capable of emulating a host system.

3. Turn all test equipment over to Owner personnel following installation of

equipment.

G. Experience

1. Supplier must have at least three (3) years of commercial operating experience and be able to provide at least ten (10) trouble free site references.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install valves in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Eccentric Plug Valves: Unless otherwise shown or specified for eccentric plug

valves installed in horizontal piping, orient the valve such that the shaft is in the horizontal position, the seat is in the downstream position and when the valve is in the open position the plug is up. Unless otherwise shown or specified, for eccentric plug valves installed in vertical piping, orient the valve with the plug up when the valve is in the closed position.

C. Floor and Bench Stands: Accurately center floor and bench stands over the valve.

Solidly bolt stands to the floor or support structure, with through-bolts wherever possible. Place approximately 3/4 inch of nonshrink cement grout beneath stands mounted on concrete or similar construction to assure uniform support. For stands installed within the area of a removable type floor, platform, or grating, securely mount them on their own support structure independent of the removable element, unless otherwise shown or specified.

AARHIP 15110-28

3.2 PAINTING AND COATING

A. General: Unless otherwise specified, coat the inside iron or steel surfaces of all valves and exterior surfaces of valves and operators that are to be buried in the ground or immersed in sewage or water with two coats of asphalt varnish. Paint exterior surfaces of other valves and operators as specified in Section 09900.


A. Manufacturer's Field Services: Furnish the services of a qualified representative of each of the various manufacturers to provide instruction on the proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, as specified in Division 1.

B. Tests: After installation of the valves, control equipment and all appurtenances,

subject the units to a field running test, as specified in Division 1, under actual operating conditions. Operate each valve through one complete open-close cycle under the maximum pressure differential practical.

3.4 OPERATION DEMONSTRATION

A. Manufacturer's Field Services: Furnish the services of a qualified representative of each of various manufacturers to demonstrate the proper operation and instruct plant personnel in the equipment's operation and maintenance, as specified in Division 1.

3.5 PAINTING

A. Paint the equipment in accordance with the requirements in Section 09900. 3.6 SCHEDULE

A. Refer to Contract Drawings for valve schedule.

3.7 MANUFACTURER’S AGREED PRICES

In consideration of the City of Ann Arbor inserting in the proposed contract to be entered into between the City and the successful Bidder for the construction of the Residuals Handling Improvements Project, a requirement for the Bidder to offer in the base bid for DeZurik plug valves, knife gate valves, butterfly valves, and Rotork actuators as scheduled. Additional Rotork components required for a complete system as specified is to be provided at the agreed price as well. DeZurik and Rotork have submitted a Proposal to the City to furnish such equipment, appurtenances and devices as described in this Section to each Bidder at an agreed

AARHIP 15110-29

price as listed in the attached proposal included herewith and made part of this Section.

END OF SECTION

AARHIP 15110-30

AARHIP 15110-31

AARHIP 15110-32

AARHIP 15122-1

SECTION 15122

PRESSURE SWITCHES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing pressure sensing devices, pressure transfer tubing, pressure switches and isolating devices as shown and specified. Some pressure switches are located within hazardous areas as defined by the NEC. Refer to Specifications Section 16050 for area classification. If the pressure switch is located within an area classified as hazardous, provide the appropriate Class I, Division1, Division 2, Group D rated pressure switch.


Following:

1. Section 15108 - Miscellaneous Piping and Fittings 2. Section 15110 - Valves 3. Section

1.2 REFERENCES


1. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings 1.3 DELIVERY, STORAGE AND HANDLING


PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Pressure Switches

a. Model No. DAW-33-153 as manufactured by Mercoid Corp.

AARHIP 15122-2

2.2 DESIGN

A. Construction: Provide pressure switches of a bourdon tube type pressure device with a sealed mercury switch. Manufacture the bourdon tube of brass. Provide a 1/4-inch NPT pressure connection protruding from the bottom of the case. Design the switch with an adjustable operating point with a range of 0 to 100 psig. Provide a single pole, double throw, switch, rated at 4 amps for 120-volt ac power to operate on pressure increase and to have automatic reset. House the entire device in an enclosure suitable for the location described in Specification Section 16050. Supply a pressure snubber. Provide Delrin bushings.

B. Diaphragm Seal: Isolate pressure switches from process fluids by a diaphragm

seal or a full line size pressure sensor. Provide the diaphragm seal with a 1/4-inch NPT pressure device connection and a 1/2-inch NPT process connection and minimum seal diameter of 2-1/2 inches. Equip the seal with a cleanout designed for continuous duty, and fitted with a 1/4-inch NPT flushing connection. Fabricate the diaphragm of Type 316 stainless steel. Construct the lower and upper case of steel with a rust-resistant coating. Provide all wetted parts which are corrosion resistant to the process liquid. Liquid fill the case as recommended by the manufacturer. Factory assemble and calibrate all liquid filled pressure switch-diaphragm seal units at the point of manufacture, and ship for installation as a unit.

C. Shutoff Cocks: Provide shutoff cocks for each process connection constructed of

(brass) (Type 316 stainless) (plastic).

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all products in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

END OF SECTION

AARHIP 15124-1

SECTION 15124

GAUGES - PRESSURE AND VACUUM

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing gauges and isolating devices as shown and specified.


Following:

1. Section 15108 - Miscellaneous Pipe and Fittings 1.2 REFERENCES


1. ASME B40.100 - Pressure Gauges and Gauge Attachments 1.3 SUBMITTALS

A. Provide all submittals, including the following, as specified in Division 1. 1.4 DELIVERY, STORAGE AND HANDLING


PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Gauges

a. Mastergauge by Marsh Instrument Company.

b. Supergauge by U.S. Gauge, a Division of Ametek, Inc.

c. Duragauge by Ashcroft, Industrial Valve and Instrument Division,

Dresser Industries.

AARHIP 15124-2

d. Helicoid Gauges by Helicoid Gauge Division, ACCO (American

Chain and Cable Company, Inc.)

2. Pressure Gauge for Chemical Feed Equipment

a. Type 1008S by Ashcroft, Industrial Valve and Instrument Division, Dresser Industries.

2.2 DESIGN

A. General: Provide gauges to include pressure, vacuum, and compound gauges of the dial-indicating bourdon tube type. Manufacture gauges to the requirements of ASME B40.100 except as modified herein. Locate gauges as shown or specified. Wall mount or independently support gauges for any vibrating equipment.

B. Pressure Gauges: Provide Grade 2A pressure gauges with a range of 0 to 100 psig,

with an accuracy of 0.5 percent of the maximum scale reading.

C. Compound Vacuum and Pressure Gauges: Provide Grade 2A compound vacuum and pressure gauges a vacuum range of 0 to 30 inches of mercury and a pressure range of 0 to 60 psig with an accuracy of 0.5 percent of the maximum scale reading,

2.3 CONSTRUCTION

A. Construct gauges with a nominal size of 4-1/2 inches. Provide bottom located pressure connection, 1/4-inch NPT, male fitting extending a minimum of 1-1/4 inches beyond the case and with large wrench flats. Construct the bourdon tube and fitting of bronze. Provide a weatherproof case of the stem mounted type, constructed of epoxy coated cast aluminum. Design the movement to be rotary gear or helical roller type designed to minimize wear and maintain accuracy. Make provisions for adjustment of zero reading. Manufacture dials white faces with black numerals and markings. Provide gasket sealed glass windows to prevent moisture and dust from entering the gauge case.

2.4 DIAPHRAGM SEALS

A. General: Furnish diaphragm seals to isolate the process fluid from the pressure gauge. Provide Grade 2A gauge (0.5 percent) seal and gauge combined accuracy of 1.0 percent of the maximum scale reading. Equip the seal with a 1/4-inch NPT pressure device connection and a 1/2-inch NPT process connection. Design the 2-1/2 inches minimum diameter seal for continuous duty, fitted with a 1/4-inch NPT flushing connection, and of the cleanout type. Manufacture the diaphragm of Type 316 stainless steel. Construct the lower and upper case of Type 316 stainless steel. Make all wetted parts corrosion resistant to the process liquid. Provide liquid filled case as recommended by the manufacturer. Factory assemble and calibrate

AARHIP 15124-3

all liquid filled pressure gauge-diaphragm seal units at the point of manufacturer and ship and install as a unit.

B. Pulsation Dampening: Provide sintered metal snubbers or orifice plate restrictors

for pulsation dampening, and of brass construction. Locate pulsation dampening devices adjacent to the pressure device.

C. Shutoff Cocks: Provide shutoff cocks, for each gauge, constructed of brass.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install pressure gauges in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

END OF SECTION

AARHIP 15124-4


AARHIP 15183-1

SECTION 15183

HYDRONIC PIPING VALVES AND SPECIALTIES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Piping systems for hot water (glycol solution) heating, make-up water for these systems, valves, and hydronic specialties.


1. Section 02316 - Excavation 2. Section 02317 - Backfilling 3. Section 02500 - Laying and Jointing Buried Pipelines 4. Section 09900 - Painting 5. Section 15060 - Supports and Anchors 6. Section 15072 - Vibration Isolation 7. Section 15080 - Mechanical Insulation 8. Section 15107 - Steel Pipe and Fittings 9. Section 15108 - Miscellaneous Pipe and Fittings 10. Section 15109 - Erecting and Jointing Interior Pipelines 11. Section 15110 - Valves and Valve Operators 12. Section 15124 - Gauges - Pressure and Vacuum

1.2 REFERENCES


1. ASME Boiler and Pressure Vessel Code Sec 9 - Welding and Brazing Qualifications

2. ASME Boiler and Pressure Vessel Code Sec 8 - Pressure Vessels

3. ASME Boiler and Pressure Vessel Code Sec 4 - Heating Boilers

4. ASME B31.9 - Building Services Piping


6. AWS D1.1 - Structural Welding Code

AARHIP 15183-2

7. ASTM A 126 - Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

1.3 DEFINITIONS

A. Pipe Sizes: Pipe sizes used in this Specification are Nominal Pipe Size (NPS). 1.4 SYSTEM DESCRIPTION

A. General: The hydronic piping systems are the "water-side" of an air-and-water heating and air conditioning system. Hydronic piping systems specified in this Section include hot water (glycol solution) piping systems. These systems are classified by ASHRAE as Low Water Temperature, Forced, Recirculating systems.

B. Pipe System: The pipe system includes hot water supply and return piping mains

in a closed loop, connecting the boilers to the terminal heat transfer units by means of primary/secondary piping loops. Circulation is accomplished by parallel, variable volume, primary pumps and independent secondary pumps.

1.5 SUBMITTALS


B. Operation and Maintenance Data: Submit operation and maintenance data for

hydronic specialties and special duty valves, for inclusion in the operation and maintenance manual as specified in Division 1. Include installation instructions, assembly views, lubrication instructions, and replacement parts list.

C. Welders' Certificates: Submit welders' certificates certifying that welders meet the

quality requirements specified in Quality Assurance below.

D. Certification: Submit certification of compliance with ASTM and ANSI manufacturing requirements for pipe, fittings, and specialties.

E. Shop Drawings: Submit shop drawings detailing dimensions, required clearances

for connection to equipment, complete hydronic piping layouts and details indicating the amount of expansion and provisions for system expansion, component details and location of miscellaneous fittings, including anchors, end seals, gland seals and field closures. Submit drawings indicating location of field joints with respect to permanent structures or markers.

F. Product Data: Submit product data for manufactured products and assemblies

specified. Include component sizes, rough-in requirements, service sizes, and finishes. Include product description, model, and dimensions.

AARHIP 15183-3

G. Pressure Settings: Submit system calculations for PRVs, Diaphragm Compression Tanks and other appurtenances required for proper system operation.


A. Regulatory Requirements: Conform to ASME - Boiler and Pressure Vessel Code Section 8D for the manufacture of tanks.

B. Valves: Provide the manufacturer's name and pressure rating marked on the valve

body.

C. Welding Materials and Procedures: Conform to ASME Section 9 for welding and brazing qualifications.

D. Welders Certification: Provide welders and brazers certification in accordance

with ASME Boiler and Pressure Vessel Code Section 9.

E. Manufacturer: Provide hydronic specialties of the same manufacturer throughout if available.



B. Delivery and Storage: Deliver and store piping and specialties in shipping

containers with labeling in place. Store indoors in a clean, dry place.

C. Protection: Protect piping and specialties from entry of contaminating material by leaving end caps and plugs in place until installation.

1.8 SEQUENCING AND SCHEDULING

A. General: Coordinate the size and location of concrete equipment pads. Cast anchor bolt inserts into pads. Concrete, reinforcement and formwork requirements are specified in Division 3. Coordinate the installation of pipe sleeves for foundation wall penetrations.

1.9 SPARE PARTS

A. Maintenance Stock: Furnish a sufficient quantity of chemicals for initial system start-up and for preventive maintenance for one year from the date of Substantial Completion.

AARHIP 15183-4

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Valves

a. Ball Valves

(1) Stockham - Model S-216-BR1-R-T (2) Crane - Model 9302-S (3) Nibco - T585-70-66

b. Manual Balancing Valves

(1) DeZurik - Series 100 (4 inches and larger) (2) Dresser - X-Centric (4 inches and larger) (3) ITT Bell & Gossett - (3 inches and smaller) (4) Taco (3 inches and smaller)

c. Flow Measuring Devices

(1) ITT Bell & Gossett - Type "A" Circuit Setter (2) Armstron Pumps Inc. - Type APD

2. Relief Valves

a. Bell & Gossett ITT b. Amtrol, Inc. c. Spirax Sarco d. Watts Regulator Co.

3. Pressure Reducing Valves

a. Bell & Gossett ITT b. Armstrong Pumps, Inc. c. Amtrol, Inc. d. Taco, Inc.

4. Air Vents (manual)

a. Bell & Gossett ITT b. Armstrong Machine Works c. Hoffman Specialty ITT d. Spirax Sarco.

AARHIP 15183-5

5. Air Vents (Automatic)

a. Hoffman No. 79 b. Armstrong I-AV

6. Air Separators:


7. Diaphragm-Type Compression Tanks

a. Bell & Gossett ITT b. Armstrong Pumps, Inc. c. Amtrol, Inc.

8. Triple Duty Valves

a. Bell & Gossett ITT b. Armstrong Pumps, Inc.

9. Trumpet Valves

a. Flow Conditionic Corp.

10. Diverting Fittings


11. Dielectric Waterway Fittings

a. Victaulic Company of America

12. Y-Pattern Strainers

a. Armstrong Machine Works b. Hoffman Specialty ITT c. Metraflex Co. d. Spirax Sarco e. Trane Co.

AARHIP 15183-6

f. Victaulic Co. of America g. Watts Regulator Co.

13. Pressure Fill for Hydronic System - Bornquist Inc. - Model BPF

a. Glycol-Water Mixing Tank

(1) Bornquist Inc.

b. Glycol Solution Pump and Pressure Tank

(1) Burks Pumps - HNAS

c. Water Feed Make-Up Assembly

(1) McDonnell - No. 247 Water Feeder

d. Flow Balance Valve

(1) Bell & Gossett - Circuit Setter Plus

e. Back Flow Check Valve

(1) Bell & Gossett - Flo-Control Valve

14. Test Plugs (P&T):

a. Universal Lancaster b. Pete-Plug

15. Thermometers

a. Moeller b. Weksler

16. Pipe Sleeves

a. Thunderline Corporation, "Link Seal" Model WS

17. Underground Heating Water Piping Systems

a. PERMA-PIPE b. Ricwil Inc. c. Rovanco Corp.

AARHIP 15183-7

2.2 MATERIALS

A. Pipe, Tubing and Fittings: Provide pipe, tubing and fitting materials as follows:

1. Provide steel pipe and fittings complying with requirements specified in Section 15107.

2. Provide copper tubing and fittings complying with requirements specified in

Section 15108.

B. Hangers and Supports: Provide hangers and supports as specified in Sections 15060 and 15109.

C. Flexible Connectors: Comply with requirements specified in Section 15072.

D. Pressure: Comply with requirements specified in Section 15124.

E. Valves: Provide valves as follows:

1. General: Provide valves recommended by their manufacturer for the

conditions of use as installed, capable of tight shutoff under those conditions, and recommended for fluid operating temperature up to 250 degrees F.

Equip valves in insulated pipes with an extended neck to clear the insulation.

Provide screwed pattern and soldered pattern valves with unions to facilitate removal from the pipe.

Provide accessible pressure rated 3/4-inch hose end gate valves at low points for draining each water piping system.

2. Butterfly Valves: Provide butterfly valves complying with requirements

specified in Section 15110.

3. Gate Valves: Provide gate valves complying with requirements specified in Section 15110.

4. Globe and Check Valves: Provide globe and swing type check valves

complying with requirements specified in Section 15110.

5. Ball Valves: Provide a screwed pattern 2-piece brass or bronze ball valve rated at 125 psi minimum, with stainless steel trim, free floating ball, stem shoulder preventing blowout, reinforced teflon stem seals and seats, and a rustproof handle with stop clearing the pipe insulation.

AARHIP 15183-8

6. Manual Balancing Valves: Provide valves 4 inches and larger rated at 125 psi SWP, nonlubricated eccentric plug type, flanged pattern, with through shaft, 0-ring seals and "memory stop" for returning to balance setting after shutoff. Provide valves through 6 inches furnished with a lever handle. Provide valves 8 inches and larger with gear operators.

Provide an orifice insert type flow measuring device for each manual balancing valve sizes 4 through 12 inches. Provide the flow measuring orifice of the flanged or butt welding type complete with built-in taps, check valves with gasketed caps or manual shutoff valves. Furnish each flow measuring orifice with a calibrated nameplate detailing its flow range through a range of differential head pressures.

Provide manual balancing valves 3 inches and smaller to be the circuit setter type with integral leakproof pressure taps and calibrated nameplate.

Provide a portable meter with required accessories for reading gpm flow throughout the range of manual balancing valve sizes.

F. Relief Valves: Provide valves suitable for 150 psig working pressure and 250

degrees F maximum operating temperature; designed, manufactured, tested and labeled in accordance with the requirements of Section IV of the ASME Boiler and Pressure Vessel Code. Fabricate valve body of cast iron, with all wetted internal working parts made of brass and rubber. Provide test lever. Select valve to suit actual system pressure and Btu capacity.

G. Pressure Reducing Valves: Provide diaphragm operated, cast-iron or brass body

valves, with low inlet pressure check valve, monel or stainless steel strainer removable without system shut-down, and noncorrosive valve seat and stem. Select the valve size, capacity, and operating pressure to suit system. Provide factory-set valves set at the operating pressure with the capability for field adjustment.

H. Manual Air Vents: Provide air vents constructed of bronze body and nonferrous

internal parts; 150 psig working pressure, 225 degrees F operating temperature; manually operated with screwdriver or thumbscrews having a 1/8-inch discharge connection and a 1/2-inch inlet connection.

I. Automatic Air Vents: Provide air vents constructed of brass with stainless steel

valve and valve seat suitable for a 75 psig working pressure, 250 degrees F operating temperature, automatic float type, having a 1/8-inch drain connection and a 1/2 inch inlet connection.

J. Air Separators: Provide air separators of welded black steel with an enamel finish;

ASME constructed, tested and labeled for a minimum 125 psig water working pressure and 375 F operating temperature; perforated stainless steel air collector tube designed to direct released air into compression tank; tangential inlet and

AARHIP 15183-9

outlet connection; integral stainer; with a free area of not less than five times the cross-sectional area of the connecting pipe, screwed connections up to and including 2-inch size; flanged connections for 2-1/2-inch size and above; threaded blowdown connection; 3/4-inch automatic air vent, sized as indicated for full system flow capacity.

K. Diaphragm-Type Compression Tanks: Provide compression tanks of the size and

number shown, constructed of welded carbon steel with enameled finish, for 125 psig working pressure, 375 degrees F maximum operating temperature. Separate the air charge from the system water to maintain the design expansion capacity, by means of a flexible heavy-duty butyl diaphragm securely sealed into tank. Provide taps for the pressure gauge, air charging fitting, and drain fitting. Support vertical tanks with steel legs or base. Construct, test and label tanks with taps and supports in accordance with ASME Pressure Vessel Code, Section VIII, Division 1. Provide an air charging valve and a tapping for system connection.

L. Triple Duty Valves: Provide triple duty valves in discharge piping of each

centrifugal pump. Provide each valve comprised of a non-slam check valve with spring-loaded weighted contoured dick and calibrated adjustment feature permitting regulation of pump discharge flow and positive shut-off. Provide pressure drop data for valve at 10 degrees F increments. Design valves to permit repacking under full line pressure and construct with cast iron body suitable for maximum working pressure of 175 psig and 250 degrees F temperature.

M. Trumpet Valves: At each base mounted pump, provide hydronic indicator having

a minimum of 3 indicating parts. Provide assembly consisting of 3 port trumpet valve manifold plus 4-1/2-inch diameter pressure gauge, reading both psig and feet head, and having accuracy of 1/2 of 1 percent. Select pressure gauge so that pointer indicates approximately center scale at operating conditions.

N. Diverting Fittings: Provide cast-iron body fittings with threaded ends, or wrought

copper with solder ends for 125 psig working pressure, and 250 degrees F maximum operating temperature. Indicate the flow direction on the fittings.

O. Dielectric Waterway Fittings: Provide threaded or soldered end connections for

the pipe materials in which installed; constructed to isolate dissimilar metals, prevent galvanic action, and prevent corrosion.

P. Y-Pattern Strainers: Provide stainers suitable for a 125 psig working pressure with

a cast-iron body (ASTM A 126, Class B), flanged ends for 2-1/2 inch and larger, threaded connections for 2-inch and smaller, bolted cover, perforated Type 304 stainless steel basket, and bottom globe valved blowdown connection. Provide strainers with a free area of at least 4 times the pipe cross-sectional area, with pressure drop through clean stainers not exceeding 0.6 psig to the design flow.

AARHIP 15183-10

Q. Pressure Fill for Hydronic Systems: Provide a complete pressure fill system for initial fill and manual make-up of 30 percent glycol-water solution to the hydronic systems with the following features.

1. Provide the glycol-water mixing steel tank to be a 55 gallon 20-inch by 48-

inch high galvanized vertical surge tank vented to the atmosphere, having reinforced top edge and a hinged removable cover, all supported on 12 inch high angle legs.

2. Provide a water feed make up assembly for level control and to allow an

open break between the water supply and the surge tank. Provide 1-inch piping for equalizing connections and 1-inch to water supply.

3. Provide a priming centrifugal pump mounted on 30 gallon galvanized steel

horizontal pressurization tank, equipped with automatic air volume control and two-pole pressure switch. Provide field connection from the surge tank to pump inlet using 1-1/4 inch pipe.

4. Provide a 1-1/4 inch calibrated flow balance valve and 1-1/4 inch back flow

check valve, for field mounting, between the surge tank and pressurization pump.

R. Test Plugs (P&T): Provide pressure-temperature test plugs with a Nordel core and

threaded brass cap in a tee or threadolet, a set of 2-inch dial thermometers, pressure gauge, necessary adapters and carrying case for use with the plugs in the following ranges:

1. Thermometer: 10 to 250 degrees F (0.5 percent accuracy).

2. Pressure Gauge: 0 to 30 psig (0.5 percent accuracy).

S. Thermometers: Provide 3-inch diameter bimetal dial thermometers or 9-inch scale

red reading industrial thermometers suitable for temperature ranges of approximately 50 to 250 degrees F and 0 to 100 degrees F in 2-degree F increments, complete with fumeproof stainless steel or cast case and glass face, 6-inch stem, and 2-1/2-inch extension neck separable well.

T. Pipe Sleeves: Provide pipe sleeves constructed of heavy gauge seamless steel pipe

with a full circle continuously welded water stop plate to provide positive water sealing and to prevent any thrust movement. Provide pipe sleeves to mate with modular mechanical type seals, consisting of interlocking synthetic rubber links shaped to continuously fill the annular space between the pipe and construction opening.

AARHIP 15183-11

U. Underground Heating Water Piping Systems. Provide underground pre-insulated steel pipes, fabricated to job dimensions with all required fittings, anchors, expansion loops, branch connections and other accessories, and as follows:

1. Construct the outer jacket of fiberglass reinforced polyester resin or

polyvinyl chloride with a minimum thickness meeting H-20 Highway Loading but at least 60 mils thick. Center the carrier pipe in the outer jacket and insulate with preformed or foamed-in-place polyurethane insulation completely filling the annular space around the carrier piping.

2. Provide 1-1/2 inch thick polyurethane insulation with a uniform density of at

least 1.8 pounds per cubic foot, with conductivity not exceeding K=0.17 BTU at 75 degrees F average temperature, and capable of withstanding 250 degrees F temperature continuously without deterioration.

3. Fabricate pre-insulated piping in the factory with matching insulated bends,

fittings and required anchor plates.

4. For a sufficient length from the elbows at expansion loops and piping offsets provide increased insulation by at least 1-inch to allow for deformation due to pipe expansion.

5. Prior to the factory insulation and jacketing of the carrier piping,

hydrostatically test the piping at 150 psig water pressure, and remake and retest leaking welded joints until joints are proved watertight.

6. Provide each section of the pre-insulated piping with factory installed

insulation and seals of the same material as the jacketing. Heat protect the insulation during the field welding of the joints.

7. Provide factory fabricated end seals, gland seals and anchors to prevent the

ingress of moisture into the system.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine all hydronic specialties at the time of delivery for damaged or missing components. Do not proceed with installation of equipment until all items found defective have been corrected.

3.2 INSTALLATION

A. General: Install hydronic specialties in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

AARHIP 15183-12

Make all necessary adjustments to provide a complete and satisfactory operation upon completion of the installation.

Provide each hydronic circuit with a balancing valve to set flow rate. Provide the manual adjustment type, as shown.

Provide unions at each flow control valve.

B. Relief Valves: Install safety relief valves on hot water boilers, and elsewhere as

required by ASME Boiler and Pressure Vessel Code. Pipe the discharge without valves, to a floor drain. Comply with ASME Boiler and Pressure Vessel Code Section VIII, Division 1 for installation requirements.

C. Pressure Reducing Valves: Install pressure reducing valves on make-up

waterlines, and elsewhere as required to regulate system pressure. Install pressure reducing valves with isolating gate valves, half size globe type bypass valve, and unions. Install the specified pressure gauges with snubbers and gauge cocks to indicate upstream and reduced pressures.

D. Manual Air Vents: Install manual air vents at high points in the system, at heat

transfer coils, and elsewhere as required for system air venting.

E. Automatic Air Vents: Install automatic air vents at heating and cooling water piping high points and where piping drops in the direction of the flow. Mount air vents on a full size nipple for up to 3-inch pipe size and at least 6 inches tall preceded by an isolating valve. Extend copper vent tubes 3/8 inch OD to acceptable drain locations.

F. Air Separators: Install combination air separators/strainer in pump suction lines.

Run piping to a compression tank with 1/4-inch per foot (2 percent) upward slope towards tank. Install an automatic air vent and blowdown piping with gate valve. Extend the piping to the nearest drain.

G. Diaphragm Type Compression Tanks: Install vertical diaphragm-type

compression tanks on floor as indicated. Vent and purge air from the hydronic system, charge the tank with the proper air charge to suit the system design requirements. Connect and valve each tank separately to the hydronic system.

H. Triple Duty Valves: Install valves on base mounted pump discharge pipes and

where shown.

I. Trumpet Valves: Install valves at base mounted pumps in easily accessible locations.

J. Dielectric Waterway Fittings: Install dielectric unions to join dissimilar metals.

AARHIP 15183-13

K. Strainers: Install strainers on the supply side of each control valve, pressure reducing valve, pressure regulating valve, solenoid valve, in-line pump, and elsewhere as indicated. Install a nipple and ball valve in the blow down connection of strainers 2-inch and larger.

L. P & T Test Plugs: Install pressure-temperature test plugs (P&T) at both inlet and

outlet of in-line pumps, heating coils, cooling coils, heaters, and where shown.

M. Thermometers: Install thermometers with ranges from 50 to 250 degrees F on hot water pipes, and with ranges from 0 to 100 degrees F on cold water pipes. Position thermometers so that they can be easily read from a normal standing position.

N. Pipe Sleeves: Provide pipe sleeves for pipes penetrating concrete and masonry

construction.

O. Underground Pre-Insulated Piping: Install underground pre-insulated piping on at least 4 inches of sand, or loose fine dirt and similar material tamped in 4-inch layers to a height at least 6 inches above the pipe. Pitch piping to drain completely to valved drains at designated drain points. Provide excavation and backfill in accordance with Sections 02316 and 02317.

P. Escutcheons: Install chrome-nickel plated brass escutcheons, sized to fit over the

pipe and its insulation, at locations where exposed pipes penetrate finished surfaces.

Q. Noise Transmission: Arrange and install equipment (and piping) to avoid noise

transmission to the structure or to other piping. Correct unacceptable noise or vibration as required, at no additional cost.

R. Flexible Connectors: Install flexible piping connectors to vibration isolated

equipment. Provide flexible connectors in accordance with Section 15072. 3.3 FIELD QUALITY CONTROL

A. Inspections: Inspect the hydronic specialties as follows:

1. Check expansion tanks to determine that they are not air bound and that the system is completely full of water.

2. Remove and clean strainers.

3. Check air vents at high points of systems and determine if they are installed

properly and bleed air completely.

4. Lubricate motors and bearings.

AARHIP 15183-14

B. Manufacturer's Field Services: Provide the services of a qualified representative of the manufacturer as specified in Division 1 to inspect the installation of equipment, certify that it meets the manufacturer's recommendations and instruct the operating personnel in its operation and maintenance.

END OF SECTION

AARHIP 15184-1

SECTION 15184

REFRIGERATION PIPING AND SPECIALTIES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Refrigeration piping and piping specialties used for air conditioning applications.


1. Section 07700 - Roof Specialties and Accessories 2. Section 07920 - Joint Sealants 3. Section 15060 - Supports and Anchors 4. Section 15080 - Mechanical Insulation 5. Section 15108 - Miscellaneous Pipe and Fittings 6. Section 15109 - Erecting and Jointing Interior Piping 7. Section 15670 - Condensing Units 8. Section 15761 - Air Coils 9. Section 15900 - HVAC Controls 10. Section 16121 - Wire and Cable - 600 Volts and Below

1.2 REFERENCES


1. ASHRAE 15 - Safety Code for Mechanical Refrigeration

2. ASME Boiler and Pressure Vessel Code SEC IX - Welding and Brazing Qualifications

3. ASME B31.5 - Refrigeration Piping

4. ASME B31.9 - Building Services Piping


6. AWS BRH - Brazing Handbook

7. ARI 760 - Solenoid Valves for Use with Volatile Refrigerants

AARHIP 15184-2

1.3 SUBMITTALS


B. Product Data: Provide the manufacturer product data for each type of valve and

for each type refrigerant piping specialty specified.

C. Shop Drawings: Submit shop drawings showing the layout of refrigerant piping, specialties, and fittings including, but not necessarily limited to, pipe and tube sizes, valve arrangements and locations, slopes of horizontal runs, wall and floor penetrations, and equipment connection details. Show the interface and spatial relationships between piping and proximate to equipment.

D. Brazer's Certification: Submit signed qualification certificates certifying that

brazers comply with the requirements specified under "Quality Assurance".

E. Maintenance Data: Submit maintenance data for refrigerant valves and piping specialties, for inclusion in the Operating and Maintenance Manual specified in Division 1.


A. Welding Materials and Procedures: Qualify brazing processes and brazing operators in accordance with ASME "Boiler and Pressure Vessel Code," Section IX, "Welding and Brazing Qualifications".

B. Regulatory Requirements: Conform work to ANSI/ASME B31.9 as applicable.


A. General: Deliver, and store piping and specialties in shipping containers with labeling in place.

B. Protection: Protect piping and specialties from entry of contaminating material by

leaving end caps and plugs in place until installation. 1.6 SEQUENCING AND SCHEDULING

A. General: Coordinate the installation of roof piping supports, and roof penetrations. Roof accessories are specified in Section 07700.

AARHIP 15184-3

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Refrigerant Valves and Specialties:

a. Alco Controls Div, Emerson Electric. b. Danfoss Electronics, Inc. c. EATON Corporation, Control Div. d. Henry Valve Company. e. Parker-Hannifin Corporation, Refrigeration and Air Conditioning

Division. f. Sporlan Valve Company.

2.2 MATERIALS

A. Pipe and Tubing Materials: Provide Type K copper tubing complying with requirements specified in Section 15108.

1. Copper Tubing Fittings: Provide copper fittings complying with

requirements specified in Section 15108.

2. Joining Materials: Provide joining materials complying with requirements specified in Section 15108.

B. Valves: Provide complete valve assemblies, UL-listed, and designed to conform to

ARI 760.

1. Globe: 450 psig maximum operating pressure, 275 degrees F maximum operating temperature; cast bronze body, with cast bronze or forged brass wing cap and bolted bonnet; replaceable resilient seat disc; plated steel stem. Provide valves capable of being repacked under pressure. Provide straight through or angle pattern valves, with solder-end connections.

2. Check Valves - Smaller Than 7/8 inch: 500 psig maximum operating

pressure, 300 degrees F maximum operating temperature; cast brass body, with removable piston, Teflon seat, and stainless steel spring; straight through globe design. Provide straight through pattern valves, with solder-end connections.

3. Check Valves - 7/8 inch and Larger: 450 psig maximum operating pressure,

300 degrees F maximum operating temperature; cast bronze body, with cast bronze or forged brass bolted bonnet; floating piston with mechanically

AARHIP 15184-4

retained Teflon seat disc. Provide straight through or angle pattern valves, with solder-end connections.

4. Solenoid Valves: 240 degrees F temperature rating, 500 psig working

pressure; packless construction, forged brass, with Teflon valve seat and stainless steel core, two-way straight through pattern, and solder end connections. Provide manual operator to open valve. Furnish complete with NEMA 1 solenoid enclosure with 1/2-inch conduit adapter, and normally closed moisture resisting holding coil.

5. Evaporator Pressure Regulating Valves: Pilot-operated, forged brass or cast

bronze; complete with pilot operator, stainless steel bottom spring, pressure gauge tappings, standard coil; and wrought copper fittings for solder end connections.

6. Thermal Expansion Valves: Straight through or angle design, with solder-

end connections, thermostatic adjustable, modulating type; size as required for specific evaporator requirements, and factory set for proper evaporator superheat requirements. Provide packless type valves with a forged brass body and corrosion resistant brass and stainless steel trim, complete with sensing bulb, a distributor having a side connection for hot gas bypass line, external superheat adjustments, and an external equalizer line.

7. Hot Gas Bypass Valve: Adjustable type, sized to provide capacity reduction

beyond the last step of compressor unloading; and wrought copper fittings for solder end connections.

C. Refrigeration Piping Specialties: Provide complete refrigeration piping specialty

assemblies designed to conform to ARI 760, and UL-listed.

1. Strainers: 500 psig maximum working pressure; forged brass body with monel 80-mesh screen, and screwed cleanout plug; Y-pattern, with solder end connections.

2. Moisture/liquid Indicators: 500 psig maximum operation pressure, 200

degrees F maximum operating temperature; forged brass body, with replaceable polished optical viewing window, moisture sensing element which changes color when an unsafe moisture level exists in the system, and solder-end connections.

3. Filter-driers: 500 psig maximum operation pressure; steel shell, flange ring,

and spring, gasketed ductile iron cover plate with steel capscrews, and wrought copper fittings for solder end connections. Furnish complete with replaceable filter-drier core kit, including gaskets, as follows:

a. High capacity desiccant sieves to provide micronic filtration and extra

drying capacity.

AARHIP 15184-5

4. Suction Line Filters: 500 psig maximum operation pressure; "T" type

corrosion resistant plated steel shell, flange ring, and spring, gasketed ductile iron cover plate with steel capscrews, and wrought copper fittings for solder end connections. Furnish complete with replaceable filter core kit, including gaskets, as follows:

a. High capacity filter kit to provide micronic filtration.

5. Flanged Unions: 400 psig maximum working pressure, 330 degrees F

maximum operating temperature; two brass tailpiece adapters for solder end connections to copper tubing; flanges for 7/8 inch through 1-5/8 inch unions of forged steel, and for 2-1/8 inch through 3-1/8 inch of ductile iron; four plated steel bolts, with silicon bronze nuts and fiber gasket. Have a factory-applied rust-resistant coating provided for flanges and bolts.

6. Flexible Connectors: 500 psig maximum operating pressure; seamless tin

bronze or stainless steel core, high tensile bronze braid covering, solder connections, and synthetic covering; dehydrated, pressure tested, minimum 7 inch in length.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine rough-in for refrigeration piping systems to verify actual locations of piping connections prior to installation.

3.2 INSTALLATION

A. Piping: Install refrigeration piping in accordance with ASHRAE Standard 15 and as specified in Section 15109.

1. Install piping in as short and direct arrangement as possible to minimize

pressure drop.

2. Install piping for minimum number of joints using as few elbows and other fitting as possible.

3. Arrange piping to allow normal inspection and servicing of compressor and

other equipment.

4. Provide adequate clearance between pipe and adjacent walls and hanger, or between pipes for insulation installation. Use sleeves through floors, walls, or ceilings, sized to permit the installation of full thickness insulation.

AARHIP 15184-6

5. Insulate lines. Insulate both liquid and suction lines. Do not install insulation until system testing has been completed and all leaks have been eliminated.

6. Install branch tie-in lines to parallel compressors with an equal length, and

pipe identically and symmetrically.

7. Install copper tubing in rigid or flexible conduit in locations where copper tubing will be exposed to mechanical injury.

8. Slope refrigeration piping as follows:

a. Install horizontal hot gas discharge piping with 1/2-inch per 10 feet

downward slope away from the compressor.

b. Install horizontal suction lines with 1/2 inch per 10 feet downward slope to the compressor, with no long traps or dead ends which may cause oil to separate from the suction gas and return to the compressor in damaging slugs.

c. Install traps and double risers where required to entrain oil in vertical

runs.

d. Liquid lines may be installed level.

9. Conceal all pipe installations in walls, pipe chases, utility spaces, above ceilings, below grade or floors, unless indicated to be exposed to view.

10. Install piping tight to slabs, beams, joists, columns, walls, and other

permanent elements of the building. Provide space to permit insulation applications, with 1 inch clearance outside the insulation. Allow sufficient space above removable ceiling panels to allow for panel removal.

11. Make reductions in pipe sizes using eccentric reducer fittings installed with

the level side down.

B. Valves and Specialties: Install valves and specialties in accessible locations to allow for servicing and inspection, and in accordance with the manufacturer's instructions.

1. Install globe valves on each side of strainers and driers, in liquid and suction

lines at evaporators, and elsewhere as indicated.

2. Install a full sized, 3-valve bypass around each drier.

AARHIP 15184-7

3. Install solenoid valves ahead of each expansion valve and hot-gas bypass valve. Install solenoid valves in horizontal lines with coil at the top.

a. Electrical wiring for solenoid valves is specified in Section 16121.

Coordinate electrical requirements and connections.

4. Thermostatic expansion valves may be mounted in any position, as close as possible to the evaporator.

a. Where refrigerant distributors are used, mount the distributor directly

on the expansion valve outlet.

b. Install the valve in such a location so that the diaphragm case is warmer than the bulb.

c. Secure the bulb to a clean, straight, horizontal section of the suction

line using two bulb straps. Do not mount the bulb in a trap or at the bottom of the line.

d. Where external equalizer lines are required make the connection

where it will clearly reflect the pressure existing in the suction line at the bulb location.

5. Install pressure regulating and relieving valves as required by ASHRAE

Standard 15.

6. Install strainers immediately ahead of each expansion valve, solenoid valve, hot gas bypass valve, compressor suction valve, and as required to protect refrigerant piping system components.

7. Install moisture/liquid indicators in liquid lines between filter/driers and

upstream of thermostatic expansion valves and in liquid line to receiver.

8. Install filter/driers upstream of solenoid and expansion valves.

9. Install unions to allow for removal of solenoid valves, pressure regulating valves, expansion valves, and at connections to compressors and evaporators.

10. Install flexible connectors at the inlet and discharge connection of

compressors and condensers.

C. Hangers and Supports: Hangers, supports, and anchors are specified in Section 15060. Install hangers and supports as specified in Section 15109.

AARHIP 15184-8

D. Pipe Joint Construction: Provide brazed joints complying with the procedures contained in the AWS "Brazing Manual."

1. WARNING: Some filler metals contain compounds which produce highly

toxic fumes when heated. Avoid breathing fumes and provide adequate ventilation.

2. CAUTION: When solenoid valves are being installed, remove the coil to

prevent damage. When sight glasses are being installed, remove the glass. Remove stems, seats, and packing of valves, and accessible internal parts of refrigerant specialties before brazing. Do no apply heat near the bulb of the expansion valve.

3. Fill the pipe and fittings during brazing, with an inert gas (ie., nitrogen or

carbon dioxide) to prevent formation of scale.

4. Heat joints using oxy-acetylene torch. Heat to the proper and uniform brazing temperature.

E. Equipment Connections: The Drawings indicate the general arrangement of

piping, fittings, and specialties. Install piping adjacent to machines to allow servicing and maintenance.

F. System Charging: Charge the system using the following procedure:

1. Install core in filter dryer after leak test but before evacuation.

2. Evacuate refrigerant system with vacuum pump, until a temperature of 35

degrees F is indicated on the vacuum dehydration indicator.

3. During evacuation, apply heat to pockets, elbows, and low spots in the piping.

4. Maintain a vacuum on the system for minimum of 5 hours after closing the

valve between the vacuum pump and the system.

5. Break the vacuum with refrigerant gas, and allow the pressure to build up to 2 psi.

6. Complete charging of system, using a new filter dryer core in the charging

line. Provide full operating charge. 3.3 FIELD QUALITY CONTROL

A. Inspection: Inspect, test, and perform corrective action of refrigerant piping in accordance with ASME Code B31.5, Chapter VI.

AARHIP 15184-9

B. Repairs: Repair leaking joints using new materials, and retest for leaks.

C. Manufacturer's Field Service: Train the Owner's maintenance personnel on procedures and schedules related to start-up and shut-down, troubleshooting, servicing, and preventative maintenance of refrigeration piping valves and refrigeration piping specialties, as specified in Division 1.

3.4 ADJUSTING AND CLEANING

A. General: Verify actual evaporator applications and operating conditions, and adjust the thermostatic expansion valve to obtain proper evaporator superheat requirements.

B. Adjust Controls and Safeties: Replace damaged or malfunctioning controls and

equipment with new materials and products.

C. Procedures: Before installation of copper tubing, clean the tubing and fittings using the following cleaning procedure:

1. Remove coarse particles of dirt and dust by drawing a clean, lintless cloth

through the tubing by means of a wire or an electrician's tape.

2. Draw a clean, lintless cloth saturated with trichloroethylene through the tube or pipe. Continue this procedure until the cloth is not discolored by dirt.

3. Draw a clean, lintless cloth, first saturated with compressor oil and then

squeezed dry, through the tube or pipe to remove any remaining lint. Inspect the tube or pipe visually for remaining dirt and lint.

4. Finally, draw a clean, dry, lintless cloth through the tube or pipe.

END OF SECTION

AARHIP 15184-10


AARHIP 15187-1

SECTION 15187

CHEMICAL (WATER) TREATMENT

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Equipment and materials for cleaning HVAC systems, and for treating those systems and their components.


1. Section 09900 - Painting 2. Section 15183 - Hydronic Piping, Valves and Specialties 3. Section 15184 - Refrigeration Piping and Specialties 4. Section 15900 - HVAC Controls 5. Section 15950 - Testing, Adjusting and Balancing

1.2 REFERENCES


1. ASTM D 1384 - Method for Corrosion Test for Engine Coolants in Glassware

1.3 SUBMITTALS


B. Product Data: Submit catalog product data indicating equipment dimensions,

general assembly, accessories, weight, rated capacities, performance ratings, and materials and finishes. Submit data indicating chemical treatment materials and chemicals.

C. Shop Drawings: Submit shop drawings indicating equipment locations.

D. Test Reports: Submit reports indicating start-up of treatment systems is completed

and operating properly. Submit reports indicating analysis of system water after cleaning and after treatment.

E. Operating and Maintenance Data: Submit data on procedures and treatment

programs for each system. Include step-by-step instructions on test procedures, including target concentrations.

AARHIP 15187-2


A. Manufacturer: Provide equipment and materials from a company specializing in manufacturing the products specified in this section with minimum 5 years documented experience, and to observe and certify the chemical cleaning of each hydronic system. Provide a company which has local representatives with water analysis laboratories and full-time service personnel.

B. Regulatory Requirements: Conform to EPA code for addition of nonpotable

chemicals to building mechanical systems, and for delivery to public sewage systems.



1. Storage and Protection: Store equipment in its original shipping containers

with labeling in place until the time of installation. Store equipment in a clean dry place protected from physical damage. Store chemicals in storage areas specifically designated for storing such products.

1.6 SPARE PRODUCTS

A. Furnish the following spare products:

1. Sufficient chemicals for treatment and testing for one year following substantial completion.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Chemical Pot Feeders

a. Dexter b. Dearborn Chemical c. Calgon d. Nalco Chemical Co.

AARHIP 15187-3

2.2 CHEMICAL POT FEEDERS

A. Construction: Provide 5 gallons capacity chemical pot feeders constructed of 10-gauge steel shell, 9-gauge steel heads and cast-iron quick opening cap with Buna-N ring, suitable for 300 psig working pressure.

PART 3 EXECUTION

3.1 PREPARATION

A. Provide systems which are operational, filled, started, and vented prior to cleaning. Use a water meter to record the capacity in each system. Place terminal control valves in the open position during cleaning.

3.2 INSTALLATION

A. General: Install all equipment in accordance with manufacturer's instructions, and approved shop drawings, complete with necessary controls for regulating the chemical treatment and as specified in Division 1. Make all necessary adjustments to equipment to provide complete and satisfactory operation upon completion of the installation.

3.3 CLEANING GENERAL

A. System Cleaning: Clean piping system before use, and before painting or insulation work is performed. Keep each piping system internally clean by installing only clean materials and by providing temporary closures as required to prevent dirt entering the systems from outside. Prepare exterior surfaces of each system to be painted as specified in Section 09900.

3.4 HYDRONIC SYSTEM CLEANING AND FILLING

A. General: Thoroughly clean and flush the hydronic systems, fill with the specified ethylene glycol and water solution and vent ready for operation.

B. Cleaning Procedure: The following is suggested cleaning procedure unless an

alternative clean and fill sequence is submitted and approved.

1. Filtration: Provide for each piping system a temporary side stream filter with sufficient capacity to filter the equivalent of the system water capacity once every 4 hours. Equip the filter with a flow rate indicator in the leaving water piping. Provide wound polypropylene cartridge filter media with 30-micron rating. Change cartridges when the flow through the filter is reduced to 20 percent of the initial clean cartridge flow rate.

AARHIP 15187-4

a. With temperature control valves open to all boilers, coils, and other heating elements, and isolating valves open, fill the hydronic system with City water through a suitable water meter to determine total water capacity taking care to bleed all air. Raise the pressure of the system to 100 psig for a period of 24 hours and check for leaks. Repair all leaks in hydronic systems and retest at 100 psig. Repeat this procedure until the system shows no evidence of leaks.

b. Operate hot water circulating pumps for each circuit for a period of 8

hours. Drain the hot water heating systems and clean the strainers.

2. Chemical Cleaning: Prior to acceptance, remove all grease, dirt, oil and metallic oxides from each piping system. Use nonfoaming cleaning agent to provide for complete wetting of all metal surfaces, lifting and dispersion of organic soil and chelation of alkaline earth metals and metallic oxides. Use an approved cleaning agent or one that includes a mixture of equal parts of caustic soda, trisodium phosphate and sodium metasilicate introduced into the hydronic system until system contains a 3 percent solution of these chemicals.

a. Fill each system through a suitable water meter to determine total

water capacity, taking care to bleed all air.

b. Dissolve cleaner in water and add to system.

c. With hot water systems, bring temperature to 180 degrees F and circulate for 48 hours.

d. During the entire cleaning period, bypass water through the side

stream filter specified above at a flow rate sufficient to filter the equivalent of the system capacity at least once every 4 hours. Change filter media whenever pressure drop across filter is within 5 psi of pressure differential across circulating pump.

e. When cleaning is complete, drain and flush system with fresh water

and clean all strainers. Continue flushing until "M" alkalinity of system water is within 50 ppm of "M" alkalinity of make-up water.

f. Drain boilers, open manhole and handholes and flush out all sediment

with a high pressure hose, using water of approximately 70 degrees F temperature or ambient. Replace manhole and handhole covers and install new gaskets.

g. Remove from site and safely dispose all cleaning chemicals used in

the cleaning of hydronic systems.

AARHIP 15187-5

3. Filling: Immediately following cleaning and upon certification thereof, fill and chemically treat each system as specified.

Pressure fill the hot water system with a corrosion-inhibited 30 percent solution by volume of ethylene glycol and water as specified.

Provide ethylene glycol fluid and aqueous solutions of the fluid meeting the following requirements:

a. Proportion aqueous solutions of ethylene glycol to provide

freeze/burst and corrosion protection, as well as efficient heat transfer in closed-loop heating water systems.

b. Provide an industrially inhibited propylene glycol heat transfer fluid,

such as Dowtherm 4000, or approved equal. Specifically excluded are automotive antifreezes or any formulations containing silicates.

c. Provide fluid for the hot water heating system with an operating

temperature range of -60 degrees F to 350 degrees F, with fluid freeze protection to below -60 degrees F and burst protection to below -100 degrees F. Provide the fluid which contains corrosion inhibitors that are specially formulated for HVAC service to keep pipes free of corrosion without fouling. Provide chemical treatment which consists of a nonchromate corrosion inhibitor for the protection of both ferrous and nonferrous metals. Provide an inhibitor harmless to nonmetallic materials.

d. Provide fluid dyed with a fluorescent color to facilitate leak detection.

e. Provide fluid which is easily analyzed for glycol concentration and

inhibitor level, and easily reinhibited using replacement inhibitor readily available from the fluid manufacturer.

f. For systems containing more than 250 gallons of fluid, provide one

annual analysis one year after substantial completion. Use convenient analytical test aids.

g. Provide fluid which passes ASTM D 1384 (less than 0.5 mils

penetration per year for all system metals).

h. Furnish the fluid such that the reserve alkalinity of the fluid is at least 25 to provide long-term resistance to acidic pH.

i. Use only good quality water in solution with the propylene glycol

fluid. Use water with low levels (less than 50 ppm) of chloride, sulfate, and hard water ions (Ca++, Mg++). Distilled or deionized water is recommended. If good quality water is unavailable, purchase

AARHIP 15187-6

prediluted solutions of industrially inhibited propylene glycol fluid from the fluid manufacturer.

In the event the system is not immediately filled, after cleaning and flushing, temporarily protect the system with an oxygen scavenger alkaline solution, such as ammonium hydroxide and hydrazine.

3.5 REFRIGERANT SYSTEM CLEANING AND CHARGING

A. General: Thoroughly clean refrigerant systems, dry, evacuate, charge with required amounts of refrigerant and oil, and make ready for operation.

B. Cleaning Procedure: The following is suggested procedure unless an alternative

procedure has been submitted and approved.

1. Blow new piping clear of dirt with clean, dry compressed air.

2. At an ambient air temperature of 60 degrees F or higher, evacuate all nonprecharged piping and components to 100 microns Hg vacuum. Place the filter drier and moisture indicator in service, and continue evacuation for an additional 4 hours.

3. Locate and repair any leaks, until the specified vacuum is held 4 hours

without change.

4. Open isolating valves to precharged components. Wait 20 minutes for the system to stabilize then charge the system with refrigerant and refrigerant oil in accordance with the equipment manufacturer's instruction.

5. Operate the system and verify actual high side and low side performance

conforming to equipment ratings, corrected for ambient temperature variation as necessary. Verify proper oil return to the compressor crankcase.

6. Check for and repair any leaks. Add refrigerant as required.


A. Manufacturer's Field Services: Provide services of a representative of the heat transfer fluid manufacturer. Provide and introduce the proper chemicals for the initial start-up, make necessary adjustments, and provide sufficient chemicals for one year of normal use.


A. General: Furnish service and maintenance of treatment systems and laboratory and technical assistance services for one year from Date of Substantial Completion.

AARHIP 15187-7

B. Inspection: Provide monthly technical service visits to perform field inspections and make water analysis on-site. Detail findings in writing on proper practices, chemical treating requirements, and corrective actions needed. Submit two copies of field service report after each visit. Provide on-site inspections of equipment during scheduled or emergency shutdown to properly evaluate success of water treatment program, and make recommendations in writing based upon these inspections.

END OF SECTION

AARHIP 15187-8


AARHIP 15190-1

SECTION 15190

NATURAL GAS SYSTEM

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Distribution piping systems for natural gas.

1. Gas pressures for systems specified in this section are limited to 5 psig.

B. Related Work Specified in Other Sections Includes, But is Not Limited to, the Following:

1. Section 02316 - Excavation 2. Section 02317 - Backfilling 3. Section 07920 - Joint Sealants 4. Section 09900 - Painting 5. Section 15060 - Supports and Anchors 6. Section 15107 - Steel Pipe and Fittings 7. Section 15109 - Erecting and Jointing Interior Piping 8. Section 15110 - Valves

1.2 REFERENCES

A. Codes and Standard referred to in this Section are:

1. NFPA 54 - National Fuel Gas Code

2. AGA - American Gas Association

3. NFPA-70 - National Electrical Code

4. ASTM D 2385 - Test Method for Hydrogen Sulfide and Mercaptan Sulfur in Natural Gas

5. ASTM D 2420 - Test Method for Hydrogen Sulfide in Liquified Petroleum

Gases

6. MSS SP 78 - Cast Iron Plug Valves, Flanged and Threaded Ends

AARHIP 15190-2

1.3 SUBMITTALS


B. Product Data and Information: Provide data and information for each gas piping

specialty and special duty valves. Include rated capacities of selected models, furnished specialties and accessories, and installation instructions.

C. Shop Drawings: Provide dimensions and required clearances, for connections to

equipment.

D. Quality Control: Provide welders' qualification certificates, certifying that welders comply and meet requirements specified under "Quality Assurance".

E. Operations and Manuals: Provide maintenance manuals for gas specialties and

special duty valves as specified in Division 1. 1.4 QUALITY ASSURANCE

A. Regulatory Requirements: Comply with requirements of the following codes and standards:

1. NFPA 54 - National Fuel Gas Code, for gas piping materials and

components, gas piping installations and inspection, testing, and purging of gas piping systems.

2. AGA - American Gas Association.



B. Handling Flammable Liquids: Remove and properly dispose of liquid from drips

in existing gas piping and handle cautiously to avoid spillage or ignition. Notify gas supplier. Handle flammable liquids used by installer with proper precautions, and do not leave flammable liquids on premises from end of one working day to beginning of next.


A. Notification of Service Interruption: Except in case of emergency, notify all affected users when gas supply is scheduled to be turned off.

B. Work Interruptions: When interruptions in Work occur while repairs or alterations

are being made to existing piping system, leave system in safe condition.

AARHIP 15190-3

1.7 SPARE PARTS

A. Furnish the following spare parts.

1. Valve Wrenches: Provide two valve wrenches for each type of gas valve installed.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Gas Cocks:

a. Jenkins Bros. b. Lunkenheimer Co. c. NIBCO, Inc. d. Powell Co. e. Stockham

2.2 PIPE AND TUBING MATERIALS

A. General: See Part 3, subsection headed "PIPE APPLICATION" for identification of systems where specified pipe and fitting materials are used.

B. Steel Pipe: Provide steel pipe complying with requirements specified in Section

15107. 2.3 FITTINGS

A. Malleable-Iron Threaded Fittings: Provide fittings complying with requirements specified in Section 15107.

B. Steel Welded Fittings: Provide fittings complying with requirements specified in

Section 15107.

C. Steel Flanges and Flanged Fittings: Provide fittings complying with requirements specified in Section 15107.

2.4 JOINING MATERIALS

A. Gasket Material: Provide material suitable for gas to be handled, and for design temperatures and pressures.

AARHIP 15190-4

2.5 PIPING SPECIALTIES

A. Unions: Provide unions complying with requirements specified in Section 15107.

B. Dielectric Unions: Provide dielectric unions complying with requirements specified in Section 15107.

2.6 VALVES

A. General: General duty valves are specified in Section 15110. Special duty valves are specified in this subsection by their generic name. Refer to Part 3, subsection headed "VALVE APPLICATION" for specific uses and applications for each valve specified.

B. Gas Cocks 2 Inches and Smaller: Provide 150 psi WOG, bronze body, gas cocks,

straightaway pattern, square head threaded ends for sizes 2 inches and smaller.

C. Gas Cocks 2-1/2 Inches and Larger: Provide MSS SP-78, 175 psi, lubricated plug-type gas cocks with semisteel body, single gland, wrench operated, and flanged ends for cocks 2-1/2 inches and larger.

PART 3 EXECUTION

3.1 PREPARATION

A. Conform with requirements in NFPA 54, for the prevention of accidental ignition. 3.2 PIPE APPLICATIONS

A. Aboveground Piping: Install steel pipe with threaded joints and fittings for 2 inches and smaller, and with welded joints for 2-1/2 inches and larger.

3.3 INSTALLATION

A. General: Conform gas pipe installation to requirements of NFPA 54 - National Fuel Gas Code.

B. Locations and Arrangements: Drawings indicate the general location and

arrangement of the piping systems. Consider pipe sizing, flow direction, slope of pipe, expansion, and other design considerations for location and arrangement of piping.

C. Concealed Locations: Except as specified below, install concealed gas piping in

an air-tight conduit constructed of Schedule 40, seamless black steel with welded

AARHIP 15190-5

joints. Vent the air-tight conduit to the outside and terminate with screened vent cap.

1. Above-Ceiling Locations: Gas piping may be installed in accessible above-

ceiling spaces (subject to approval of authority having jurisdiction), whether or not such spaces are used as plenum. Do not locate valves in such spaces.

2. Piping In Partitions: Do not located concealed piping in solid partitions. Do

not run tubing inside hollow walls or partitions unless protected against physical damage. This does not apply to tubing passing through walls or partitions.

3. Prohibited Locations: Do not install gas piping in or through a circulating

air duct, breeching, chimney, gas vent, ventilating duct, or elevator shaft. These prohibited locations do not apply to accessible above-ceiling space specified above.

D. Drips and Sediment Traps: Install a drip leg at points where condensate may

collect, including at the outlet of the gas meter, each gas appliance, and in locations readily accessible to permit cleaning and emptying. Do not install drips where condensate is likely to freeze.

1. Construct drips and sediment traps using tee fittings with the bottom outlets

plugged or capped. Use a minimum of three pipe diameters in length for the drip leg. Use the same size pipe for the drip leg as the connected pipe.

2. Install gas piping at uniform grade of 1/4 inch in 15 feet, upward to risers,

and from risers to service regulator or equipment.

3. Connect branch outlet pipes from top or sides of horizontal lines, not from bottom.

4. Provide hangers and supports as specified in Section 15060.

3.4 PIPE JOINT CONSTRUCTION

A. General:

1. Note the internal length of threads in fittings or valve ends, and proximity of internal seat or wall, to determine how far pipe should be threaded into joint. Refer to NFPA 54, for guide for number and length of threads for field threading steel pipe.

2. Other joint construction to be as specified in Section 15060.

AARHIP 15190-6

3.5 VALVE APPLICATIONS

A. Shutoff Duty: Use gas cocks specified in Part 2. 3.6 VALVE INSTALLATIONS

A. Install valves in accessible locations, protected from physical damage.

1. Valve Location: Install a gas cock upstream of each gas pressure regulator and on each appliance outlet. Where two gas pressure regulators are installed in series in a single gas line, a manual valve is not required at the second regulator.

2. Pressure Relief: Install pressure relief or pressure limiting devices so they

can be readily operated to determine if the valve is free, so they can be tested to determine the pressure at which they will operate, and examined for leakage when in the closed position.

3.7 TERMINAL EQUIPMENT CONNECTIONS

A. General: Install a gas cock upstream and within 6 feet of gas appliance. Install a union or flanged connection downstream from the gas cock to permit removal of controls.

B. Sediment Traps: Install tee fitting with bottom outlet plugged or capped as close

to inlet of gas appliance as practical. Provide the drip leg to be a minimum of three pipe diameters in length.

3.8 ELECTRICAL BONDING AND GROUNDING

A. Install aboveground portions of gas piping systems, upstream from equipment shutoff valves electrically continuous and bonded to a grounding electrode in accordance with NFPA 70 - "National Electrical Code."

1. Do not use gas piping as a grounding electrode.

2. Conform to NFPA 70 - "National Electrical Code," for electrical

connections between wiring and electrically operated control devices. 3.9 FIELD QUALITY CONTROL

A. Piping Tests: Inspect, test, and purge natural gas systems in accordance with NFPA 54, and local utility requirements.

AARHIP 15190-7

3.10 PAINTING

A. Paint all gas piping yellow in accordance with requirements specified in Section 09900.

END OF SECTION

AARHIP 15190-8


AARHIP 15400-1

SECTION 15400

PLUMBING EQUIPMENT

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Furnishing and installing plumbing equipment and accessories required for a complete plumbing installation. Plumbing equipment includes the following:

1. Water Heater - Gas Fired, Storage Type 2. Domestic Water Circulating Pump and Control 3. Water Heater - Gas Fired, Tankless Type


Following:

1. Section 09900 - Painting 2. Section 15060 - Supports and Anchors 3. Section 15080 - Mechanical Insulation 4. Section 15405 - Plumbing Piping and Valves 5. Section 15900 - HVAC Controls 6. Section 16055 - Electrical Requirements for Shop-Assembled Equipment 7. Section 16220 - Electric Motors

1.2 REFERENCES


1. ASHRAE 90.1 - Energy Efficient Design of New Buildings Except Low-Rise Residential Buildings

2. ASME Boiler and Pressure Vessel Code Section VIII, Div 1 - Pressure

Vessels

3. NFPA 54 - National Fuel Gas Code

4. NFPA 70 - National Electrical Code

5. UL 1453 - Electric Booster and Commercial Storage Tank Water Heaters

AARHIP 15400-2

6. NEMA 250 - Enclosure for Electrical Equipment (1000 Volts Maximum)

1.3 SUBMITTALS


B. Product Data and Information: Submit the following:

1. Include dimension drawings of water heaters indicating components and

connections to other equipment and piping.

2. Indicate pump type, capacity, power requirements and affected adjacent construction.

3. Submit certified pump curves showing pump performance characteristics

with pump and system operating point plotted. Include NPSH curve when applicable.

4. Provide electrical characteristics and connection requirements.

C. Shop Drawings: Submit the following:

1. Include heat exchanger dimensions, size of tappings and performance data.

2. Include dimensions of tanks, tank lining methods, anchors, attachments,

lifting points, tappings, drains and operating weight.

D. Operation and Maintenance Manuals: Submit operation and maintenance manuals for the water heaters, and circulating water pumps as specified in Division 1.

1. Include operation, maintenance and inspection data, replacement part

numbers. 1.4 QUALITY ASSURANCE

A. Pumps and Water Heaters: Provide pumps and water heaters with manufacturer's name, model number and rating/capacity identified.

1. Manufacture products and install specified products in conformance with

recommendations and requirements of the following organizations:

a. American Gas Association (AGA).

b. American Society of Mechanical Engineers (ASME).

AARHIP 15400-3

c. National Board of Boiler and Pressure Vessel Inspectors (NBBPVI).

d. National Electrical Manufacturers' Association (NEMA).

e. Underwriters Laboratories (UL).

2. Provide pumps to operate at specified system fluid temperatures without vapor binding and cavitation, that are nonoverloading in parallel or individual operation, to operate within 25 percent of midpoint of published maximum efficiency curve.

B. Regulatory Requirements: Conform equipment to the following requirements:

1. AGA, NFPA 54, requirements for water heaters.

2. ASME Broiler and Pressure Vessel Code Section VIII, Division 1 Section

VIIID Pressure Vessels 1.5 DELIVERY, STORAGE AND HANDLING


B. Temporary Caps: Provide temporary inlet and outlet caps in-place until

installation.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Water Heater - Gas Fired, Storage Tank:

a. A.O. Smith Corporation b. Lochinvar Corporation c. Rheem Manufacturing Co.

2. Domestic Water Circulating Pump:

a. Bell and Gossett ITT b. Amtrol Inc. Thrush Division

AARHIP 15400-4

3. Water Heater - Gas Fired, Tankless Type:

a. Takagi 2.2 WATER HEATER - GAS FIRED, STORAGE TANK - (GWH)

A. General: Provide a commercial package unit, including an insulated tank, atmospheric natural gas burner, enameled steel jacket, support legs, draft diverter, hose drain valve, and automatic adjustable controls. Provide storage, input and heat recovery capacities meeting those specified.

B. Construction: Provide a steel tank constructed of glass-lined steel ASME rated for

a 150 psig operating pressure, with a boiler type handhole cleanout, and containing a rigidly supported magnesium anode rod. Fuse the glass lining to the steel at a high temperature. Certify the storage water heater as meeting all requirements of the current ASHRAE 90 Standard, including standby heat loss, thermal efficiency and ignition system.

C. Burner: Provide a burner of the raised port type, having an automatic 100 percent

safety shutoff upon flame or pilot failure, and thermostatic control of the gas valve. Provide a high temperature limit control to shut off all gas if an excessive temperature occurs in the tank. Provide a gas pressure regulator preceded by an eccentric plug shutoff valve.

D. Safety Valves: Provide an ASME-rated temperature-pressure relief valve piped to

the floor, and a UL-approved Type B double wall vent with a stainless steel liner.

E. Accessories: Install a thermometer with separable well in the hot water supply, and provide isolating shutoff valves in the cold, hot and circulating water pipes.

2.3 DOMESTIC WATER CIRCULATING PUMP AND CONTROL - (DCP)

A. General: Provide the domestic hot water circulating pump of an in-line all bronze type with horizontal bronze oil-lubricated sleeve bearings, and rubber-mounted motor with spring-linked coupling for quiet operation. Provide thermal overload protection for the motor with the pump unit. Provide the pump to meet the minimum capacity and characteristics scheduled.

B. Aquastat: Provide a 120-volt adjustable clamp-on aquastat on the circulated water

return set at 100 degrees F to operate the pump. Provide the aquastat meeting the requirements specified in Section 15900.

2.4 WATER HEATER - GAS FIRED, TANKLESS TYPE - (GWH)

A. General: Provide tankless packaged heater with atmospheric burner, enameled steel housing, and adjustable temperature controls. Provide the heater meeting performance characteristics scheduled.

AARHIP 15400-5

B. Construction: Provide compact design heater designed to generate a continuous,

unlimited supply of hot water at a maximum rate of 6 GPM. Provide the unit with thermal efficiency of minimum 84 percent.

2.5 MOTORS

A. General: Provide motors meeting the requirements of Section 16220.

PART 3 EXECUTION

3.1 INSTALLATION

A. Coordination: Coordinate plumbing, fuel piping, gas venting and electrical Work for complete operating systems.

B. Installation: Install heaters, tanks and pumps in accordance with manufacturer's

instructions.

C. Safety Valves and Drain: Pipe relief valves and drains to nearest floor drain, equipment drain, or open drain.


A. Paint the plumbing equipment meeting the requirements of Section 09900. 3.3 FIELD QUALITY CONTROL

A. Manufacturers Service Representative: Provide the services of a qualified representative of the equipment manufacturer to insure that the installation of each piece of plumbing equipment is as recommended, to make any necessary adjustments, and to instruct the operating personnel in its proper operation and maintenance, as specified in Division 1.

END OF SECTION

AARHIP 15400-6


AARHIP 15405-1

SECTION 15405

PLUMBING PIPING AND VALVES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Furnishing and installing pipe, fittings, valves, accessories, specialties as shown, specified or required for a complete installation and satisfactory operation. Provide pipe and fittings of new materials, protected from dirt, moisture and mechanical damage.


Following:

1. Section 02316 - Excavation 2. Section 02317 - Backfilling 3. Section 02500 - Laying and Jointing Buried Pipelines 4. Section 02512 - Disinfection 5. Section 02516 - Leakage Test 6. Section 09900 - Painting 7. Section 15060 - Supports and Anchors 8. Section 15080 - Mechanical Insulation 9. Section 15106 - Ductile Iron Pipe and Fittings 10. Section 15107 - Steel Pipe and Fittings 11. Section 15108 - Miscellaneous Pipe and Fittings 12. Section 15109 - Erecting and Jointing Interior Piping 13. Section 15110 - Valves

1.2 REFERENCES


1. ASME - Boiler and Pressure Vessel Code

2. ASSE 1010 - Water Hammer Arrestors

3. ASTM A 518 - Specification for Corrosion-Resistant High Silicon Iron Castings

4. PDIWH 201 - Water Hammer Arrestors

AARHIP 15405-2

1.3 SUBMITTALS


B. Product Data and Information: Provide data on pipe materials, pipe fittings, valves

and accessories. Provide manufacturers catalog information and indicate valve data and ratings.

C. Shop Drawings: Provide shop drawings showing the following:

1. Layout of pipes, fittings, supports, valves and equipment.

2. Sections showing elevations of pipes, fittings, supports, valves and

equipment.

3. Pipe size, type, material and schedule. 1.4 DELIVERY, STORAGE AND HANDLING


1. Accept valves on site in shipping containers with labeling in place. Inspect

valves for damage.

2. Provide temporary protective coating on cast-iron and steel valves.

3. Provide temporary end caps and closures on piping and fittings. Maintain end caps in place until installation.

4. Protect piping systems from entry of foreign materials by temporary covers,

completing sections of the Work, and isolating parts of completed system.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Check Valves - Lift Type

a. Combination Pump Valve Co. b. Smalensky Valve Co. c. Williams-Hager

AARHIP 15405-3

2. Check Valves - Clapper Type

a. Valve and Primer Corp. - "Apco" b. Flomatic Corp.

3. Ball Valves

a. Stockham - Model S-216BR-R-T b. Crane - Model 9302 c. Nibco - Model T-585-70

4. Hose Bibbs

a. Chicago Faucet Co. - Model No. 387-E27 b. The Speakman Co.

5. Shock Absorbers

a. Josam - "Absorbatron" b. Wade - "Shokstop" c. Zurn - Shoktrol"

6. Cleanouts

a. Josam b. Wade

7. Backflow Preventers

a. Hersey Products, Inc. - Model FRP II b. Watts Regulator Co. - Series 909

8. Pipe Sleeves

a. Thunderline Corp. - "Link Seal "Model WS".

2.2 MATERIALS

A. Pipe, Tubing and Fittings: Provide pipe, tubing and fittings as follows:

1. Provide ductile iron pipe and fittings complying with requirements specified in Section 15106.

2. Provide steel pipe and fittings complying with requirements specified in

Section 15107.

AARHIP 15405-4

3. Provide cast iron pipe and fittings complying with requirements specified in Section 15108.

4. Provide copper tubing and fittings complying with requirements specified in

Section 15108.

B. Valves: Provide valves meeting the requirements of Section 15110, except as specified herein.

1. Provide valves recommended by their manufacturer for the conditions of use

as installed, and capable of tight shutoff under those conditions. Provide valves recommended for a fluid operating temperature up to 250 degrees F.

2. Provide valves in insulated pipes with an extended neck to clear the

insulation.

3. Provide combination temperature and pressure relief valves at the domestic water heaters meeting the requirements of the ASME pressure temperature rating.

4. Provide a chromium-plated stop valve with handwheel at an accessible

location on each water connection at each plumbing fixture.

5. Provide screwed pattern and soldered pattern valves with unions to facilitate removal from the pipe.

6. Provide accessible pressure rated 3/4-inch hose-end gate valves at low

points for draining each water piping system.

7. Check Valves - Lift Type: Provide check valves in closed system vertical pipes with 125 psi SWP, nonslam guided lift type, bronze screwed pattern for valves 2 inches and smaller, and flanged-iron body bronze mounted for valves 2-1/2 inches and larger.

8. Check Valves - Clapper Type: Provide check valves in sump pump or

sewage ejector discharge lines of the integral nonmetallic clapper type or the plastic ball type, opening out of the flow path, closing nonslam, and specifically recommended for sewage service by their manufacturer.

9. Ball Valves: Provide a screwed pattern 2-piece brass or bronze ball valve

rated at 125 psi minimum, precision ground, free floating ball, stem shoulder preventing blowout, reinforced teflon stem seals and seats, and a rustproof handle with stop clearing the pipe insulation.

10. Balancing Valves: Provide the domestic hot water return circuit with a

balancing valve to set flow rate of either the automatic flow control type or the manual adjustment type. Provide the balancing valve with integral flow

AARHIP 15405-5

measuring taps, or in conjunction with a flow measuring device for use in verifying or adjusting the flow rate.

C. Hose Bibbs: Provide interior hose bibbs (HB-1) with 3/4-inch hose thread outlet,

lockshield cap, removable tee handle, 3/4-inch threaded female inlet flange, and 3/4-inch spout outlet in-line vacuum breaker for back-siphonage protection.

D. Hangers and Supports: Provide hangers and supports as specified in Sections

15060 and 15109.

E. Shock Absorbers: Provide each shock absorber meeting the requirements and be sized no smaller than recommended by Plumbing and Drainage Institute "Standard WH201" as ASSE Standard 1010. Isolate each absorber from the piping system by a ball valve, locate accessible for service, and prevent "water hammer" by absorbing surge pressures created by the quick-closing valve(s). Construct absorber of stainless steel or other material which is nonrusting, and include a wetted bellows contained in a pressurized chamber and rated for 150 psi working pressure.

F. Escutcheons: Provide chrome nickel-plated brass escutcheons, sized to fit over the

pipe and its insulation, at locations where exposed pipes penetrate finished surfaces.

G. Cleanouts: Provide cleanouts meeting the following requirements.

1. Floor Cleanouts in Finished Rooms: Provide floor cleanouts in finished

rooms with an adjustable cast-iron floor cleanout installed flush with finished floor, with cutoff sections, brass internal plug, satin finish nickel alloy top, and with secured cover.

2. Floor Cleanouts in Unfinished Rooms: Provide floor cleanouts in

unfinished rooms with a satin finish brass top, and secured heavy-duty brass cover.

3. Cleanouts on Exposed Piping: On exposed risers and horizontal piping

provide cleanouts with cast-brass, with countersunk, iron pipe size male threaded plug.

4. Cleanouts on Concealed Piping: On concealed risers provide cleanouts with

cast-brass, countersunk, with stainless steel round access cover plate secured to plug with countersunk screw.

AARHIP 15405-6

H. Backflow Preventers: Provide backflow preventers of the reduced pressure type with two check valves, an automatically operating pressure differential relief valve located between the two check valves, and three test cocks for testing purposes.

1. Construct all moving parts and trim of corrosion-resistant materials with

neoprene valve discs.

2. Provide each backflow preventer assembly complete with a strainer on the inlet side, and gate valves at both inlet and outlet sides.

3. Provide backflow preventers suitable for a maximum working pressure of

175 psi, and water temperatures from 32 to 145 degrees F.

PART 3 EXECUTION

3.1 INSTALLATION

A. Piping Installation: Install plumbing piping clear of all building elements.

1. Pitch drain-line piping uniformly downward in the direction of flow not less than 1/8-inch per lineal foot.

2. Review elevations before proceeding with the Work, and the location, depth

and size of sewers before connections are made.

3. Before running any drains and sewers within buildings, or any vent or drain stacks, or any water lines, verify that they can be run without trapping, sagging or interfering with columns, beams, piping, fixtures, ducts, or other system components. Coordinate necessary changes before pipes are installed.

4. Pitch horizontal water pipes to facilitate draining through drain hose valves

installed at low points.

5. Flash pipes passing through the roof watertight with 4-pound per square foot sheet lead, except as otherwise shown. Extend flashing out on the roof not less than 18 inches from the pipe or edge of drain in all directions, and turn down into vent pipes.

B. Shock Absorbers: Install shock absorbers on each water pipe supplying solenoid

valves or other automatic or manual quick-closing valves.

C. Cleanouts: Provide cleanouts at ends of mains, each change in direction of more than 45 degrees, spaced not more than 50 feet apart in all straight runs, and at the base of all soil stacks, downspouts, and fixture traps. Terminate cleanouts for concealed pipes flush with finish floor, wall or grade with trim as specified.

AARHIP 15405-7

Provide cleanouts of the same size as the pipe up to 4 inches in diameter, and 4-inch size for larger pipes and located for convenient access.

D. Backflow Preventers: Install backflow preventers where shown and where

necessary to prevent contamination of the City water supply caused by possible cross-connection with a contaminated source. Pipe the relief valve vent to discharge over the nearest floor drain.

E. Sound and Vibration Control: Arrange and install all equipment and piping to

avoid noise transmission to the structure or to other piping. Correct or replace any installation giving an unacceptable noise or vibration level, as required, at no additional cost to the OWNER.

1. Provide flexible electrical and piping connections to vibration isolated

equipment. Provide flanged stainless steel bellows connectors with braided sleeve in each pipe connected to such equipment.

F. Pipe Expansion Provisions: Connect, support and guide piping to permit and

control pipe expansion and contraction and to accommodate building expansion, contraction and settling without damage.

1. Provide piping expansion loops or expansion joints sized to accommodate

possible expansion without exceeding allowable pipe and fitting stresses in straight sections of hot water piping more than 50 feet in length. Locate expansion devices midway between anchor points, and the pipes guided as recommended. Provide pipe loop legs, cold sprung at the time of assembly to one-half the calculated maximum expansion.

2. Provide expansion joints of the guided, restrained, multiply Type 316

stainless steel bellows type guaranteed for at least 15,000 cycles, with rated capacity equal to twice the calculated pipe expansion.

3. Provide anchors for piping within a structure consisting of welded plates,

angles, channels, or beams braced and securely fastened to the pipe and to structural members adequate to safely withstand resulting stresses.

G. Pipe Sleeves: Provide steel pipe sleeves for pipes piercing concrete and masonry

construction. Install pipe sleeves with welded water stop plates in floors, exterior walls and foundation walls.

1. Seal watertight insulated and uninsulated lines installed in the pipe sleeves

with an elastic mechanical pipe sleeve seal of size and service designation as recommended by the manufacturer for proper sealing.

2. Furnish appropriate fire-rated sleeve seal and insulated pipe protectors for

fired rated walls and floors.

AARHIP 15405-8


A. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, as specified in Division 1.

B. Tests: After installation of the piping, control equipment and all appurtenances,

subject each unit to a field running test as specified in Division 1, under actual operating conditions and requirements of Section 02516.

C. Disinfection: Disinfect pipelines that convey potable water in accordance with the

requirements of Section 02512. 3.3 CLEANING AND PAINTING

A. Paint all piping and equipment, including insulated piping, as specified in Section 09900. Clean and paint pipe, valves and fittings subject to rust before rusting occurs.

B. Do not paint bright metal parts, such as fixtures, connections, escutcheons, fittings,

knobs and nameplates, and thoroughly clean and polish same just before the completion of the Work.

END OF SECTION

AARHIP 15406-1

SECTION 15406

PLUMBING SPECIALTIES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing floor and roof drains, and plumbing specialties shown, specified or required for a complete system. In addition, furnish and install the following:

1. Gauges and Thermometers 2. Drip Pans 3. Vacuum Breakers 4. Drain Valves

Securely support drains at the correct elevation for proper drainage. Furnish each floor drain with a deep seal cast-iron trap.


Following:

1. Section 09900 - Painting 2. Section 15400 - Plumbing Equipment 3. Section 15405 - Plumbing Piping and Valves 4. Section 15410 - Plumbing Fixtures and Trim

1.2 REFERENCES


1. ASSE 1011 - Hose Connection Vacuum Breakers

2. ASSE 1012 - Backflow Preventers with Immediate Atmospheric Vent

3. ASSE 1013 - Backflow Preventers, Reduced Pressure Principle

4. ASME A112.21.1 - Floor Drains

5. AWWA C511 - Reduced Pressure Principle Backflow Prevention

Assembly

6. ASME A112.21.2M - Roof Drains

AARHIP 15406-2

1.3 SUBMITTALS


B. Product Data and Information: Provide component sizes, outlet type, rough-in

requirements, service sizes, and finishes.

C. Shop Drawings: Indicate dimensions, weights and placement of openings and holes.

D. Operation and Maintenance Manuals: Submit operation and maintenance manuals

for the gauges and thermometers as specified in Division 1.

1. Maintenance Data: Include installation instructions, spare parts lists, exploded assembly views.



B. Acceptance: Accept specialties on-site in original factory packaging. Inspect for

damage.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Floor and Roof Drains:

a. Josam Co. b. Wade Division/Tyler Pipe c. J.R. Smith Mfg. Co. d. Zurn

2. Downspout Nozzle:

a. Josam Co. b. J.R. Smith Mfg. Co. c. Zurn

AARHIP 15406-3

3. Gauges:

a. Ametek Co. b. Marsh Co.

4. Thermometer:

a. Moeller Co. b. Reotemp Co.

5. Vacuum Breaker:

a. Watts Regulator Co. b. A.W. Cash Valve Mfg. Corp.

6. Drain Valves:

a. Stockham Co. b. Jenkins Co. c. Nibco Co.

2.2 MATERIALS

A. Roof Drain (RD-1): Provide coated cast-iron type drain, with large cast-iron locking dome, nonpuncturing flashing clamp ring with integral gravel stop, large sump with roof flange and bottom caulked outlet.

1. Provide Model Josam Series 21500.

B. Roof Drain (RD-2): Provide coated cast-iron type drain, with cast-iron dome,

flashing clamp and gravel stop, exterior water dam, bottom caulked outlet.

1. Provide J. R. Smith Fig. 1080

C. Floor Drain (FD-1): Provide coated cast-iron type drain, with two-piece body with double drainage flange, weepholes, bottom caulked outlet, and adjustable secured nickel brass strainer.

1. Provide Model Josam Series 30000-A.

D. Floor Drain (FD-2): Provide coated cast-iron type drain with two-piece body with

double drainage flange, weepholes, bottom caulked outlet and adjustable 7-inch satin finish nickel-brass oval funnel strainer.

1. Provide Model Josam Series 30000E-3.

AARHIP 15406-4

E. Floor Drain (FD-3): Provide coated cast-iron type drain with two-piece body, double drainage flange, weepholes, bottom caulked outlet, and round top loose-set anti-titling grate.


F. Gauges: Provide pressure gauges that is 4-1/4-inch diameter, and of bourdon tube

type with aluminum black flange case, with an accuracy of one percent within scale range and constructed of materials impervious to the fluid measured.

1. Provide the type such that the standard dial range installed is standard range

double normal operating pressure with graduations not exceeding one percent of range or one psi maximum.

2. Install, at each gauge connection, a 1/4-inch brass tee handle gauge cock and

a pressure variation snubber.

3. Where gauges are required at pumps, pipe connections from the pump suction and discharge through gauge cocks to pressure gauge so that either pump suction or pump discharge pressure may be read, unless otherwise specified.

4. Position gauges to be easily read from a normal standing position, and

provide inclined or adjustable type where required.

G. Thermometers: Provide bimetal 3-inch diameter dial thermometer or 9-inch scale red reading industrial type with fumeproof stainless steel or cast case and glass face with 6-inch stem and 2-1/2-inch extension neck separable well.

1. Provide thermometer range of approximately 50 to 250 degrees F in 2

degrees F increments for hot water lines, and approximately 0 to 100 degrees for cold water lines unless otherwise specified.

2. Provide accuracy within one percent over the entire scale range.

3. Position thermometers to be easily read from a normal standing position,

and provide thermometers of the inclined or adjustable type where required.

H. Drip Pans: Install polished, 16-ounce reinforced copper drip pans under all pipes that pass over or near electrical control equipment.

1. Provide drip pans with suitable connections to the drainage system.

I. Vacuum Breaker: Provide tamperproof vacuum breakers of the type preventing

backflow as recommended by the manufacturer in an accessible location at plumbing fixtures and water using devices, conforming to local and State plumbing health codes.

AARHIP 15406-5

1. Provide vacuum breakers of Watts model number:

a. 8-AC Interior Hose Bibb Type

J. Drain Valves: Provide each cold water, hot water and circulating water piping

system with 3/4-inch globe valves with vacuum breaker hose adapters, accessibly located at piping low points for completely draining the system.

1. Provide Stockham Model B-13T.

K. Downspout Nozzle: Provide cast-bronze nozzle, with secured wall hange and

threaded inlet connection.


PART 3 EXECUTION

3.1 PREPARATION

A. Coordination: Coordinate cutting and forming of roof and floor constructions to receive drains to required invert elevations.

3.2 INSTALLATION

A. General: Install plumbing specialties in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Equipment Drains: Confirm that the final locations of equipment drains are as

required to serve approved equipment.

C. Roof Drains: Flash roof drains watertight with a 4-pound per square foot sheet lead, except as otherwise detailed or specified elsewhere. Provide flashing to extend out on the roof not less than 18 inches from the edge of the drain in all directions and to be secured by roof drain flashing clamp.

3.3 PAINTING

A. Paint specialties as specified in Section 09900.

END OF SECTION

AARHIP 15406-6


AARHIP 15410-1

SECTION 15410

PLUMBING FIXTURES AND TRIM

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing the following plumbing fixtures, trim and supports as indicated, and specified, completely installed and connected:

1. Water closets 2. Urinals 3. Lavatories 4. Showers 5. Kitchen sinks 6. Sampling sinks 7. Service sinks 8. Emergency showers and eyewashes 9. Hot water thermostatic control


Following:

1. Section 06200 - Interior Finish Carpentry 2. Section 07920 - Joint Sealants 3. Section 15060 - Supports and Anchors 4. Section 15400 - Plumbing Equipment 5. Section 15405 - Plumbing Piping and Valves 6. Section 15406 - Plumbing Specialties 7. Section 16055 - Electrical Requirements for Shop-Assembled Equipment

1.2 REFERENCES


1. ASME A112.6.1M - Supports for Off-the-Floor Plumbing Fixtures for Public Use

2. ASME A112.18.1M - Finished and Rough Brass Plumbing Fixture

Fittings

3. ASME A112.19.1M - Enameled Cast-Iron Plumbing Fixtures

4. ASME A112.19.2M - Vitreous China Plumbing Fixtures

AARHIP 15410-2

5. ASME A112.19.3M - Stainless Steel Plumbing Fixtures (Designed for

Residential Use)

6. ASME A112.19.4 - Porcelain Enameled Formed Steel Plumbing Fixtures

7. ASME A112.19.5 - Trim for Water-Closet Bowls, Tanks, and Urinals

(Dimensional Standards)

8. ANSI Z358.1 - Emergency Eyewash and Shower Equipment 1.3 SUBMITTALS


B. Product Data and Information: Provide catalogue illustrations of fixtures, sizes,

rough-in dimensions, utility sizes, carriers, trim and finishes, and all electrical requirements.

C. Operation and Maintenance Manuals: Submit operation and maintenance manuals

for the faucets, mixing valves, flush valves and emergency equipment as required in Division 1.



B. Acceptance: Accept fixtures on-site in factory packing and inspect for damage.

C. Storage and Protection: Protect installed fixtures from damage by securing areas

and by leaving factory packing in place to protect fixtures and prevent use. At time of acceptance, replace any unit found to be defective, damaged or improperly installed.

1.5 FIELD MEASUREMENTS

A. General: Verify that field measurements are as indicated on shop drawings and as instructed by the manufacturer.

B. Millwork: Confirm that millwork is constructed with adequate provision for the

installation of countertop lavatories and sinks.

AARHIP 15410-3

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Plumbing fixtures:

a. Crane Plumbing b. American Standard c. Kohler

2. Flush Valves:

a. Sloan Valve Company b. Zurn c. Coyne and Delany Co.

3. Carriers and Supports:

a. Josam Co. b. J.R. Smith Mfg. Co. c. Zurn d. Wade Division/Tyler Pipe

4. Toilet Seats:

a. Church b. Olsonite c. Bemis

5. Faucets, Stops and Trim:

a. Crane Plumbing b. American Standard c. Kohler d. Chicago Faucet Co.

6. Emergency Equipment:

a. Haws Drinking Faucet Co. b. Speakman Co. c. Bradley Co.

AARHIP 15410-4

7. Showers:

a. American Standard b. Kohler c. Crane Plumbing

8. Hot Water Thermostatic Control:

a. Powers Regulator Co. b. Lawler ITT Co. c. Leonard Valve Co.

2.2 MATERIALS

A. General: Provide chromium plating on exposed metal work, loose key type stops. Provide exposed piping passing through walls, floors and ceilings with cast-brass chromium-plated escutcheon plates.

B. Water Closet (WC-1): Provide a siphon jet action, elongated, vitreous china closet

bowl, wall mounted with 1-1/2-inch top inlet spud.

1. Model: Crane Plumbing 3-446 Placidus.

2. Flush Valve: Provide an exposed chrome-plated, diaphragm type flush valve with metal oscillating nonhold open handle, 1-inch IPS screwdriver angle stop with protective cap, adjustable tail piece, vacuum breaker flush connection and spud coupling, wall and spud flanges, and 3 gpf flush rate.

a. Model, Sloan Royal No. 110-3.

3. Seat: Provide a heavy weight, solid black plastic, elongated open front seat,

with external check hinges having stainless steel posts.

a. Model: Church 9500CC.

4. Carrier: Provide a coated cast-iron floor-mounted universal closet carrier with adjustable closet connection, pylon feet, ABS extension with integral test cap, chrome-plated trim, coated accessories, no-seep fixture gasket, and stud-mounted high impact polystyrene positioning frame. Verify code flush valve height requirement or restriction and grab bar requirements.

a. Model: Josam Series 12000.

b. Arrangements: Adjustable horizontal or vertical, single or back-to-

back, carrier fitting as required by fixture arrangement.

5. Set the bowl and carrier height for the physically handicapped.

AARHIP 15410-5

C. Urinal (UR-l): Provide a vitreous china, wall-mounted, siphon jet urinal with

integral extended shields, integral trap, 3/4-inch top inlet spud, and two wall hangers.

1. Model: Crane Plumbing 7-150 Embassy.

2. Flush Valve: Provide an exposed chrome-plated, diaphragm type flush

valve with metal oscillating nonhold open handle, 3/4-inch screwdriver angle stop with protective cap, vacuum breaker with a flush connection and spud coupling, and wall spud flanges.

a. Model: Sloan Royal 186.

3. Carrier: Provide concealed floor-mounted carrier with hanger plate, bearing

plate, adjustable supporting rods, structural uprights, and block bases.

a. Model: Josam, Series 17810.

4. Set the urinal height for the physically handicapped.

D. Lavatory (L-1): Provide a vitreous china, self-rimming, countertop, lavatory 19 by 16 inches, with faucet ledge drilled on 8-inch centers and front overflow.

1. Model: Crane Plumbing 1-283-S Sonnet.

2. Trim: Provide chrome-plated dual-control supply fitting with aerator, wrist

blade handles, and union rings. No. C-1065-G P.O. plug with open strainer and tail piece, No. C-1151 angle supplies with wheel handle stops and flexible risers, and No. 8-5260 adjustable P-trap with cleanout and tubing waste to wall with escutcheon. Offset tail pipe and water to accommodate physically handicapped.

a. Model: Crane Plumbing C-1123 Citadel.

E. Shower (SH-1): Provide a thermostatic mixing valve with concealed valve body,

built-in adjustable temperature limit stop, check stops, stainless steel face plate, and lucite knob type handle. Provide ADA approved ball joint shower head.

1. Model: Powers Hydroguard Type T421-A.

2. Provide ADA approved sloped shower basin.

F. Service Sink (SS-1): Provide a 24- by 20- by 11-inch deep enameled cast-iron

sink with a 9-inch high drilled back, stainless steel rim guard, concealed hanger and No. 7798.176 3-inch trap standard with strainer inlet and cleanout plug.

AARHIP 15410-6

1. Model: American Standard AKRON 7695.018.

2. Faucet: Provide a chrome-plated service sink faucet with integral stop arms, short spout, 3/4-inch hose thread outlet, pail hook, lever handles, and spout outlet in-line vacuum breaker for back-siphonage protection.

a. Model: Chicago Faucet No. 305-R-E27.

G. Sampling Sink: Provide a 24- by 20- by 11-inch deep enameled cast-iron sink

with a 9-inch high plain back, stainless steel rim guard, concealed hanger and No. 7798.176 3-inch trap standard with strainer inlet and cleanout plug.

1. Model: American Standard AKRON 7696.016.

2. Faucet: Provide a 3/4-inch rough brass, single faucet with 3/4-inch hose

thread outlet, removable tee handle and 3/4-inch hose, thread outlet vacuum breaker for back-siphonage protection.

a. Model: Chicago Faucet No. 7T-E27.

b. Inlet connection: Provide connecting cast-brass (copper to FPT) 90

degrees elbow for mounting to wall or column.

H. Kitchen Sink (KS-1): Provide Type 304 stainless steel 20 gauge selt riming countertop sink unit, 22 inches by 25 inches for single bowl size and 22 inches by 33 inches for double bowl size, with 10 inch deep bowl and with faucet holes drilled on 4 inch centers.

1. Model: Elkay DCR-252210 and CR-3322 with LK-35 strainer.

2. Trim: Provide a chrome plated supply fitting with gooseneck spout and

aerator, and wrist blade handles.

I. Emergency Shower and Eye Wash (ESE): Provide a combination unit with eye face washes with push to operate, stay open ball valve; corrosion-resistant stainless steel bowl and ABS plastic anti-surge heads. Provide a deluge shower with a 10-inch ABS plastic head with instant action stay open ball valve and pull rod. Provide pipe standard with 1-1/4-inch water supply and waste connection, adjustable water pressure control in the eye wash connection and universal emergency sign attached to unit. Paint the pipe standard with an epoxy coating resistant to chlorine fumes and hydrogen sulfide.

1. Model: HAWS 8300 CRP.

J. Emergency Eye and Face Wash (EE): Provide pedestal mounted unit equipped

with floor flange. Provide the eyewash with corrosion resistant stainless steel bowl and ABS plastic anti-surge heads. Provide push type, stay open chrome plated ball

AARHIP 15410-7

valve activated by hand plate or foot treadle. Coat all exposed piping and trim with CRP green coating. Provide 3/4 inch water supply and 1-1/2 inch waste connection.

1. Model: HAWS 7461

K. Shower Alarm and Light: Provide a watertight flow switch, junction box, alarm

and light, with the flow switch located on the supply line.

1. Model: HAWS 9001.

2. Flow switch: 5 amps, single pole, double throw. UL listed and CSA approved.

3. Pipe size: 1-1/4 inch IPS.

L. Hot Water Thermostatic Control: Provide the control range to be between 90 to

115 degrees with plus or minus 2 degrees F accuracy.

1. Model: Powers Regulator Co., Hydroguard Series 430.

2. Accessories: Union inlet strainer check stops, outlet volume and shutoff valve, dial thermometer with scale 0 to 200 degrees F, fittings all chrome plated and mounted in a surface mounted painted steel cabinet with chrome plated key lock.

PART 3 EXECUTION

3.1 EXAMINATION

A. Verification: Verify that walls and floor finishes are ready for installation of fixtures.

3.2 INSTALLATION

A. General: Install plumbing fixtures in accordance with manufacturer's instructions.

B. Fixture Trap: Install each fixture trap, easily removable for servicing and cleaning.

C. Level and Plumb: Install components level and plumb.

D. Securing of Fixtures: Install and secure fixtures in place with wall supports or carriers and bolts.

E. Sealing of Fixtures: Seal fixtures to wall and floor surfaces with sealant as

specified in Section 07900, color to match fixture.

AARHIP 15410-8

3.3 INTERFACE WITH OTHER PRODUCTS

A. Shop drawings: Review millwork shop drawings. Confirm the location and size of fixtures and openings before rough-in and installation.

3.4 ADJUSTING

A. General: Adjust stops or valves for intended water flow rate to fixtures without splashing, noise or overflow.

3.5 CLEANING

A. Cleaning of fixtures: Clean Work as specified in Division 1. 3.6 PROTECTION OF FINISHED WORK

A. Protection: Protect finished Work as specified in Division 1.

B. Fixture Use: Do not permit use of fixtures.

END OF SECTION

AARHIP 15446-1

SECTION 15446

SUMP PUMPS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing sump pumps with capacities and details as scheduled, and installed as shown with controls, control panels and all accessories necessary for complete installation.

B. Section Includes:

1. Duplex Submersible Sump Pumps 2. Simplex Submersible Sump Pump 3. Magnetic Starters 4. Lubrication of Equipment 5. Spare Parts

C. Related Work Specified in Other Sections Includes, But is Not Limited to, the

Following:

1. Section 09900 - Painting 2. Section 15060 - Supports and Anchors 3. Section 15405 - Plumbing Piping and Valves 4. Section 16055 - Electrical Requirements for Shop-Assembled Equipment 5. Section 16121 - Wire Cable - 600 Volts and Below 6. Section 16220 - Electric Motors

1.2 SUBMITTALS


B. CONTRACTOR's Shop Drawings: Provide shop drawings, including arrangement

of equipment and control equipment, details of control panel, schematic control diagrams, electrical connections, complete description of control system, and equipment characteristics. Include following:

1. Certified pump curves, including flow, head, brake horsepower, and

efficiency

2. General arrangement drawing showing location of pumps and control panel

AARHIP 15446-2

3. Cross-section drawings

4. Parts list with materials of construction identified

5. Motor performance characteristics

C. Operation and Maintenance Manuals: Furnish operator and maintenance manuals for the pumps, valves and controls


A. Furnish all sump pump equipment specified in this Section from single pump equipment manufacturer if available.



B. Acceptance: Accept pump equipment on-site in factory packing. Inspect for

damage. 1.5 SPARE PARTS

A. General: Provide following spare parts for each pump delivered and securely wrapped or boxed, indexed and tagged with complete information for use and recording.

1. One set upper ball bearings 2. One set lower ball bearings 3. One set double mechanical seals 4. One set lockwasher, O-rings and gaskets

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Weil Pump Co. 2. Pacific Pump Co.

AARHIP 15446-3

2.2 MATERIALS

A. Duplex Submersible Pumps: Provide ejector type submersible pumps with stainless steel shaft, double mechanical seals, factory-lubricated upper and lower ball bearings, and extra heavy-duty waterproof casing of close-grained cast iron with integrally cast legs for supporting pump on bottom of sump. Provide cast-iron, nonclog impeller capable of passing 2-inch solids.

1. Provide motors as specified in Section 16220.

2. Provide liquid level controls consisting of NEMA 6 sealed mercury float

switches for pump start and pump stop for each pump and high water alarm, (2-pole type for local and remote alarm circuit), with height adjustable on 1-inch stainless steel support rod. Position float switches for liquid level controls and alarm as follows and at levels as indicated on the Drawings.

Switch No. 1 - Float switch opens control holding circuit on liquid drop.

Switch No. 2 - Float switch starts one pump through electric alternator in

control panel on liquid rise.

Switch No. 3 - Float switch starts second pump liquid rise.

Switch No. 4 - High water alarm wired to operate audible and visual alarm on pump control panel.

Pump(s) continue to operate until Float Switch No. 1 opens control holding circuit.

3. Provide heavy-duty waterproof power cables rated at 600 volts and control

cables rated at 600 volts, with sufficient slack to permit pump removal from sump for servicing without disconnecting the cables.

4. Provide prewired control panel for wall mounting with top of cabinet 6 feet

above floor. Panel consists of U.L. Inc. approved, side-hinged NEMA 4, gasketed, weatherproof enclosure containing following:

2 Circuit breaker disconnect switches with lockout handles 2 Magnetic starters with overload and low voltage protection 2 Test-Off-Automatic selector switches 1 Electric alternator 2 Control circuit transformers for pump control circuits 1 Control circuit transformer with disconnect switch for high water alarm circuit 2 Red pump running lights 2 Manual reset buttons (3-coil overload) 1 Alarm bell and blue alarm light mounted on panel door

AARHIP 15446-4

1 Alarm silencing switch 1 Numbered and wired terminal strip with extra terminals wired from

alarm contacts

B. Simplex Submersible Pump: Provide ejector type submersible pump with stainless steel shaft, double mechanical seals, factory-lubricated upper and lower ball bearings, and extra heavy-duty waterproof casing of close-grained cast iron with integrally cast legs for supporting pump on bottom of sump. Provide cast-iron, nonclog impeller.

1. Weil Pump Co., Series 1600.

2. Provide motor as specified in Section 16220.

3. Provide liquid level controls consisting of NEMA 6 sealed mercury float

switches for pump start and pump stop and high water alarm (2-pole type for remote alarm circuit) with height adjustable on 1-inch stainless steel support rod. Position float switches for liquid level controls and alarm as follows and at levels as indicated.

Switch No. 1 - Float switch opens control holding circuit on liquid drop.

Switch No. 2 - Float switch closes and starts pump.

Switch No. 3 - High water alarm wired to operate audible and visual alarm

on pump control panel.

Pump continues to operate until Float Switch No. 1 opens control holding circuit.

4. Provide prewired control panel for wall mounting with top of cabinet 6 feet

above floor. Panel consists of U.L., Inc. approved side hinged NEMA 4 gasketed, weatherproof enclosure containing following:

1 Circuit breaker disconnect switch with lockout handle 1 Magnetic starter with overload and low voltage protection 1 Test-Off-Automatic selector switch 1 Control circuit transformer for the pump control circuit 1 Red pump running light 1 Manual reset button (3-coil overload) 1 Alarm bell and blue alarm light mounted on the panel door 1 Alarm silencing switch 1 Numbered and wired terminal strip

5. Provide heavy-duty waterproof power cables rated at 600 volts and control

cables rated at 600 volts with sufficient slack to permit pump removal from the sump for servicing without disconnecting the cables.

AARHIP 15446-5

C. Magnetic Starters: Provide magnetic starters that meet the requirements of Section

16055.

D. Lubrication of Equipment: Provide equipment with internal or concealed bearings lubrication fittings extended to accessible location outside casing, excepting hermetically sealed units with lifetime lubrication.

1. Lubricate prior to start-up, and at recommended intervals before turning

equipment over to the OWNER. Provide linen tag or heavy duty shipping tag attached to each piece of equipment showing date of lubrication and name and number of lubricant used. Provide typewritten list, in triplicate, of each item lubricated and type of lubricant used.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install pump units in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

1. Clean before pump installation.

2. Complete all piping and wiring, make adjustments to equipment to provide

complete operating system.

3. Provide each sump pump installation, except as noted, with a 1/2-inch thick flush aluminum floor plate with separate openings and covers for 12- by 18-inch inspection-cleanout access, outside air vent, and individual pump installation. Provide each pump with discharge pipe, water level control device, and electric cables to pass through separate openings in cover to permit service removal without disturbing other equipment. Provide openings with aluminum covers, gasketed, bolted to floor plate with rustproof bolts.

4. Equip each discharge pipe or vent opening in cover or floor plate with

cast-iron flange collar with tapered (Buna-N) gasket and rustproof bolts to achieve gastight seal around pipe; and, provide rubber grommet to seal cable openings in sump cover for each power and control cable.

5. Provide specified rubber flap type or ball type check valve, union and gate

valve in each pump discharge pipe in manner to permit pump unit to be disconnected and removed separately.

6. Provide check valve with flanged connection and with full pipe area when

open, quick closing and quiet in operation, and recommended for sewage

AARHIP 15446-6

service by manufacturer. Provide Series 100 replaceable reinforced Buna-N rubber flapper swing check valve as manufactured by APCO/Valve and Primer Corp., a Type 50 phenolic ball check valve with rubber seat as manufactured by Flomatic Corp., or equal.

7. Provide sump pump discharge pipe and fittings having threaded or flanged

joints, or both, up to the gravity collector line. 3.2 FIELD QUALITY CONTROL

A. Control System: Demonstrate that pump equipment operates as specified with the control system.


A. Manufacturer's Service Representative: Provide services of qualified representative of manufacturer to inspect installation, make any necessary adjustments, test equipment, and instruct operating personnel in operation and maintenance of sump pumping equipment.

END OF SECTION

AARHIP 15510-1

SECTION 15510

BOILERS AND BOILER ROOM EQUIPMENT

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Packaged fire tube boilers, boiler controls and trim.


1. Section 15072 - Vibration Isolation 2. Section 15183 - Hydronic Piping, Valves and Specialties 3. Section 15187 - Chemical (Water) Treatment 4. Section 15190 - Natural Gas System 5. Section 15550 - Breechings, Chimneys and Stacks 6. Section 15900 - HVAC Controls 7. Section 15950 - Testing Adjusting and Balancing 8. Section 16055 - Electrical Requirements for Shop Assembled Equipment

1.2 REFERENCES


1. ABMA - Packaged Firetube Rating

2. ASHRAE 90.1 - Energy Efficient Design of New Buildings Except Low-Rise Residential Buildings

3. ANSI Z21.13 - Gas-Fired Low-Pressure Steam and Hot Water Boilers

4. ANSI Z223.1 - National Fuel Gas Code

5. ASME Boiler and Pressure Vessels Code SEC. 1 - Rules for Construction of

Power Boilers

6. ASME Boiler and Pressure Vessels Code SEC. 4 - Rules for Construction of Heating Boilers

7. ASME Boiler and Pressure Vessels Code SEC. 8 DIV 1 - Rules for

Construction of Pressure Boilers

AARHIP 15510-2


9. HI - Pump Standards 1.3 SUBMITTALS


B. Product Data: Submit manufacturer's complete catalog, technical product data,

including rated capacities of selected models, clearly indicating dimensions, weights (shipping, installed and operating), operating and sequencing controls, service connections, required clearances, furnished specialties and accessories, and installation and start-up instructions.

C. Shop Drawings: Submit shop drawing, including construction, materials,

dimensions, capacity, arrangements, accessories, weight, required clearances, location and size of field connections, operating and safety controls, operating sequence descriptions, electrical characteristics and electrical schematic and wiring diagrams.

1. Submit ladder-type wiring diagrams for power and control wiring required

for final connections to boilers and controls. Clearly differentiate between portions of wiring that are factory-installed and portions to be field-installed.

2. If the arrangement of the proposed boiler is different from that shown, do

not order the boiler until detailed plan and elevation views relating it to (new and existing) piping, breeching and other equipment and obstructions have been submitted and approved.

D. Maintenance Data: Submit maintenance data and a parts list for boilers, controls,

and accessories, including a "trouble-shooting" maintenance guide and preventative maintenance schedule and procedures. Include this data and product data in the operation and maintenance manual.

E. Rigging Instruction: Submit rigging instructions.

F. Test Reports: Submit a factory inspection report and National Board inspection

report prior to shipping.

G. Operation and Maintenance Manuals: Submit a complete operation and maintenance manual as specified in Division 1.

AARHIP 15510-3


A. Manufacturer: Provide equipment from a company specializing in the design and manufacture of boilers which has a minimum of 5 years documented experience and issues complete catalog data on these products.



1. Shipping and Handling: Rig boilers in compliance with the manufacturer's

rigging and moving instructions for unloading boilers, and moving them to their final location.

a. Handle boilers and components carefully to prevent damage,

breaking, denting and scoring. Do not install damaged boilers or components; replace damaged items with new ones.

2. Storage and Protection: Store boilers in the original shipping packaging

with labeling in place until the time of installation.

a. Store boilers and components in a clean dry place protected from weather, dirt, fumes, water, construction debris, and physical damage.

1.6 SEQUENCE AND SCHEDULING

A. Coordinate the size and location of concrete pads on which boilers are to be mounted. Coordinate required imbedded anchor devices.

1.7 SPARE PARTS

A. General: Furnish the following spare parts.

1. 1 wire brush. 2. 1 flame sensor element for each boiler.

PART 2 PRODUCTS

2.1 MANUFACTURES


AARHIP 15510-4

1. Fire Tube Boilers

a. Cleaver Brooks Model CB b. Johnson Boilers

2. Blow-Down Separator

a. Cleaver-Brooks b. DeLaval Separator Co.

2.2 HOT WATER BOILERS

A. General: Provide assembled and tested boilers, including all accessories for completed installation, and meeting following requirements.

1. Provide boilers which have the minimum output shown and operate at not

less than 80 percent efficiency from full fire down to 30 percent of rating for the specified fuels.

2. Provide boilers constructed in accordance with the ASME Heating Boiler

Code governing the construction of boilers, with adequate handholes to facilitate boiler inspection and cleaning.

3. Provide boilers which meet ASME Boiler code requirements for at least 125

psig construction and maximum operating temperature of 250 degrees F.

4. Provide ready access to burner and heat exchange surfaces for cleaning, inspection, and replacement. For this purpose, provide hinged manway access door not less than 20-inch by 30-inch into the combustion chamber.

5. Provide observation ports for inspection of flame conditions at both ends of

boiler.

6. Provide boiler insulation consisting of a minimum 2-inch thick fiberglass blanket or mineral fiber-board under removable and reusable sectional pre-formed zinc coated and painted rust-resistant sheet metal lagging.

7. Factory paint the boiler base, frame, jacket, and attached components with a

hard finish enamel.

B. Features: Provide boilers of the minimum size, capacity, and arrangement shown and scheduled complete with the following features.

1. Provide boiler of the packaged horizontal firetube type with at least 5 square

feet of fire side heating surface per rated boiler horsepower, designed to heat a 30 percent by volume solution of propylene glycol and water to a temperature of 225 degrees F.

AARHIP 15510-5

2. Provide boiler mounted on a heavy steel frame with integral forced draft

burner and burner controls, ready for mounting on a concrete floor pad and the attachment of supply, return, fuel, blowdown, drain, electrical, and flue connections.

3. Provide boiler completely preassembled and fire tested on natural gas at

factory.

4. Provide forced draft burner as integral part of boiler, high radiant type, design to fire natural gas.

5. Provide fuel trains meeting recommendations of Industrial Risk Insurers

(IRI).

C. Forced Draft Blower: Provide blower assembly to meet following requirements:

1. Supply air for combustion by forced draft blower mounted in front boiler door, above burner, to eliminate vibration and reduce noise level. Provide blower impeller of cast aluminum, radial blade, carefully balanced, and directly connected to boiler motor shaft.

D. Boiler Controls: Provide boiler controls meeting the requirements of Section

16055 as required and as follows:

1. Provide electronic flame detector and program controller to cause approved prepurge of combustion chamber before ignition. Include in program sequence intermittent electric ignition of pilot flame burning natural gas. Provide approved flame safety device to prove pilot flame before main flame ignition is permitted to occur. Design system such that failure of the pilot or main flame causes burner to be shut down and such that burner shutdown at end of normal firing cycle or due to safety controls, or is followed by postpurge of combustion chamber.

2. Provide burner to operate on full modulation principle with properly

adjusted fuel air ratio for optimum efficiency over entire firing range. Upon manual or automatic shutdown, provide electronic programming relay to recycle and start the burner at low fire on next firing cycle.

3. Provide combustion air control damper and gas butterfly firing valve to be

operated through jackshaft linkage arrangement connected to electric modulating damper motor designed to adjust firing rate and combustion air according to load demand, for optimum combustion efficiency over entire firing range.

AARHIP 15510-6

4. Provide modulating type temperature controller to sense hot water temperature and control firing rate when AUTOMATIC-MANUAL switch is set on AUTOMATIC.

E. Boiler Control Panel: Provide boiler control panel meeting the requirements of

Section 16055 with key lock mounted on each boiler. Provide panel of NEMA 4X enclosure complete with flame safeguard control, motor starters for motor-driven equipment, transformers, relays, switches, indicating and alarm lights, and accessory equipment factory prewired to numbered terminal strip.

Provide and identify following switches and indicating lights for each boiler, on face of boiler control panel.

1. Power ON/OFF selector switch

2. MANUAL/AUTO switch to select manual or automatic control of firing

rate.

3. Potentiometer type damper motor positioning control for manually setting continuous firing rate at any level between low and high fire when selector switch is on MANUAL.

4. Low water shutdown (Red).

5. City water make-up (Red).

6. Main flame failure shutdown (Red).

7. High or low gas pressure shutdown (Red).

8. Load demand (White).

9. Natural gas valve open (White).

Provide boiler control panel with indicating lights and switches mounted in a manner giving easy access to all wiring.

Furnish self-checking solid-state electronic flame safeguard control to provide flame-out protection, and automatic sequencing of burner motor, damper motor, pilot valve, and ignition. Provide flame safeguard control, in conjunction with ultraviolet flame detector to provide prepurge, postpurge, pilot ignition trial, main flame trial, pilot and main flame failure response, and safety switch timing.

F. Boiler Trim and Accessories: Provide each boiler with safety controls and

equipment as required by the applicable local codes and regulations and conforming to Section 16055. Provide following accessory equipment as part of each boiler assembly.

AARHIP 15510-7

1. ASME rated safety relief valves of type and size complying with the ASME

Code.

2. Flue gas thermometer mounted on breeching collar, 4-1/2-inch minimum diameter.

3. 4-1/2-inch water temperature gauge and 4-1/2-inch pressure gauge.

4. Modulating type temperature controller mounted where shown to regulate

burner operation.

5. Boiler drain valves complying with the ASME Code.

6. Float operated low water cutoff control wired in burner control circuit to shut down burner and energize identified alarm at boiler control panel if water level falls below safe condition.

7. A manual reset high limit thermostat to shut down burner if boiler water

temperature exceeds 230 degrees F.

G. Pilot Ignition: Provide a pilot ignition system as required and as follows:

1. Provide natural gas pilot of premix type with automatic electric ignition. Provide electronic flame detector to monitor pilot and ensure that the primary gas valve opens until pilot flame has been established.

2.3 BLOWDOWN SEPARATOR

A. Features: Provide separator of minimum 14D x 34H size furnished complete with 1-1/4-inch automatic self-contained cooling water temperature regulator with all components suitable for cold water supplied at a maximum temperature of 85 degrees F. Provide regulator bulb to sense mixed temperature of hot water and cold water, regulating cooling so that mix does not exceed 140 degrees F at outlet side of blowdown separator. Provide gate valve and wye strainer on the cold water supply pipe.

B. Construction Requirements: Construct blowdown separator conforming to the

ASME Code, suitable for maximum pressure stamped on separator body of 250 psig.


A. Tests: Provide tests as follows:

1. Provide factory tests to check construction, controls, and operation of boiler.

AARHIP 15510-8

B. Inspections: Provide authorized boiler inspection prior to shipment; submit copy of inspection report.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine equipment at time of delivery for damaged or missing components.

Examine and verify size, location, and condition of concrete pads upon which equipment is to be installed. Do not proceed with installation until unsatisfactory conditions have been corrected.

B. Power Supply: Verify that proper power supply is available.

3.2 INSTALLATION

A. General: Install equipment in accordance with manufacturer's installation instructions, requirements of applicable local codes, National Fuel Gas Code, and requirements of local utility company.

Maintain manufacturer's recommended clearances around equipment.

B. Support: Install boilers and other floor mounted equipment on 6-inch high

concrete pad.

C. Gas Train Vents: Pipe the vent ports and vent valves on the gas trains through the roof, weatherproof.

D. Erection: Assemble boiler trim shipped loose or unassembled for shipment

purposes. Follow manufacturer's installation instructions.

E. Gas Piping: Connect gas piping to boiler, full size of boiler gas train inlet, and provide union with sufficient clearance for burner removal and service.

F. Hot Water Piping: Connect supply and return boiler trappings as indicated, with

shutoff valve and union or flange at each connection.

G. Relief Valves: Pipe relief valves to nearest floor drain.

H. Breeching: Connect breeching to boiler outlet, full size of outlet.

I. Thermometers: Mount thermometers in boiler breeching within 12-inches of flue nozzle.

AARHIP 15510-9

J. Electrical: Refer to Section 16055 for electrical requirements.

K. Blowdown Separator: Provide flash vent to roof and drain piping to adequate trapped equipment drain.

L. Controls: Install complete control systems in accordance with Section 15900.

3.3 CLEANING

A. Flush and clean boilers upon completion of installation, in accordance with manufacturer's instructions.


A. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, and instruct operating personnel in its operation and maintenance as specified in Division 1.

B. Tests: After installation of the boilers and accessories, control equipment and all

appurtenances, subject each unit to a field running test as specified in Division 1, under actual operating conditions.

C. Inspections: Arrange with National Board of Boiler and Pressure Vessel

Inspectors for inspection of boiler installation, piping connections, observation of hydrostatic testing, and for certification of completed boiler units.


A. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to demonstrate the proper operation and instruct operating personnel in the equipment's operation and maintenance, as specified in Division 1.

B. Start-up: Perform services in accordance with manufacturer's written start-up

instructions. Test controls and demonstrate compliance with requirements. Replace damaged or malfunctioning controls and equipment.

Submit signed Boiler Start-Up Report, including following minimum data for HIGH fire and LOW fire operation for each boiler, while burning natural gas.

1. Fuel usage rate.

2. Electric ignition operation.

3. Stack temperature and draft reading.

AARHIP 15510-10

4. Orsate analysis for carbon monoxide, carbon dioxide and oxygen reading of

the flue gas and corresponding boiler efficiency.

5. Control point settings of all operating and safety controls.

6. Operating functional check of low water cutoff and all other operating and limit controls.

7. Failure test of the electronic flame safeguard controls.

C. Maintenance and Operation Training: As a part of the maintenance and operating

instructions, review data in operating and maintenance manual, including preventative maintenance schedule and procedures, and procedures for obtaining repair parts and technical assistance. Demonstrate all phases of operation including start-up and shutdown.

1. Schedule training with OWNER, provide at least 7-day notice to

ENGINEER.

END OF SECTION

AARHIP 15550-1

SECTION 15550

BREECHINGS, CHIMNEYS AND STACKS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Metal breechings, chimneys and vents and accessories for gas fired appliances.


Following:

1. Section 15080 - Mechanical Insulation 2. Section 15400 - Plumbing Equipment 3. Section 15510 - Boilers and Boiler Room Equipment

1.2 REFERENCES


1. ASTM A 167 - Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

2. ANSI Z223.1 - The National Fuel Gas Code

3. ASHRAE - Handbook, Equipment Volume, Chapter "Chimney, Gas

Vent, and Fireplace Systems"

4. NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances

5. SMACNA - HVAC Duct Construction Standards - Metal and Flexible

6. UL 103 - Standard for Factory Built Low Heat Chimneys

7. AWS D9.1 - Specifications for Welding Sheet Metal

1.3 SUBMITTALS


AARHIP 15550-2

B. Product Data: Submit product data including materials, dimensions, weights, and accessories.

C. Shop Drawings: Submit shop drawings drawn to scale of not less than 1/4 inch

representing one foot showing plans and sections, including required clearances, expansion flashing and counter-flashing, rustproof materials and finishes, assembly and installation instructions, and support details of all components as complete system.

D. Quality Control:

1. Certificates: Submit certificates of materials compliance with specified

ASTM, UL, and ASHRAE requirements.

2. Certificates: Submit Welders' Qualification Certificates.

3. Certificates: Submit a complete engineering report certifying that stacks meet design wind loads.


A. Manufacturers Qualifications: Provide equipment from a Company specializing in the manufacture of products specified in this Section with minimum 5 year documented experience.

B. Welder's Qualifications: Certify all welders in accordance with AWS Standard

D9.1.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Breeching, Gas Vents, Chimneys and Stacks.

a. Selkirk Metalbestos. b. Van Packer.

2.2 MATERIALS

A. General: Except as otherwise indicated, provide manufacturer's standard breechings, gas vents, chimneys and stacks where shown, of size and type indicated, constructed of materials and components as indicated, and as required for complete installation.

AARHIP 15550-3

B. Double Wall Breeching: Provide double wall breeching as specified for double

wall prefabricated type gas vents, chimneys, and stacks.

C. Double Wall Prefabricated Gas Vents, Chimneys and Stacks: Provide double wall prefabricated metal gas vents, chimneys and stacks, tested to UL 103 and UL listed, for use with building heating equipment burning gas in compliance with NFPA 211.

1. Fabricate the gas vents, chimneys and stacks with 2 inch mineral wool

insulation between the walls. Construct the inner jacket of 20 gauge ASTM A 167 Type 316 stainless steel. Construct the outer jacket of Type 316 stainless steel 24 gauge for sizes 10 to 24 inches and 20 gauge for sizes 28 to 48 inches.

2. Provide accessories each bearing factory applied UL label including

insulated fittings, roof support assembly, ventilated roof thimble, storm collar with tall flashing to fit the concrete curb, full angle ring with required supporting steel, drained tee cap, a half angle ring with threaded support rods, insulated exit cone, and an adapter to match the outlet flange of the boiler.

3. Seal the joints with silicone sealant rated for 600 degrees F temperature.

Assemble gas vent, chimney and stack sections with V-type draw bands and formed channel bands, bolted together with Type 316 stainless steel bolts.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install breechings, gas vents, chimneys and stacks in accordance with manufacturer's installation instructions and UL listing. Maintain minimum clearances from combustibles as specified in UL listing.

1. Install products in accordance with the recommendations of ASHRAE -

Handbook, Equipment Volume, Chapter "Chimney, Gas Vent, and Fireplace Systems", and ANSI Z223.1 (NFPA 54).

B. Joints: Install breechings and gas vents with minimum number of joints. Align

them accurately at connections, with internal surfaces smooth.

1. Seal joints between sections of positive pressure gas vents in accordance with the manufacturer's installation instructions, and using only sealants recommended by manufacturer.

AARHIP 15550-4

C. Supports: Support breechings and gas vents from building structures, rigidly, with suitable ties, braces, hangers and anchors to hold to shape and prevent buckling. Support gas vents, chimneys and stacks to adjacent structural surfaces, or at floor penetrations at 12 foot spacing. Refer to SMACNA HVAC Duct Construction Standards - Metal and Flexible for equivalent duct support configuration and size.

1. Install concrete inserts for support of breechings, gas vents, chimneys, and

stacks in coordination with formwork.

2. Support gas vents at the intervals recommended by the manufacturer to support the weight of the vent and all accessories, without exceeding loading of appliances.

D. Equipment Connection: Pitch breechings with positive slope up from the

fuel-fired equipment to chimney or stack.

E. Stacks: Assemble and install stack sections in accordance with NFPA 82, industry practices, and in compliance with UL listing. Connect base section to foundation using anchor lugs.

1. Install chimney and stacks level and plumb.

F. Roof Penetration: Terminate chimneys and stacks 10 feet above the roof.

G. Thermal Expansion: Install expansion joints on breechings, gas vents, chimneys

and stacks, to allow for thermal expansion.

H. Slip Joints: At appliances, provide slip joints permitting the removal of appliances without the removal or dismantling of breechings, gas vents, chimneys, or stacks.

1. Provide a minimum of 2 feet of breeching or gas vent to connect appliances

to chimneys. 3.2 ADJUSTING AND CLEANING

A. General: Clean breechings and gas vents internally during installation, to remove dust and debris. Clean external surfaces to remove welding slag and mill film. Grind welds smooth.

3.3 PROTECTION

A. Temporary Closure: At ends of breechings, gas vents and chimneys which are not completed or connected to equipment, provide a temporary closure to prevent the entrance of dust and debris until installations are completed.

END OF SECTION

AARHIP 15670-1

SECTION 15670

CONDENSING UNITS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Air-cooled condensing units complete with refrigerant compressors, condensing coils, condenser fans, controls, and accessories.


Following:

1. Section 03310 - Cast-in-Place Concrete 2. Section 15072 - Vibration Isolation 3. Section 15080 - Mechanical Insulation 4. Section 15184 - Refrigeration Piping and Specialties 5. Section 15720 - Air Handling Units 6. Section 15761 - Air Coils 7. Section 15900 - HVAC Controls 8. Section 16055 - Electrical Requirements for Shop Assembled Equipment

1.2 REFERENCES



2. NEMA MG 1 - Motors and Generators

3. UL 207 - Refrigerant-Containing Components and Accessories, Non-Electrical

4. UL 303 - Refrigeration and Air-Conditioning Condensing, and

Compressor Units

5. UL 465 - Air Conditioners, Central Cooling

6. ARI 210/240 - Unitary Air-Conditioning and Air-Source Heat Pump Equipment

7. ARI 520 - Positive Displacement Refrigerant Compressors, and

Condensing Units

AARHIP 15670-2

8. ASHRAE 23 - Methods of Testing for Rating Positive Displacement Condensing Units

9. ARI 270 - Sound Rating of Outdoor Unitary Equipment

10. ASHRAE 90.1 - Energy Conservation in New Building Design

1.3 SUBMITTALS


B. Product Data and Information: Submit catalog product data indicating dimensions,

general assembly, specialties and accessories, weights, rated capacities, performance ratings, materials and finishes, controls, electrical requirements, and wiring diagrams.

C. Shop Drawings: Submit shop drawings indicating components, assembly,

equipment locations, dimensions, weights and loadings, required clearances, and location and size of field connections. Include schematic layouts showing condensing units, cooling coils, refrigerant compressors, refrigeration piping, and accessories required for complete system.

D. Operations and Maintenance Manuals: Submit Operations and Maintenance

Manuals as specified in Division 1 including manufacturer's descriptive literature including installation and operation instructions, start-up instructions, controls, accessories, maintenance and repair data, and parts lists.


A. General: Provide equipment from a company specializing in the design and manufacture of condensing units which has a minimum of 5 years documented experience, and issues complete catalog data on these products.



B. Shipping and Handling: Comply with the manufacturers instructions for rigging,

unloading and transportation of units.

C. Storage and Protection: Store equipment in its original shipping crates or containers, with labeling in place until time of installation. Store equipment in clean, dry place and protect coils from physical damage.

AARHIP 15670-3

1.6 SPARE PARTS

A. General: Furnish one complete change of lubricating oil.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Air Cooled Condensing Units.

a. The Trane Company b. Carrier Corporation

2.2 MATERIALS

A. General: Factory fabricate, assemble, test and finish condensing units with indicated capacities and characteristics, and including all necessary accessories for complete installation.

B. Air Cooled Condensing Units: Provide air cooled condensing units of minimum

size, capacity and arrangement shown and scheduled, meeting the following requirements.

1. Provide factory assembled, air cooled condensing unit prepiped and

prewired, comprising refrigeration compressor equipment, condenser coil, condenser fans and motors, magnetic starters, controls, and fan guards mounted in heavy gauge steel casing. Construct casing of one piece welded assembly with removable panels for access to all components and protect exterior surfaces with one coat of epoxy primer, finished with baked enamel.

2. Provide hermetic type compressor with forced feed lubrication provided by

positive displacement reversible oil pump, a crankcase sight glass, and electric crankcase heater. Provide compressor equipped with suction and discharge shutoff valves, and mounted on spring vibration isolators.

3. Provide operating and safety controls for condensing unit including

refrigerant high and low pressure safety cutouts, low oil pressure cutout, and compressor winding thermostat cutout. Provide condensing unit complete with circuit breaker and magnetic starter, control circuit fusing and control power transformer. Provide necessary relays, timers and manual reset overloads.

AARHIP 15670-4

4. Provide condenser coil constructed of seamless copper tubing mechanically bonded to heavy duty aluminum plate fins. Test condenser coils at factory at 425 psig air pressure under water, and vacuum dehydrate at 175 degrees F minimum.

5. Fabricate each condensing unit at factory as one unit including all internal

piping and with internal wiring to identified terminal strips in unit control panel.

6. Provide direct-driven condenser fans of propeller type, with all exposed fan

and shaft surfaces weatherproofed and arranged to give vertical air discharge, and with permanently sealed ball bearings.

7. Provide factory wired controls mounted in an accessible location in

weatherproof enclosure. Provide thermal and current sensitive overload devices for compressor motor protection. Provide solid state compressor protection control system to prevent short cycling due to safety devices or power interruptions, controlled by positive acting timer. Provide accessory equipment including filter-drier, liquid line moisture indicating sight glass, refrigeration tubing, and insulation package. Charge system with recommended refrigerant and oil.


A. Provide units constructed and rated in accordance with ARI 210/240, ANSI/UL 207 and ANSI/UL 303. Test in accordance with ASHRAE 23.

B. Provide units with Energy Efficiency Rating (EER) and Coefficient of

Performance (COP) not less than prescribed by ASHRAE 90.1.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine condensing units at the time of delivery for damaged or missing components. Do not proceed with installation of units until all items found defective have been corrected.

3.2 INSTALLATION

A. Install all units in accordance with manufacturer's instructions. Make all necessary adjustments to equipment to provide complete and satisfactory operation upon completion of installation.

B. Connect to electrical service.

AARHIP 15670-5

C. Install units on vibration isolation. Refer to Section 15072.

D. Install units on concrete base as indicated. Refer to Section 03310.

E. Provide connection to refrigeration piping system and evaporators. Refer to Section 15184 and comply with ANSI/ASHRAE 15.

F. Supply the initial charge of refrigerant and oil for each refrigerant circuit. Replace

losses of refrigerant and oil. 3.3 FIELD QUALITY CONTROL

A. Operation and Checkout: Provide initial and cooling season start-up, and winter season shut down during first year of operation, including routine servicing and check out.

B. Manufacturer's Field Services: Furnish the services of a qualified representative of

the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, and instruct operating personnel in its operation and maintenance as specified in Division 1.

C. Tests: After installation of the units, control equipment and all appurtenances,

subject each unit to a field running test as specified in Division 1, under actual operating conditions.

END OF SECTION

AARHIP 15670-6


AARHIP 15720-1

SECTION 15720

AIR HANDLING UNITS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Prepackaged air handling units manufactured in a modular form.


1. Section 09900 - Painting 2. Section 15072 - Vibration Isolation 3. Section 15080 - Mechanical Insulation 4. Section 15183 - Hydronic Piping Valves and Specialties 5. Section 15184 - Refrigeration Piping and Specialties 6. Section 15670 - Condensing Units 7. Section 15761 - Air Coils 8. Section 15810 - Ductwork 9. Section 15820 - Ductwork Accessories 10. Section 15830 - Fans 11. Section 15900 - HVAC Controls 12. Section 15950 - Testing, Adjusting and Balancing 13. Section 16055 - Electrical Requirements for Shop Assembled Equipment 14. Section 16220 - Electric Motors 15. Section 16445 - Motor Control Centers

1.2 REFERENCES


1. AMCA 99 - Air Movement and Control Association Standards Handbook

2. AMCA 210 - Laboratory Methods of Testing Fans for Rating Purposes

3. AMCA 300 - Reverberant Room Method for Sound Testing of Fans

4. AMCA 301 - Methods for Calculating Fan Sound Ratings from

Laboratory Test Data

5. AMCA 500 - Test Methods for Louver, Dampers, and Shutters

AARHIP 15720-2

6. AFBMA 9 - Load Ratings and Fatigue Life for Ball Bearings

7. AFBMA 11 - Load Ratings and Fatigue Life for Roller Bearings

8. UL 900 - Test Performance of Air Filter Units

9. ARI 410 - Forced-Circulation Air-Cooling and Air-Heating Coils

10. ARI 430 - Standard for Central-Station Air Handling Units

11. NFPA 90A - Installation of Air Conditioning and Ventilation Systems

12. SMACNA - HVAC Duct Construction Standards 1.3 SUBMITTALS


B. Product Data: Submit complete catalog product data, including the following:

1. Dimensions

2. Assembly

3. Weights

4. Specialties and accessories

5. Rated capacities

6. Performance ratings

7. Controls

8. Certified fan performance curves with system operating conditions

indicated, including brake horsepower, static pressure, and static efficiency plotted against air volume for the duty scheduled

9. Certified fan sound power ratings for both fan outlet and casing radiation at

rated capacity

10. Certified coil performance ratings with system operating conditions indicated

11. Motor ratings and electrical characteristics plus motor and fan accessories

AARHIP 15720-3

12. Electrical requirements for power supply wiring, including wiring diagrams for interlock and control wiring, clearly indicating factory-installed and field-installed wiring

13. Materials gauges and finishes

14. Filters with performance characteristics assembly and frames

15. Dampers, including housings, linkages, and operators

C. Shop Drawings: Submit shop drawings indicating assembly, locations,

dimensions, weight loading, required clearances, construction details, and location and size of each field connection.

D. Field Reports: Submit field quality control test reports.

E. Operation and Maintenance Manuals: Submit manufacturer's descriptive literature,

including operation instructions, lubrication instructions, filter replacement data, motor and drive replacement instructions, wiring diagrams, controls, accessories, maintenance and repair data, and parts listing. Include this data and product data in an operation and maintenance manual as specified in Division 1.


A. Fan Performance Ratings: Conform to AMCA 210 and provide the AMCA Certified Rating Seal.

B. Sound Ratings: Conform to AMCA 301, test to AMCA 300 and provide AMCA

Certified Sound Rating Seal.

C. Fabrication: Conform to AMCA 99 and ARI 430.

D. Filter Media: Provide UL 900 listed filter, Class I or Class II.

E. Air Coils: Certify capacities, pressure drops, and selection procedures in accordance with ARI 410.

F. Manufacturers: Provide equipment from a company regularly engaged in the

manufacture of air handling units, of the types and capacities required, whose products have been in satisfactory use in similar service for not lest than 5 years, and which issues complete catalog data on these products.


A. General: Deliver, store, and handle all products and materials as specified in Division 1 and as follows:

AARHIP 15720-4

B. Delivery and Handling: Deliver products to the site in factory-fabricated protective containers, with factory-installed shipping skids and lifting lugs. Handle products properly to prevent damage, breaking, denting and scoring. Do not install damaged equipment, replace damaged units with new ones. Comply with the manufacturer's rigging instructions for unloading and transporting equipment to its final location.

C. Storage and Protection: Store equipment in its original containers with labeling in

place until the time of installation.

1. Store in clean dry place, protect from weather, dirt, fumes, construction traffic, debris, and physical damage.


A. Equipment Pads: Coordinate the size and location of concrete equipment pads. Cast anchor bolt inserts into pad.

B. Structural Supports: Coordinate the size and location of structural steel support

members. 1.7 SPARE PARTS

A. General: Deliver spare parts securely wrapped or boxed, indexed and tagged with complete information for use and reordering.

Furnish the following spare parts.

1. One complete set of filters for each air handling unit

2. One complete set of belts for each air handling unit

3. One gasket for each sectional joint of each air handling unit

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Air Handling Units

a. The Trane Company b. Carrier Corporation

AARHIP 15720-5

2. Air Filters

a. Panel-type filters

(1) Servodyne Corp. - Series Hi-E-40A (2) Farr Company - Model 30/30

3. Filter Gauges

a. Dwyer - Durablock 200 b. Cambridge Filter Corp.

2.2 AIR HANDLING UNITS

A. General: Factory fabricate, assemble, test and finish air-handling units of the arrangement, minimum size, capacities and characteristics scheduled. Provide units having hot water and refrigeration coils and suitable for externally mounted air cooled condensing units.

B. Protective Coating: Provide protective coatings where indicated meeting the

following requirements.

1. Primer and Enamel Finish: Provide units with factory applied rustproof primer and corrosion-resistant baked enamel finish.

2. Manufacturer Recommendation: Perform cleaning and coating procedures

as specified and in accordance with the coating manufacturers published recommendations. As a minimum provide SSPC-SP3 Power Tool Cleaning.

C. Casing: Fabricate the unit casing of insulated double wall heavy-gauge steel,

reinforced and braced with steel angle framework, rigidly constructed and braced to prevent vibration, complete with removable panels for access to all internal parts. Make the casing section joints airtight by using a gasketed or caulked assembly.

D. Blower: Provide the blower of a double width, double inlet, multiblade,

centrifugal type, statically and dynamically balanced at the factory, with a rigid steel shaft with grease lubricated fan bearings and lubrication fittings extended to the service side. Provide the belt drive, including a fan sheave, an adjustable motor sheave permitting adjustment of at least 5 percent above rated cfm, V-belts, and a removable belt guard. Provide adjustable motor supports.

E. Motors: Provide TEFC high energy efficient type motors as specified in Section

16220.

F. Electrical Equipment: Provide all electrical equipment and materials in accordance with Section 16055. Provide combination motor starters, circuit

AARHIP 15720-6

breakers and disconnect circuit breakers meeting the requirements specified in Section 16445.

G. Drives and Guards: Provide belt drives, including machine matched belts of the

size and type recommended for the piece of equipment, with a capacity rating not less than 150 percent of motor rating. Provide each belt drive and each direct coupled drive with a substantial removable guard giving adequate clearance and safety protection at all positions of drive adjustment. Provide openings in the guard to permit measurement of driver and driven pulley speeds.

H. Drain Pans: Provide drain pans mounted under the fan and coil section with

cooling coils and where shown. Provide condensate drain pans of a double wall construction with threaded drain connections on both ends. Insulate the condensate drain pan with 5/8-inch thick foam faced on both sides with an additional aluminum foil vapor barrier, installed between the steel outer pan and the heavy-gauge steel inner pan. Coat the inner pan with corrosion-resistant elastomeric based material. Extend a drain line from the drain connection on the drain pan full size to the nearest floor drain.

I. Insulation: Comply with NFPA Standard 90A for insulation. Insulate the coil

section, fan section and accessory sections of the unit with 1-inch thick, 3-pound density, mat-faced fiberglass. Secure insulation to the casing with waterproof adhesive and permanent mechanical fasteners.

J. Coils: Provide coils meeting the requirements of Section 15761, and the minimum

capacity and maximum air and water resistance values scheduled.

K. Dampers: Provide low leak type dampers meeting the requirements of Section 15900.

L. Combination Filter/Mixing Box: Provide parallel-blade dampers in a reinforced,

galvanized steel cabinet. Provide aluminum damper blades mechanically fastened to aluminum operating rods. Connect operating rods for each set of dampers together with a common linkage and interconnect linkages so that dampers operate simultaneously and in the opposite direction (one opens when the other closes). Provide cabinet support members to hold 2-inch-thick, pleated, flat throwaway filters. Provide mixing boxes with hinged access panels or doors to allow removal of filters for both sides of the unit.

M. Air Filters: Comply with NFPA Standard 90A for air filters. Provide air filters as

required and as follows.

1. Provide panel filters of the sizes scheduled, 2-inch thick, pleated media replaceable type, with not less than 30 percent atmospheric dust spot efficiency on the ASHRAE Standard 52 Test.

AARHIP 15720-7

2. Equip panel filter units with side removal filter racks and sealing devices to accommodate the filters, complete with hinged access doors with cam fasteners to facilitate filter replacement.

N. Filter Gauges: Provide filter gauges for measuring the pressure drop across each

bank of air filters. Provide gauges complete with all necessary tubing, static tips, and accessories, including 3-way cocks arranged for ease in checking liquid level.


A. Test: Perform the following factory tests.

1. Sound Power Level Ratings: Comply with AMCA Standard 301 "Method for Calculating Fan Sound Ratings from Laboratory Test Data." Test fans in accordance with AMCA Standard 300 "Test Code for Sound Rating."

2. Units Fan Performance Ratings: Establish flow rate, pressure, power, air

density, speed of rotation, and efficiency by factory tests and ratings in accordance with AMCA Standard 210/ ASHRAE Standard 51 - Laboratory Methods of Testing Fans for Rating.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Perform examination of equipment and field condition as follows.

1. Examine units at the time of delivery for damaged or missing components.

2. Examine areas and conditions for compliance with requirements for installation tolerances, housekeeping pads, and other conditions affecting performance of central-station air handling units.

3. Examine rough-in for hydronic, refrigerant, drainage piping and electrical to

verify actual locations of connections prior to installation.

4. Do not proceed until unsatisfactory conditions have been corrected.

B. Power Supply: Verify that proper power supply is available. 3.2 INSTALLATION

A. General: Install equipment in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

AARHIP 15720-8

B. Support: Support air handling units as follows.

1. Support floor-mounted units on concrete equipment pads using housed spring isolators. Secure units to anchor bolts installed in concrete equipment pads.

C. Access Space: Provide access space around air handling units, coils and motors

for service. Provide no less than the minimum as recommended by the manufacturer. Allow space for motor, coil, and filter removal.

D. Ductwork and Piping Connections: Make final connections of ductwork and

piping as detailed on approved shop drawings. Install air handling units in conformance with ARI 435. Provide flexible connections at inlet and discharge of air handling equipment and where shown.

E. Electrical Leads: Install air handing units as shown and specified, with flexible

electrical leads.

F. Air Filters: Install a new set of filters in each system at the time of substantial completion.

G. Operating Requirements: Do not operate air handling units for any purpose until

ductwork is clean, filters are in place, bearings lubricated, and fan has been test run under observation.

H. Filter Gauges: Install air filter gauges for measuring the air flow resistance

through filters at all filter sections and filter banks for all air handling units. Install filter gauge static pressure tips upstream and downstream of filters. Mount filter gauges on outside of filter housing or filter plenum, in accessible position. Adjust and level. Permanently mark each gauge to show the normal resistance rating and the recommended resistance at which the air filters should be replaced.

I. Lubrication: Properly lubricate all pieces of equipment, furnished with lubrication

fittings, prior to start-up and at recommended intervals up to substantial completion. Attach a linen tag or heavy-duty shipping tag to each piece of equipment showing the date of lubrication and the name and number of lubricant used. Furnish typewritten list, in triplicate, of each item lubricated and the type of lubricant used.


A. Adjustment and Cleaning: Perform adjusting and cleaning as follows.

1. Align, adjust and balance each belt drive to prevent noise and vibration.

2. Adjust damper linkages for proper damper operation.

AARHIP 15720-9

3. Start air handling units and check for excessive vibration and correct.

4. Remove all loose materials and obstructions from interior of equipment.

5. Remove debris and waste materials resulting from installation.

6. Clean tar, adhesive, dirt or marks from exterior of units.

B. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, and instruct the operating personnel in its operation and maintenance as specified in Division 1.

C. Tests: After installation of the units, control equipment and all appurtenances,


END OF SECTION

AARHIP 15720-10


AARHIP 15730-1

SECTION 15730

PACKAGED AIR CONDITIONING UNITS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Packaged indoor air conditioning units, computer room air conditioning units.


following:

1. Section 15072 -Vibration Isolation 2. Section 15107 - Steel Pipe and Fittings 3. Section 15110 - Valves 4. Section 15183 - Hydronic Piping Valves and Specialties 5. Section 15184 -Refrigeration Piping and Specialties 6. Section 15670 - Condensing Units 7. Section 15720 - Air Handling Units 8. Section 15761 - Air Coils 9. Section 15810 - Ductwork 10. Section 15900 - HVAC Controls 11. Section 15950 - Testing Adjusting and Balancing 12. Section 16055 -Electrical Requirements for Shop-Assembled Equipment 13. Section 16220 - Electric Motors

1.2 REFERENCES


1. ASME Boiler and Pressure Vessel Code Section VIII, Division 1 - Pressure Vessels

2. ANSI/NEMA 250 - Enclosures for Electrical Equipment (1000 Volts

Maximum)

3. ANSI/NFPA 90A - Installation of Air Conditioning and Ventilation Systems

4. ARI 210/240 - Standard for Unitary Air-Conditioning Equipment


AARHIP 15730-2

1.3 SUBMITTALS:


B. Product Data: Submit the manufacturer's technical product data, including rated

capacities of the selected model clearly indicated, weights of units, furnished specialties and accessories, and installation and start-up instructions.

C. Shop Drawings: Submit the manufacturer's assembly-type shop drawings

indicating dimensions, weight loadings, required clearances, and methods of assembly of components.

D. Service Connections: Indicate water, drain, electrical, and refrigeration rough-in

connections on shop drawings and product data.

E. Wiring Diagrams: Submit the manufacturer's electrical requirements for power supply wiring to packaged air conditioning units. Submit the manufacturer's ladder-type wiring diagrams for interlock and control wiring required for final installation of packaged air conditioning units and controls. Clearly differentiate between portions of wiring that are factory-installed and portions to be field-installed.

F. Maintenance Data: Submit maintenance data and a parts list for each packaged air

conditioning unit, control, and accessory; including "trouble-shooting" maintenance guide. Include this data and product data in an operation and maintenance manual as specified in Division 1.


A. Regulatory Requirements: Conform to ANSI/NFPA 90A for the installation of packaged air conditioning units.

B. Manufacturer: Provide equipment from a Company specializing in the

manufacture of the products specified in this section with a minimum of 5 years documented experience.



B. Handling: Handle packaged air conditioning units, and components carefully to

prevent damage, breaking, denting and scoring. Do not install damaged packaged air conditioning units, or components. Replace damaged units with new units.

AARHIP 15730-3

C. Storage and Protection: Store packaged air conditioning units, and components in a clean dry place. Protect from weather, dirt, fumes, water, construction debris, and physical damage.

D. Unloading: Comply with the manufacturer's rigging and installation instructions

for unloading packaged air conditioning units, and moving units to final location for installation.

1.6 SPARE PARTS

A. Furnish the following spare parts.

1. One complete set of filters for each packaged air conditioning unit

2. One complete set of belts for each belt driven piece of equipment

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Packaged Indoor Air Conditioning Units

a. Carrier Corporation b. The Trane Company

2.2 PACKAGED INDOOR AIR CONDITIONING UNITS

A. General: Provide air conditioning units that are factory fabricated and assembled, factory tested and factory finished, and of a size, capacity, arrangement and characteristics as specified and scheduled. Provide units with ARI-rated cooling capacity. Provide units having hot water heating and electric refrigeration. Provide each unit comprised of casing and frame, evaporator fans, controls and filters, cooling coils, and suitable connections for externally mounted air-cooled condensing unit.

B. Casing: Provide casing constructed of heavy gauge zinc coated sheet steel with

front access panel, stamped louver type return and discharge grilles, and finished with a high grade semi-gloss baked enamel color as selected. Provide an extruded anodized aluminum outdoor air louver, intake collar, cabinet adapter collar and subbase for attachment to the cabinet.

C. Insulation: Provide 1 thick acoustic insulation for lining unit interior.

AARHIP 15730-4

D. Fans: Provide forward-curved aluminum centrifugal evaporator fans, statically and dynamically balanced, direct driven by permanent split capacitor motors with oilers for bearing lubrication. Provide the evaporator fan motor wired for a minimum of two speeds.

E. Hot Water Heating Coil: Provide a hot water heating coil complete with a

normally closed electric solenoid valve, connecting piping and valves factory prepiped. Provide the coil meeting the requirements specified in Section 15761 and 16055.

F. Evaporator Coil: Provide an evaporator coil of nonferrous construction with

seamless copper tubes mechanically bonded to aluminum fins. Factory test the coil for leakproofness at 300 psig air pressure under water. Clean and dehydrate the refrigerant system and completely charge the system with refrigerant and recommended oil before shipment. Provide the coil with a remote bulb thermal expansion valve for each refrigerant circuit.

G. Drain Pan: Provide insulated coil condensate drain pan constructed of zinc-coated

steel with an additional coat of insulating sealer and a drain line connection extended from the drain pan to discharge at an approved drain point.

H. OA Damper: Provide manually-operated outside air damper capable of

introducing 25 percent of outside air.

I. Filters: Provide a polyurethane foam washable air filter media mounted in a permanent retaining frame.

J. Control Box: Provide a unit-mounted control box containing an adjustable

thermostat and OFF-HEAT-COOL-HIGH-LOW selector switches.

K. Controls: Provide controls as specified in Section 15900 and conformance in Section 16055.

L. Service Connections: Provide air conditioning units that require power connection

drain connection and hot water piping connections for units with hot water heating.

PART 3 EXECUTION

3.1 INSPECTION

A. General: Examine areas and conditions under which packaged air conditioning units are to be installed. Do not proceed with installation work until unsatisfactory conditions have been corrected in an acceptable manner.

AARHIP 15730-5

B. Field Verification: Verify that the floor system the structural support and the ceiling system is ready to receive Work and opening dimensions are as indicated on shop drawings and instructed by the manufacturer.

C. Service Connections: Examine rough-in for hydronic, refrigeration, and

condensate drainage piping, and electrical conduits, to verify the proper locations of connections prior to installation.

3.2 INSTALLATION

A. General: Install units in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Electrical Wiring: Install electrical devices furnished by the manufacturer but not

specified to be factory-mounted. Furnish a copy of the manufacturer's field wiring diagram with equipment. Verify that the electrical wiring installation is in accordance with the manufacturer's submittal and installation requirements specified in Section 16055. Do not proceed with equipment start-up until the wiring installation is acceptable.

C. Drain Piping: Connect each unit drain to the nearest indirect waste connection. At

drain pans provide a trap constructed at least 1-inch deeper than the fan pressure as indicated in inches of water.


A. Start-Up: Start up packaged units, in accordance with the manufacturer's start-up instructions. Test controls and demonstrate compliance with requirements. Replace damaged or malfunctioning controls and equipment.

B. Manufacturer's Field Services: Furnish the services of a qualified representative of

the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, and instruct the operating personnel in its operation and maintenance as specified in Division 1.

C. Tests: After installation of the packaged air conditioning units, control equipment

and all appurtenances, subject each unit to a field running test as specified in Division 1, under actual operating conditions.

END OF SECTION

AARHIP 15730-6


AARHIP 15740-1

SECTION 15740

HEATING, VENTILATING AND AIR CONDITIONING PUMPS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Heating, ventilating and air conditioning pumps.


1. Section 03310 - Cast-In-Place Concrete 2. Section 15072 - Vibration Isolation 3. Section 15080 - Mechanical Insulation 4. Section 15124 - Gauges-Pressure and Vacuum 5. Section 15183 - Hydronic Piping, Valves and Specialties 6. Section 15900 - Heating, Ventilating and Air Conditioning Controls 7. Section 15950 - Testing, Adjusting and Balancing 8. Section 16121 - Wire and Cable - 600 Volts and Below 9. Section 16220 - Electric Motors

1.2 REFERENCES


1. HI -Pumps Standards 1.3 SYSTEM DESCRIPTION

A. Design Requirements: The drawings indicate sizes, profiles, connections and dimensional requirements of heating, ventilating and air conditioning pumps, and are based on the specific manufacturer types and models indicated. Pumps having equal performance characteristics by other manufacturers may be considered, provided deviations in dimensions and profiles and efficiencies do not change the design concept or intended performance.

B. Performance Requirements: Provide pumps operating at the specified capacities

and heads, and over the range of operating conditions specified, without cavitation, undue noise or vibration, when pumping at the specified temperatures.

AARHIP 15740-2

1.4 SUBMITTALS


B. Product Data: Provide product data including certified performance curves of

selected models indicating selected pump's operating point, weights (shipping, installed, and operating), furnished specialties, and accessories. Include NPSH curve.

C. Shop Drawings: Submit shop drawings showing the layout and connections for

heating, ventilating and air conditioning pumps. Include setting drawings with templates, and directions for installation of foundation bolts and other anchorages.

D. Wiring Diagrams: Provide wiring diagrams detailing wiring for power, signal, and

control systems, differentiating between manufacturer-provided wiring and field-installed wiring.

E. Maintenance Data: Submit maintenance data for heating, ventilating and air

conditioning pumps for inclusion in the Operation and Maintenance Manual specified in Division 1.


A. Hydraulic Institute Compliance: Design, manufacture, and install heating, ventilating and air conditioning pumps in accordance with "Hydraulic Institute Standards."

B. Manufacturer: Provide equipment from a company specializing in the

manufacture, assembly and field performance of pumps with minimum of 5 years documented experience.

C. Alignment: Provide base mounted pumps aligned by a qualified millwright and

alignment certified.

D. Single Source Responsibility: Provide all heating, ventilating and air conditioning pumps from a single manufacturer if available.



B. Preparation for Shipping: After assembly and testing, clean flanges and exposed

machined metal surfaces and treat them with an anticorrosion compound. Protect the flanges, pipe openings, and nozzles. Apply a factory finish paint to assembled, tested units prior to shipping.

AARHIP 15740-3

C. Storage and Protection: Store the pumps in a dry location. Retain the shipping

flange protective covers and protective coatings during storage. Protect the bearings and couplings against damage from sand, grit, and other foreign matter.

D. Extended Storage: For storage times greater than 30 days, dry internal parts with a

hot air or a vacuum-producing device to avoid rusting internal parts. Upon drying, coat internal parts with a protective liquid, such as light oil, kerosene, or antifreeze. For storage times greater than 6 months, dismantle bearings and couplings, dry and coat them with an acid-free heavy oil, and then tag and store in a dry location.

E. Rigging: Comply with the manufacturer's rigging instructions for handling.

1.7 SPARE PARTS

A. General: Furnish spare parts securely wrapped and boxed, indexed and tagged with complete information for use and reordering.

B. Seals: Provide one spare set of mechanical seals for each type and size of pump

containing such a seal.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Base-Mounted Pumps.

a. Bell & Gossett, ITT.

2. Inline Pumps.

a. Bell & Gossett, ITT. b. Taco, Inc. c. Armstrong Pumps, Inc.

2.2 PUMPS

A. General: Provide factory-assembled and factory-tested pumps. Fabricate casings to allow for removal and replacement of impellers without the necessity of disconnecting the piping. Provide pumps of the type, sizes, and capacities indicated.

AARHIP 15740-4

B. Motors: Provide motors as specified in Section 16220. 2.3 BASE-MOUNTED PUMPS

A. General: Provide base-mounted centrifugal pumps with horizontal shaft, double-suction, single-stage, bronze-fitted, horizontally split case design, and rated for 250 psig working pressure at 250 degree F continuous water temperature.

B. Casing Construction: Provide cast iron casings, with flanged piping connections,

threaded gauge tappings at the inlet and outlet flange connections, seal flush connection, drain plug, and vent port.

C. Impeller Construction: Provide statically and dynamically balanced, closed,

overhung, double suction impellers, fabricated from cast bronze keyed to shaft and secured by a locking capscrew.

D. Wear Rings: Provide replaceable, bronze wear rings.

E. Pump Shaft and Sleeve Bearings: Provide pumps with a stainless steel shaft and

shaft sleeves with lubricated ball bearings.

F. Seals: Provide carbon/ceramic. Provide seals internally flushed or equipped with an external flushed line with filter.

G. Pump Couplings: Provide pump couplings which are flexible, capable of

absorbing torsional vibration and shaft misalignment, complete with a metal coupling guard. Provide couplings of the drop-out spacer type to allow for impeller removal without disturbing motor.

H. Mounting Frame: Provide a factory-welded frame and cross members, fabricated

of steel channels and angles for mounting the pump casing, coupler guard, and motor. Grind welds smooth prior to application of the factory finish.

I. Motor: Secure the motor to the mounting frame with adjustable alignment on the

mounting frame. 2.4 IN-LINE PUMPS

A. General: Provide in-line centrifugal pumps, single stage, bronze fitted horizontally split casing, and rated for 250 psig working pressure at 250 degrees F continuous water temperature.

B. Casing Construction: Provide cast iron casings, with flanged piping connections,

threaded gauge tappings at inlet and outlet flange connections, seal flush connection, and drain plug.

AARHIP 15740-5

C. Impeller Construction: Provide statically and dynamically balanced, single suction, cast bronze fully enclosed impeller, keyed directly to the motor shaft.

D. Shaft and Sleeve: Stainless steel shaft, with bronze sleeve.

E. Seals: Carbon/ceramic seals. Provide internally flushed seals or provide external

flush lines and filters. 2.5 EQUIPMENT PADS

A. Construct concrete equipment pads meeting the requirements as specified in Section 03310.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine areas, equipment foundations, and conditions, for compliance with the requirements for installation tolerances and other conditions affecting performance of heating, ventilating and air conditioning pumps.

B. Piping: Examine the rough-in for piping systems to verify the actual locations of

piping connections prior to installation.

C. Equipment Foundations: Examine equipment foundations for suitable conditions where pumps are to be installed.

D. Approval: Do not proceed until unsatisfactory conditions have been obtained.

3.2 INSTALLATION

A. General: Install pumps in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Space Requirements: Arrange and install pumps in locations to provide access for

periodic maintenance, including removal of motors, impellers, couplings, and accessories.

C. Support: Support pumps and piping separately so that the weight of the piping

system does not rest on the pump.

D. Hangers: Suspend inline pumps using all thread hanger rods and vibration isolation hangers of sufficient size to support the weight of the pump independent from the piping system.

AARHIP 15740-6

E. Mounting Procedure: Set base-mounted pumps on concrete foundations. Disconnect coupling halves before setting. Do not reconnect couplings until the alignment operations have been completed.

1. Support the pump base plate on rectangular metal blocks and shims, or on

metal wedges having a small taper, at points near the foundation bolts. Provide a gap of 3/4 to 1-1/2 inches between the pump base and the foundation for grouting.

2. Adjust the metal supports or wedges until the shafts of the pump and driver

are level. Check the coupling faces and suction and discharge flanges of the pump to verify that they are level and plumb.

F. Field Work: Field drill motor mounting holes for field installed motors.

G. Alignment: Align pump and motor shafts and piping connections after setting on

foundation, after grout has been set and foundations bolts have been tightened, and after piping connections have been made.

1. Meet manufacturers recommendations for alignment tolerances.

H. Adjustments: Adjust the alignment of pump and motor shafts for angular and

parallel alignment by one of the two methods specified in the Hydraulic Institute "Centrifugal Pumps - Instructions for Installation, Operation and Maintenance."

I. Field Grouted Pads: After alignment is correct, tighten the foundation bolts

evenly, but not too firmly. Fill the base plate completely with nonshrink, nonmetallic grout, with metal blocks and shims or wedges in place. After grout has cured, fully tighten foundation bolts.

3.3 CONNECTIONS

A. Pipe Sizes: Install suction and discharge pipe sizes equal to or greater than the diameter of the pump nozzles. Correct misaligned suction and discharge lines before connecting pumps.

B. Valves: Install valves that are the same size as the piping connecting the pump.

1. Install a nonslam check valve and globe valve on the discharge side of inline

pumps.

2. Install a triple-duty valve on the discharge side of base-mounted pumps.

3. Install a gate valve and strainer on the suction side of inline pumps.

AARHIP 15740-7

C. Flexible Connections: Install flexible connectors on the suction and discharge side of each base-mounted pump. Install flexible connectors between the pump casing and the discharge valves, and upstream from the pump.

D. Gauges: Install pressure gauges on the suction and discharge of each pump at the

integral pressure gauge tappings provided.

1. Install temperature and pressure gauge connector plugs in suction and discharge piping around the pump. Temperature and pressure gauge connector plugs are specified in Section 15124.

E. Electrical Connections: Provide control wiring and connections as specified in

Section 15900 and electrical wiring and connections as specified in Section 16121.

F. Lubrication: Lubricate oil-lubricated bearings. Remove grease-lubrication bearing covers and flush the bearings with kerosene and thoroughly clean. Fill with new lubricant in accordance with the manufacturer's recommendations.

G. Field Check: Disconnect couplings and check motor for proper rotation. Confirm

rotation in the direction of rotation marked on the pump casing. Check that the pump is free to rotate by hand. For pumps handling hot liquids, ascertain that the pump is free to rotate with the pump hot and cold. If the pump is bound or even drags slightly, do not operate the pump until the cause of the trouble is determined and corrected.


A. General: Make the field checks specified in Division 1 and the following:

1. Check suction line connections for tightness to avoid drawing air into the pump.

2. Check pump alignment with piping.

3. Check pump shaft alignment (radial and angular).

4. Check level, grouting and foundation bolts.

5. Check that pump freely rotates by hand.

6. Check that pump has been lubricated.

7. Check installation of filter mesh, and pressure gauges.

8. Check nameplate and tag.

AARHIP 15740-8

B. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, and instruct the operating personnel in its operation and maintenance as specified in Division 1.

C. Tests: After installation of the pumps, control equipment and all appurtenances,


END OF SECTION

AARHIP 15761-1

SECTION 15761

AIR COILS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Heat transfer coils utilizing glycol/water, and refrigerants as heat transfer media for installation in air systems.

B. Related Work Specified in Other Sections, But is Not Limited to, the Following:

1. Section 15080 - Mechanical Insulation 2. Section 15183 - Hydronic Piping, Valves and Specialties 3. Section 15184 - Refrigeration Piping and Specialties 4. Section 15720 - Air Handling Units 5. Section 15810 - Ductwork 6. Section 15900 - HVAC Controls 7. Section 16055 - Electrical Requirements for Shop-Assembled Equipment

1.2 REFERENCES


1. ARI 410 - Forced-Circulation Air-Cooling and Air-Heating Coils.

2. NEC - National Electrical Code.

3. UL 1096 - Electric Central Air Heating Equipment.

4. SMACNA - HVAC Duct Construction Standards, Metal and Flexible. 1.3 SUBMITTALS


B. Product Data and Information: Submit product data indicating coil and frame

configurations, dimensions, materials, rows, connections, and rough-in dimensions.

C. Shop Drawings: Submit shop drawings indicating coil and frame configurations,

dimensions, materials, rows, connections and rough-in dimensions.

AARHIP 15761-2

D. Diagrams: Submit complete wiring and control diagrams.

E. Quality Control: Submit manufacturer's certificate that coil capacities, pressure drops and selection procedures meet or exceed specified requirements.


A. General: Provide equipment from a company specializing in manufacturing the products specified in this Section with minimum 5 years documented experience.



B. Storage and Protection: Protect coil fins from crushing and bending by leaving

them in the shipping cases until installation, and by storing indoors, in a clean, dry place.

Protect coils from entry of dirt and debris with pipe caps or plugs.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Hot Water Heating Coils.

a. The Trane Company. b. Carrier Corporation.

2. Direct Expansion Cooling Coils.

a. The Trane Company. b. Carrier Corporation.

2.2 COILS - GENERAL

A. General Design: Factory fabricate and assemble, factory test, and factory finish air coils, with indicated capacities and characteristics, and including all necessary accessories for complete installation.

AARHIP 15761-3

B. Protective Coating: Provide a protective coating for each piece of equipment as specified, meeting the following requirements.

1. Baked Phenolic Coating: Where a baked phenolic corrosion-resistant is

required, thoroughly clean, prepare and protect against corrosion all metal parts of each unit with one coat of primer and at least two coats of a baked phenolic corrosion-resistant coating to obtain a minimum total dry film thickness of four to six mils.

2.3 HOT WATER HEATING COILS

A. General: Provide units meeting the minimum face area and maximum air and water friction drop as scheduled coated with baked phenolic coating and as follows:

B. Headers: Provide headers constructed of cast iron with tubes expanded into

headers, pitched to drain.

C. Tubes: Provide tubes of 5/8 inch OD seamless copper arranged in a parallel or staggered pattern, expanded into fins, with silver brazed joints.

D. Fins: Provide aluminum continuous plate type fins with full fin collars or

individual helical finned tube type wound under tension.

E. Casing: Construct casing of heavy gauge galvanized sheet steel with drilled mounting flanges.

F. Testing: Provide coils air tested under water to 350 psig for a working pressure of

200 psig and 220 degrees F.

G. Supports: Fabricate supports for each coil unit or bank of coils of steel channels pitched as required for venting and drainage.

H. Arrangement: Provide individually removable coil units.

I. Selection: Select coils based on 30% glycol/70% water solution.

2.4 DIRECT EXPANSION COOLING COILS

A. General: Provide units meeting the minimum face area and maximum air friction drop as scheduled coated with baked phenolic coating, and as follows:

B. Headers: Construct headers of seamless copper tubes with silver brazed joints.

C. Liquid Distributors: Provide copper venturi type distributor with seamless copper

distributor tubes.

AARHIP 15761-4

D. Tubes: Provide tubes of 5/8 inch OD seamless copper arranged in parallel or staggered pattern, expanded into fins, with silver brazed joints.

E. Fins: Provide aluminum continuous plate type fins with full fin collars or

individual helical finned tube type wound under tension.

F. Testing: Provide coils air tested under water at 300 psig for working pressure of 250 psig; clean, dehydrate and seal with dry nitrogen charge.

G. Accessory: Provide refrigeration accessory equipment as specified in Section

15184.

PART 3 EXECUTION

3.1 EXAMINATION

A. Delivery: Examine units at the time of delivery for damaged or missing components. Do not proceed with the installation of units until all items found defective upon examination have been corrected.

3.2 INSTALLATION

A. General: Install coils in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1. Make all necessary adjustments to the equipment to provide a complete and satisfactory operation upon completion of the installation.

B. Removal Space: Install to permit removal of coils. Provide no less space for

removal than minimum as recommended by the manufacturer.

C. Supports: Support coil sections independent of piping on steel channel or double angle frames and secure to casings. Arrange supports to avoid piercing drain pans. Provide an airtight seal between coil and duct or casing.

D. Protection: Protect coils to prevent damage to fins and flanges. Comb out bent

fins.

E. Alignment: Install coils level.

F. Connection: Make connections to coils with unions and flanges.

G. Accessories: On water coils, provide a shut-off valve on the supply line and a balancing valve on the return line. Locate the water supply at bottom of supply header and return water connection at the top. Provide the float operated automatic air vents at high points complete with stopvalve. Ensure water coils are drainable and provide drain connection at low points.

AARHIP 15761-5

H. Flow Arrangement: On water heating coils, connect the water supply to the

leaving air side of coil counterflow arrangement.

I. Moisture Eliminators: For cooling coils where the air velocity exceeds 500 ft/min, provide six break moisture eliminators of 24 gauge galvanized steel.

J. Drain Pans: Provide drain pan and drain connections for cooling coils. Fabricate

drain pans from 20 gauge galvanized steel. Extend the drain pan 3 inches from face of coil entering air side, 6 inches from face of coil leaving air side, and 4 inches from face of eliminators. Pipe drain pans individually to floor drain with water seal trap.

K. Sight Glass: On refrigerant coils, provide a sight glass in the liquid line within 12

inches of the coil.

L. Insulation: Insulate headers located outside air flow as specified for piping. Refer to Section 15080.


A. Manufacturer's Field Service: Provide the services of a qualified representative of the manufacturer to inspect the installation of air coils, certify that it meets the manufacturer's recommendations, and instruct the operating personnel in their operation and maintenance.

END OF SECTION

AARHIP 15761-6


AARHIP 15765-1

SECTION 15765

TERMINAL HEAT TRANSFER UNITS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Terminal units used in hydronic heating systems.


1. Section 15060 - Supports and Anchors 2. Section 15072 - Vibration Isolation 3. Section 15183 - Hydronic Piping, Valves and Specialties 4. Section 15900 - HVAC Controls 5. Section 16055 - Electrical Requirements for Shop Assembled Equipment

1.2 REFERENCES


1. NFPA 70 - National Electrical Code.

2. ARI 410 - Forced Circulation Air Cooling and Air Heating Coils.

3. ASHRAE 33 - Methods of Testing Forced Circulation Air Cooling and Heating Coils.

4. ARI 440 - Room Fan Coil Air Conditioners.

5. UL 883 - Safety Standards for Fan Coil Units and Room Fan

Heater Units. 1.3 SUBMITTALS


B. Product Data: Submit manufacturer's specifications for terminal heat transfer units

showing dimensions, capacities, ratings, performance characteristics, gages and finishes of materials, and installation instructions.

AARHIP 15765-2

C. Shop Drawings: Submit assembly type shop drawings showing unit dimensions, construction details and field connection details.

D. Wiring Diagrams: Submit the manufacturer's electrical requirements for power

supply wiring to terminal units. Submit manufacturer's ladder-type wiring diagrams for interlock and control wiring. Clearly differentiate between those portions of wiring that are factory-installed and portions to be field-installed.

E. Samples: Submit 3 samples of each type of cabinet finish furnished.

F. Maintenance Data: Submit maintenance instructions, including lubrication

instructions, motor and drive replacement, and spare parts lists. Include this data, product data, and shop drawings in operation and maintenance manuals as specified in Division 1.


A. Manufacturer's Qualifications: Provide equipment from firms regularly engaged in the manufacture of terminal units, of the types and sizes required, whose products have been in satisfactory use in similar service for not less than 5 years.

B. UL Compliance: Provide electrical components for terminal units which are listed

and labeled by UL. 1.5 DELIVERY, STORAGE, AND HANDLING


B. Protection Handle terminal units and components carefully to prevent damage,

breaking, denting and scoring. Do not install damaged terminal units or components, replace them with new units.

C. Storage: Store terminal units and components in a clean dry place, protected from

weather, dirt, fumes, water, construction debris, and physical damage.

D. Handling: Comply with the Manufacturer's rigging and installation instructions for unloading terminal units, and moving them to final location.


A. Install terminal heat transfer units after walls are finished and painted to avoid damage to the units.

AARHIP 15765-3

1.7 SPARE PARTS


1. Two sets of air filters for each hot water cabinet heater.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Hot Water Unit Heaters

a. The Trane Company b. Modine Manufacturing Company

2. Finned Tube Radiation

a. The Trane Company b. Sterling Radiator Co.

3. Hot Water Cabinet Heaters

a. The Trane Company b. McQuay, Inc.

2.2 MATERIALS

A. Hot Water Unit Heaters: Provide hot water unit heaters of the minimum size, heating and air capacities and arrangement shown, meeting the following requirements.

1. Provide each unit comprised of a casing, heating coil, fan and motor, and 4-

way louver type discharge deflectors.

2. Fabricate the casing of minimum 20 gauge die formed steel, protected from rust by bonderizing and finished inside and outside with a high grade baked enamel.

3. Provide the heating coil comprised of seamless copper tubing hydraulically

expanded into aluminum plate fins to give a permanent bond. Test the coils at a minimum hydrostatic pressure of 200 psig. Construct headers of steel, copper or cast iron, to which the tubes are pitched for drainage.

AARHIP 15765-4

4. Provide the fan of the propeller type, with guard, lightweight dynamically balanced blades pitched to move the air evenly and quietly, direct-driven by a continuous duty totally enclosed electric motor.

5. Suspend unit heaters using hanger rods and neoprene vibration isolators

meeting the requirements specified in Section 15072.

B. Finned Tube Radiation: Provide finned tube radiators of the type, minimum capacity and materials specified, meeting the following requirements:

1. Construct enclosures of heavy gauge steel with a baked enamel finish in a

color selected from the manufacturer's color chart. Fabricate enclosures to be continuous between columns, with concealed slip joints and end sleeve supports. Provide covers with end closures.

2. Provide pedestal mounted units with hinged access doors at valves and air

vents. Space pedestals at a maximum distance of 4 feet on centers, near pipe ends, and at the pipe supporting pedestal bracket assemblies with ball bearing slide cradles.

3. Provide finned elements constructed of 5/8-inch diameter steel tube with

steel fins permanently bonded. Finned lengths noted are actual active not nominal lengths.

C. Hot Water Cabinet Heaters: Provide cabinet heaters of the minimum size, heating

and air capacities and arrangement shown, meeting the following requirements:

1. Provide units listed by the Underwriters Laboratories Inc.

2. Provide the heating element constructed of seamless copper tubes hydraulically expanded into aluminum plate fins to give a permanent bond.

3. Construct cabinets of heavy gauge bonderized sheet steel, with a baked

enamel finish of a standard color selected. Construct front panels of die formed steel, with top inlet and bottom discharge grilles.

4. Construct blowers of aluminum, of the forward curved, centrifugal, double

width, double inlet type, balanced to give quiet operation. Provide the permanent split capacitor type motor, 3-speed, with automatic overload protection and resilient base. Provide the motor of the direct drive type with lubricated bearings, and with the speed selector switch mounted inside the cabinet.

5. Provide units complete with 1 inch thick fiberglass disposable type air

filters, arranged for easy removal and replacement.

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PART 3 EXECUTION

3.1 INSPECTION

A. General: Examine areas and conditions under which terminal units are to be installed. Verify that the required utilities are available, in the proper location, and ready for use. Do not proceed with Work until unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. General: Install terminal heat transfer units, in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Unit Heaters: Hang unit heaters from the building structure, with pipe hangers

anchored to the building, not from piping. Mount the units as shown on equipment schedule.

C. Finned Tube Radiation: Locate finned tube radiation on outside walls and run the

cover wall-to-wall unless otherwise indicated. Center elements under windows. Install wall angles where units butt against walls.

D. Equipment Protection: Protect units with protective covers during the balance of

construction.

E. Valves: Provide hydronic units with a shut-off valve on the supply and a lockshield balancing valve on the return piping. If not easily accessible, extend the vent to an exterior surface of the cabinet for easy servicing. For unit heaters, provide float operated automatic air vents with stop valves.


A. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, as specified in Division 1.

B. Tests: After installation of the terminal heat transfer units, control equipment and

all appurtenances, subject each unit to a field running test as specified in Division 1, under actual operating conditions.


A. General: After construction is completed, including painting, clean exposed surfaces of units, vacuum clean terminal coils and the inside of cabinets.

AARHIP 15765-6

B. Touch-Up: Retouch any marred or scratched surfaces of factory-finished cabinets, using finish materials furnished by the manufacturer.

C. Filters: Install new filters at the time of substantial completion.

END OF SECTION

AARHIP 15810-1

SECTION 15810

DUCTWORK

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Ductwork materials, construction, hangers and supports, and cleaning.


Following:

1. Section 07920 - Joint Sealants 2. Section 08310 - Access Doors and Panels 3. Section 09900 - Painting 4. Section 10210 - Wall Louvers 5. Section 11395 - Odor Control Equipment 6. Section 15072 - Vibration Isolation 7. Section 15080 - Mechanical Insulation 8. Section 15820 - Ductwork Accessories 9. Section 15850 - Air Outlets and Inlets 10. Section 15950 - Testing, Adjusting and Balancing

1.2 REFERENCES


1. ASHRAE - ASHRAE Handbook - Fundamentals; Duct Design

2. ASHRAE - ASHRAE Handbook - HVAC Systems and

Equipment; Duct Construction

3. ASTM A 36/A36M- Specification for Structural Work

4. ASTM A 90/A90M- Weight of Coating on Zinc-Coated (Galvanized) Iron or Steel Articles

5. ASTM A 167 - Stainless and Heat-Resisting Chromium-Nickel

Steel Plate, Sheet, and Strip

AARHIP 15810-2

6. ASTM A 653 - Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

7. ASTM A 700 - Practices for Packaging, Marking and Loading

Methods for Steel Products for Domestic Shipment

8. ASTM B 209 - Aluminum and Aluminum Alloy Sheet and Plate

9. ASTM C 411 - Test Method for Hot-Surface Performance of

High-Temperature Thermal Insulation

10. ASTM C 581 - Practice for Determining Chemical Resistance of Thermosetting Resins Used in Glass Fiber-Reinforced Structures, Intended for Liquid Service

11. ASTM C 916 - Specification for Adhesives for Duct Thermal

Insulation

12. ASTM C 920 - Specification for Elastomeric Joint Sealants

13. ASTM C 1071 - Specification for Thermal and Acoustical Insulation

14. ASTM D 638 - Test Method for Tensile Properties of Plastics

15. ASTM D 790 - Test Method for Flexural Properties of

Unreinforced and Reinforced Plastics and Electrical Insulating Materials

16. ASTM D 2563 - Recommended Practice for Classifying Visual

Defects in Glass-Reinforced Plastic Laminate Parts

17. ASTM D 2996 - Specification for Filament-Wound Fiberglass

18. ASTM D 4024 - Specification for Reinforced Thermosetting Resin

Flanges

19. ASTM E 84 - Test Method for Surface Burning Characteristics of Building Materials

20. AWS D1.1 - Structural Welding Code - Steel

21. AWS D9.1 - Sheet Metal Welding Code

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22. NFPA 90A - Installation of Air Conditioning and Ventilating Systems

23. NFPA 90B - Installation of Warm Air Heating and Air

Conditioning Systems

24. NFPA 255/ - Test Method for Surface Burning ASTM E 84 Characteristics of Building Materials

25. SMACNA - HVAC Duct Construction Standards

26. SMACNA - Fibrous Glass Duct Construction Standards

27. SMACNA - Fire Damper Guide

28. UL 181-Factory - Made Air Ducts and Connectors

1.3 DEFINITIONS

A. Sealing Requirements Definitions: The following definitions apply for duct system sealing requirements:

1. Seams: Joining of two longitudinally (in the direction of airflow) oriented

edges of duct surface material occurring between two joints. All other duct surface connections made on the duct perimeter are deemed to be joints.

2. Joints: Joints include girth joints; branch and subbranch intersections; so-

called duct collar tap-ins; fitting subsections; louver and air terminal connections to ducts; access door and access panel frames and jambs; duct, plenum, and casing abutments to building structures.


A. Design Requirements: The duct system design, as indicated, has been used to select and size air moving and distribution equipment and other components of the air system. Changes or alterations to the layout or configuration of the duct system must be specifically approved in writing. Accompany requests for layout modifications with calculations showing that the proposed layout will provide the original design results without increasing the system total pressure.

1.5 SUBMITTALS

A. General: Provide all submittals, including the following as specified in Division 1.

B. Shop Drawings: Submit 1/4 inch scale shop drawings indicating duct systems routing, sizes, fitting details, reinforcing, support, required clearances, and installed accessories and devices.

AARHIP 15810-4

C. Installation Data: Submit manufacturer's installation instructions for glass fiber

ducts. Submit manufacturer's certificate that installation of glass fiber ducts meets or exceeds recommended fabrication and installation requirements.

D. Samples: Submit representative laminate samples for (FRP) ductwork, prior to

fabrication for approval of surface finish and visual defects.

E. Quality Control: Provide the FRP ductwork supplier's certification for the following:

1. The resin test results performed in accordance with ASTM C 581 certifying

that the resin is compatible with an environment consisting of air, hydrogen sulfide gas, methane, various aromatic hydrocarbon vapors, droplets of salt water, droplets of ammonium sulfate, and droplets of water containing sodium hypochlorite, sodium hydroxide, hydrogen peroxide, sulfuric acid, and any other chemicals mentioned in the specifications sections.

2. The FRP ductwork has a flame spread rating of 25 or less and a smoke

developed rating of 50 or less as measured in accordance with NFPA No. 255 ASTM E 84.

3. That the ductwork supplies meets the visual defects level and the deflection

requirements under the vacuum pressure and hoop (point) loading specified. 1.6 QUALITY ASSURANCE

A. General: Provide materials from a company specializing in the design and manufacture of ductwork and duct fittings having a minimum of 5 years documented experience, which issues complete catalog data on these products.

B. Codes: Qualify welding processes and welding operators in accordance with AWS

D1.1 for hangers and supports and AWS D9.1 Certify that each welder qualification is current.



B. Delivery: Deliver sealant and fire-stopping materials to site in original unopened

containers or bundles with labels informing about manufacturer, product name and designation, color, expiration period for use, pot life, curing time, and mixing instructions for multicomponent materials. Deliver stainless steel sheets with mill-applied adhesive protective paper, maintained through fabrication and installation.

AARHIP 15810-5

C. Storage and Protection: Store and handle sealant fire-stopping materials in compliance with manufacturers' recommendations to prevent their deterioration or damage due to moisture, high or low temperatures, contaminants, or other causes. Store ductwork and duct fittings in a clean dry place and protect from physical damage.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Gasket for flanged connections for sheet metal ductwork

a. Ductmate Industries 440 Butyl Gasket

2. Fiberglass duct

a. ATS Products, Inc.

2.2 DUCTWORK

A. General: Provide ductwork and plenums conforming to the more stringent recommendations of the current editions of the ASHRAE Handbook and of the SMACNA "HVAC Duct Construction Standards", and "Accepted Industry Practice for Industrial Duct Construction".

B. Steel Ductwork: Provide galvanized steel ductwork as follows:

1. Galvanized sheet steel of lock-forming quality, ASTM A 653, coating

designation G 90 with mill-phosphatized finish for exposed surfaces of ducts exposed to view.

C. Corrosion-Resistant Ductwork: Provide corrosion-resistant ductwork where the

ambient air or air conveyed may cause corrosion. Provide the type of corrosion-resistant ductwork in accordance with the following designations:

1. Type A: ASTM B 209, Aluminum Alloy 3003-H-14 sheet and Alloy

6061-T6 bars and angles for low pressure ductwork.

2. Type B: Fiberglass Reinforced Plastic (FRP) ductwork, see subsection headed "Fiberglass Reinforced Plastic (FRP) Ductwork - Type B".

AARHIP 15810-6

D. Construction Material: Unless otherwise specified, provide duct reinforcing and duct accessories constructed of the same materials as the duct, if commercially available. Otherwise, provide such reinforcing and duct specialties fabricated of Type 316L stainless steel. Provide extruded aluminum grilles, registers, and diffusers on corrosion-resistant duct systems as specified with Type 316L stainless steel ductwork. Where dissimilar metals join, isolate metals electrolytically to prevent corrosion.

E. Reinforcing: Reinforce ductwork to prevent sagging, flexing and drumming, and

build ductwork to be airtight at the fan static pressures scheduled.

F. Dimensions: The dimensions of the ducts shown are not to be considered absolute; however, any changes from dimensions indicated are subject to approval. Where it is necessary to change dimensions of ducts, do not exceed equivalent friction loss.

1. Duct sizes noted are the clear dimensions inside the duct.

G. Pressure Loss: Provide duct curves, bends, offsets, transitions and transformation

pieces to be gradual, to minimize air turbulence. In general, design duct transformations changing air velocity for minimum loss in total pressure.

1. Refer to equipment schedules for duct system pressure.

2.3 SHEET METAL DUCTWORK

A. Construction: Construct sheet metal ducts in accordance with requirements recommended by SMACNA and ASHRAE.

1. Provide materials that are free from visual imperfections, such as pitting,

seam marks, roller marks, stains, and discolorations.

2. Crossbreak or bead duct sides that are 19 inches and larger and are 20 gauge or less, with more than 10 square feet of unbraced panel area unless they are lined or are externally insulated. In addition, crossbreak on both diagonals duct section surfaces exceeding 4 square feet unless the duct perimeter is beaded at 18-inch or closer spacing.

3. Fabricate and brace ducts to be quiet in operation.

B. Curved Rectangular Elbows: Fabricate curved rectangular elbows with the

centerline radius of at least 1-1/2 times the duct dimension parallel to the radius. Where space limitations require elbows with a smaller radius ratio, fabricate the elbows with sufficient full radius turning vanes to result in a pressure loss not greater than that for the elbow specified above.

C. Mitered Rectangular Elbows: Equip mitered rectangular elbows with turning

vanes.

AARHIP 15810-7

D. Joints and Seams: Fabricate sheet metal rectangular joints and seams meeting the

following requirements:

1. Submit certified test results, material safety data sheets, and applicable spec sheets for proprietary transverse duct connectors with shop drawings.

2. Conform certified test results to the entire sheet and joint deflection criteria

defined by SMACNA, in Section VII, of the SMACNA HVAC Air Duct Leakage Test Manual.

3. The nonproprietary TDC/TDF connectors may be used, constructed as the

nonproprietary SMACNA T-24 Flange, whose duct construction limits are defined on page 1-25 of the SMACNA HVAC Air Duct Leakage Test Manual. No other duct construction methods concerning TDC/TDF will be accepted.

4. Fabricate longitudinal seams with the Pittsburgh lock seam on all ductwork.

E. Sealing Materials: Provide sealing materials as follows:

1. Joint and Seam Sealants, General: The term sealant used here is not limited

to materials of adhesive or mastic nature, but also includes tapes and combinations of open weave fabric strips and mastics.

2. Joint and Seam Sealant: Provide one-part, nonsag, solvent-release-curing,

polymerized butyl sealant complying with FS TT-S-001657, Type I; formulated with a minimum of 75 percent solids.

3. Flanged Joint Mastics: Provide one-part, acid-curing, silicone elastomeric

joint sealants, complying with ASTM C 920, Type S, Grade NS, Class 25, Use O.

4. Flanged Connections: Provide approved gasket between all SMACNA T-

24, TDC/TDF flanged connections on metal ducts.

F. Fire Stopping: Refer to Specifications Section 07920 for fire-stopping.

G. Hangers and Supports: Provide duct hangers and supports meeting the following requirements.

1. Building Attachments: Fasten duct hangers and supports to concrete

surfaces with stainless steel threaded expansion type concrete anchors when cast-in-place concrete inserts are not installed. Do not cut reinforcing steel. Do not use powder actuated concrete fasteners.

AARHIP 15810-8

2. Hangers: Securely support horizontal ducts from the building structure by means of hanger rods or angle supports not more than 8 feet apart. Provide the hanger rods sized for the weight carried, threaded at both ends, and equipped with nuts and washers. Fabricate entire assembly from Type 316 stainless steel. Provide angles as duct bottom supports. When angle hangers are used, extend the hangers from flanged duct connections, extended stiffeners, or fabricated trapezes.

3. Duct Attachments: Provide sheet metal screws, blind rivets, or self-tapping

metal screws; compatible with duct materials.

4. Trapeze and Riser Supports: Provide steel shapes conforming to ASTM A 36/A36M as follows:

a. Where galvanized steel ducts are installed, provide hot-dipped

galvanized steel shapes and plates.

b. Where aluminum ducts are installed provide aluminum shapes and plates.

2.4 FIBERGLASS REINFORCED PLASTIC (FRP) DUCTWORK - TYPE B

A. General: Provide Type B corrosion-resistant ductwork, constructed of glass fiber reinforced plastic (FRP), including plenums, casings, ducts, fittings, turning vanes, isolation and balancing dampers, splitters, access doors, hangers, supports and all other miscellaneous items required for a complete system. Provide FRP motor-operated dampers as specified in Section 15900.

B. Resin: Provide fiberglass duct constructed of fiberglass-reinforced resin,

conforming to the applicable sections of ASTM C 581. Do not add a thixotropic agent to resin used on the interior surface of any duct in contact with scrubber exhaust. Provide final white pigment gel coat such that no glass fiber is exposed. Provide fiberglass containing an ultraviolet absorber to protect the resin from ultraviolet degradation.

C. Reinforcement: Fabricate FRP duct by the filament winding method or hand lay

up, for tubular shapes, using a "helix angle" of 70 degrees plus or minus 5 degrees. Fabricate the corrosion liner of the duct using one "C" veil and one chopped strand mat (1-1/2 ounce) or one layer of chopped strand prior to filament winding. Provide the minimum liner thickness of 30 mils. Fabricate all nontubular shapes by the hand layup, chopped strand or a combination of both using the specified corrosion liner.

D. Physical Properties of Laminate: Provide laminate having the following physical

properties:

AARHIP 15810-9

Physical Properties (at 73 F) ASTM Test Units Value

1. Minimum Ultim. Tensile Strength

D 638 psi 12,500

2. Minimum Flexural Strength D 790 psi 19,000 3. Minimum Flexural Modulus

of Elasticity (tangent) D 790 psi 800,000

E. Fabrication: As a minimum, and unless otherwise specified, provide laminate

materials of construction and fabrication of fiberglass ducts and plenums in accordance with the National Bureau of Standards "Voluntary Product Standard PB 15-69" for molded reinforced polyester chemical-resistant process equipment, Sections 3.1.1 through 3.4.9. and ASTM D 2996 for filament-wound pipe. Fabricate the exterior surface of the ducting suitable for a corrosive environment and to conform to Section 3.3.3.1 of PS 15-69. Fabricate all interior duct surfaces, with the inner veil of reinforcement overlapping, providing reinforcement base for 100 percent of the interior surface of the duct. Design the duct specifically to facilitate water drainage where indicated on the drawings, raised lips at duct are not accepted. Provide a final coat of intumescent paint to achieve a smoke development rating of less than 50 for ducts within buildings. Provide a final coat if corrosion and UV resistant gel coat to the final exterior layer of veil for outdoor service.

F. Duct Wall Thickness: Provide duct wall thickness minimum of 1/4-inch, 5/16-

inch, and 3/8-inch for duct sizes 2 through 20 inches, 24 through 36 inches, and 42 inches and over, respectively, with the exception of isolated small spots which may be as thin as 1/4-inch. Additional thickness may be required to meet deflection requirements. Design ductwork to accommodate the following minimum conditions:

Vacuum 15 inches WC Positive Pressure 15 inches WC Temperature -20 degrees to 120 degrees F Humidity 100 percent Soil Load 2,800 LB/LF Wind Load 70 mph Snow Load 50 psf

G. Duct Fittings: Design fittings, elbows, transitions, branch takeoffs and similar

items installed in FRP duct systems for low pressure loss and good air flow in accordance with accepted ventilation practices in accordance with the current edition of the applicable SMACNA manual.

Fabricate radius rectangular elbows with a minimum inside radius equal to the width of the duct. Where radius rectangular elbows with an inside radius less than

AARHIP 15810-10

the width of the duct are permitted, fabricate the vaned elbows with a minimum inside radius of 6 inches. Provide minimum of one vane for elbows up to 18 inches wide; two vanes for elbows 19 to 42 inches wide; and three vanes for widths over 43 inches. Fabricate vaned elbows with a full radius vanes and full heel radius. Brace the vane leading edges and provide the stays on a maximum spacing of 18 inches.

Provide square elbows with a 3-inch throat and heel radius and internal vaning as specified. Provide single thickness turning vanes on square elbows with duct widths up to 18 inches. Space double thickness vanes not more than 2-1/2 inches apart for ducts up to 36 inches in width and not more than 3-1/2 inches apart for ducts over 36 inches. Field constructed and fabricated turning vanes for square elbows are not acceptable.

Fabricate round cross-section elbows of minimum 5-piece construction.

H. Duct Dimensions: The duct and plenum dimensions indicated on the drawings are

net inside, indicating the clear space required inside the duct or plenum.

I. Field Joints: Make the field joints by wrapping using RMRMR sequence with strips of reinforcement saturated with resin, the reinforcement being at least the thickness of the heaviest plastic section being joined. Extension to a sufficient distance on each side of the joint is required to make the joint at least as strong as the pieces joined. Fill the mating edges with resin paste to cover cut edges and voids. Seal the inside surface of the joint with one layer of reinforcement where accessible.

J. Flanges: Provide flanges in accordance with the specifications in ASTM D 4024,

PS 15-69, Sections 3.4.7.1 to 3.4.5.

K. Flanged Joints: Provide flanged joints sealed watertight with minimum 1/8-inch thick Viton gaskets and assembled with 316 stainless steel bolts and washers.

L. Drains: Provide a 2-inch drain at each low point of FRP ductwork. Provide drains

comprised of a gusseted flanged nozzle, 9-inch long transparent PVC pipe and 2-inch flanged PVC ball valve at the nozzle and at the end of the drain.

M. Duct Deflection: Design the ductwork to meet the following specification with

respect to supports shown. Furnish additional supports at no extra cost. Provide rectangular ducts which have a maximum deflection of a duct side not exceeding two percent of the width of the side at a test vacuum pressure of 15 inches w.c. Provide round ducts which have a maximum deflection not exceeding two percent or 1/4 inch of the duct diameter under an imposed hoop (point) loading of 550 pounds. Provide horizontal rectangular ducts which after the installation do not sag in excess of two percent of the shortest side as measured from a straight and true centerline of the duct to the actual midpoint of the installed duct. Similarly, provide horizontally installed round ducts which have a maximum sag not

AARHIP 15810-11

exceeding two percent of the diameter. Design duct supports and install such that the maximum deflections and sags specified are not required to meet the deflection requirements. Design any internal support components of the ductwork such that they do not increase the system pressure drop.

N. Workmanship: Provide the finished laminate free from visual defects, such as

foreign inclusions, dry spots, air bubbles, pin holes, pimples, delamination, exposed reinforcement (glass fibers) and runoff and to conform to ASTM D 2563, Level II, for visual defects. Fabricate ductwork with the smooth surface and no sharp projections. Fill voids and crevices at joints and fittings.

Provide qualified, experienced mechanics to fabricate all FRP ductwork who have a minimum of five years experience with lay-up, fabrication and joining of this type of materials, including resins, as specified herein.

O. Hangers and Supports: Adequately support FRP ductwork from the building

structure to prevent sagging. Space the hangers for ducts up to 48 inches maximum side at maximum of 6 feet 0 inches on centers. Space hangers for ducts larger than 48 inches maximum side at maximum of 4 feet 0 inches on centers. Space hangers closer if required to meet the sag requirements specified. Furnish calculations for alternative spacing. Support FRP ductwork by trapeze type hangers with minimum 3/8-inch diameter Type 316 stainless steel hanger rods. Support the bottom of the duct with minimum 2-inch by 2-inch by 1/4-inch Type 316 stainless steel angles securely bolted. Provide complete assemblies with 3/8-inch Type 316 stainless steel bolts, nuts and washers against the duct.

PART 3 EXECUTION

3.1 APPLICATION

A. General: Except as otherwise indicated construct all ductwork as specified of galvanized steel in accordance with SMACNA standards.

B. Type A Ductwork: The following systems require Type A corrosion-resistant

ductwork (aluminum):

1. All ductwork except ductwork associated with air conditioning unit CR4-AHU-1.

C. Type B Ductwork: The following systems require Type B corrosion-resistant

ductwork (fiberglass reinforced plastic):

1. All odor control ductwork.

AARHIP 15810-12

3.2 DUCT INSTALLATION, GENERAL

A. Duct System Pressure Class: Construct and install each duct system for the specific duct pressure classification as required.

B. Joints: Install ducts with the fewest possible joints.

C. Fittings: Use fabricated fittings for all changes in directions, changes in size and

shape, and connections.

D. Duct Openings: Provide openings in ductwork where required to accommodate thermometers and controllers. Provide pitot tube openings where required for testing of systems, complete with metal can with spring device or screw to ensure against air leakage. Where openings are provided in insulated ductwork, install insulation material inside a metal ring.

E. Duct Location: Locate ducts, except as otherwise indicated, vertically and

horizontally, parallel and perpendicular to building lines; avoid diagonal runs. Install ducts close to walls, overhead construction, columns, and other structural and permanent enclosure elements of building. Install duct systems in shortest route that does not obstruct useable space or block access for servicing building and its equipment.

F. Construction Penetrations: Determine the exact location and size of floor opening

required for ductwork. Core drill all penetrations through existing floors, walls or ceilings. Chipping is not allowed in lieu of core drilling. Obtain written approval prior to making any new penetrations through existing floors, walls or ceilings. Drill pilot holes before core drilling to locate any interference with existing conduits, equipment, etc. Neatly patch and seal opening after installation of new equipment to match existing walls, floors, ceilings, etc.

G. Clearances: Where insulated or uninsulated ducts pass through walls, floors, or

partitions, provide the opening in the construction not exceeding 1-inch clearance on all sides. Where ducts pass through walls, floors, or partitions required to have a fire-resistance rating and fire dampers are not required, provide the opening in the construction not exceeding 1-inch clearance on all sides, filled solidly with an approved material capable of preventing the passage of flame and hot gases sufficient to ignite cotton waste when subject to the same NFPA 251 time-temperature fire conditions required for fire barrier penetration. Where fire dampers are installed, maintain proper clearance for expansions.

H. Flexible Connections: Support at free end within 12 inches of flexible connection

all ducts at flexible connections with air-handling equipment and fans.

I. Shafts and Enclosures: Conceal ducts from view in finished and occupied spaces by locating in mechanical shafts, hollow wall construction, or above suspended

AARHIP 15810-13

ceilings. Do not encase horizontal runs in solid partitions, except as specifically shown.

J. Layout: Coordinate layout with suspended ceiling and lighting layouts and similar

finished Work.

K. Electrical Equipment Spaces: Route ductwork to avoid passing through transformer vaults and electrical equipment spaces and enclosures.

L. Nonfire-Rated Partition Penetrations: Where ducts pass interior partitions and

exterior walls, and are exposed to view, conceal the space between construction opening and duct or duct insulation with sheet metal flanges of same gauge as duct. Overlap openings on four sides by at least 1-1/2 inches.

M. Seal: Seal externally insulated ducts prior to insulation installation.

N. Concrete Insert: Install concrete inserts prior to placing concrete.

O. Plenum Access Doors: Set plenum access doors 6 to 12 inches above floor.

Arrange door swings so that fan static pressure holds door in closed position.

P. Blank Off Panels: Blanked off unused portions of louvers with insulated panels provided under Section 10210.

Q. Flexible Duct: Provide flexible duct connectors at final connection to air handling

and where shown.

R. Temporary Closures: During construction, provide temporary closures of metal or taped polyethylene on open ductwork to prevent construction dust from entering ductwork system.

S. Hanging and Supporting: Support ductwork as follows:

1. Make provisions for supporting all ductwork, dampers, and other ductwork

accessories, where necessary.

2. Construct, reinforce, support and brace ductwork to prevent buckling, warping, sagging, flexing and vibrating and be quiet in operation under all operating conditions and airtight at the fan static pressures scheduled.

3. Securely support horizontal ducts from the building structure by means of

hanger rods or angle supports not more than 8 feet apart. Size hanger rods for the weight carried, thread at both ends, and equip with nuts and washers.

AARHIP 15810-14

4. Support horizontal ducts within 2 feet of each elbow and within 4 feet of each branch intersection.

5. Support vertical ducts at a maximum interval of 16 feet and at each floor.

3.3 FRP DUCT INSTALLATION

A. General: Obtain manufacturer's inspection and acceptance of fabrication and installation of FRP ductwork at beginning of installation. Install in the strict accordance with manufacturer's instructions.


A. Tests: After installation of the FRP duct system, control equipment and all appurtenances, subject each unit to a field running test as specified in Division 1, under actual operating conditions.

3.5 CLEANING

A. General: Perform cleaning Work in accordance with the following:

1. Keep each duct system internally clean by installing only clean materials and by providing temporary closures during the installation.

2. Remove all loose materials and obstructions from interior of ducts.

3. Clean duct system and force air at high velocity through duct to remove

accumulated dust. To obtain sufficient air, clean half the system at a time. Protect equipment which may be harmed by excessive dirt with temporary filters, or bypass during cleaning.

4. Clean large duct systems with high power vacuum machines. Protect

equipment which may be harmed by excessive dirt with filters, or bypass during cleaning. Provide adequate access into ductwork for cleaning purposes.

END OF SECTION

AARHIP 15820-1

SECTION 15820

DUCTWORK ACCESSORIES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Ductwork accessories such as turning vanes, volume dampers, splitter dampers, air extractors, duct hardware, access doors, instrument test holes, gravity backdraft dampers, fire dampers and barometric dampers.


Following:

1. Section 15072 - Vibration Isolation 2. Section 15080 - Mechanical Insulation 3. Section 15810 - Ductwork 4. Section 15950 - Testing, Adjusting and Balancing

1.2 REFERENCES


1. SMACNA - HVAC Duct Construction Standards, Metal and Flexible.

2. ASHRAE - Handbook - Systems and Equipment; Recommendations pertaining to construction of ductwork accessories.

3. UL 555 - Fire Dampers and Ceiling Dampers.

4. UL 33 - Heat Responsive Links for Fire Protection Services.

5. NFPA 90A - Installation of Air Conditioning and Ventilating Systems.

1.3 SUBMITTALS


B. Product Data: Submit catalog product data indicating dimensions, assembly,

materials and finishes, and operation and performance data.

C. Shop Drawings: Submit shop drawings for shop fabricated assemblies. Provide product data for the hardware used.

AARHIP 15820-2

D. Operation and Maintenance Data: Submit the manufacturer's installation,

maintenance, and repair data as specified in Division 1 including a parts lists for each type of duct accessory. Include this data, product data, and shop drawings in the operation and maintenance manual.


A. Provide equipment from manufacturers regularly engaged in the design and manufacture of ductwork accessories, of the types and sizes required, which have a minimum of 5 years documented experience and which issue complete catalog data on these products.



B. Storage and Protection: Store products in a clean, dry place and protect from

physical damage in their original shipping packings, with labeling in place until the time of installation.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Turning Vanes.

a. Aero Dyne Co. b. Tuttle and Bailey

2. Volume Dampers

a. Ruskin b. Young Regulator Co.

3. Splitter Dampers

a. Ventfabrics Inc. b. Young Regulator Co.

AARHIP 15820-3

4. Air Extractors

a. Barber-Colman Co. b. Titus

5. Duct Hardware


6. Access Doors

a. Air Balance Inc. b. Ruskin Mfg. Co. c. Ventfabrics Inc.

7. Instrument Test Holes


8. Gravity Backdraft Dampers

a. Air Balance Inc. b. American Warming and Ventilating Inc. c. Ruskin Mfg. Co. d. Swartwout Model 426 - FRP Dampers

9. Fire Dampers

a. Air Balance Inc. b. American Warming and Ventilating Inc. c. Ruskin Mfg. Co.

10. Barometric Dampers

a. Greenheck Model HPR-230 b. Ruskin Mfg. Co.

2.2 MATERIALS

A. General: Provide ductwork accessories of the same materials as the duct, if commercially available. Otherwise fabricate such ductwork accessories of Type 316L stainless steel, protected inside and outside with a factory applied 4-6 mil heresite, or equal, air dried phenolic coating. Construct duct accessories in accordance with SMACNA “HVAC Duct Construction Standards.”

AARHIP 15820-4

B. Turning Vanes: Provide turning vanes as follows:

1. Fabricated Turning Vanes: Provide fabricated turning vanes and vane runners, constructed of aluminum in accordance with SMACNA "HVAC Duct Construction Standards".

2. Manufactured Turning Vanes: Factory fabricate turning vanes of a

streamlined design, with single thickness vanes not more than 1-1/2 inch apart for ducts 24 inches and smaller and with double thickness vanes spaced 3-1/4 inches apart for ducts larger than 24 inches.

C. Volume Dampers: Provide volume dampers complete with brass bushings, steel

rods, brackets, locking quadrant controls, and of closed end type designed for use on high pressure ducts. Provide multiple opposed blade type volume dampers if the duct dimension perpendicular to the damper shaft exceeds 10 inches.

D. Manual Splitter Dampers: Provide splitter dampers of a length 1-1/2 times the

width of the branch duct served with self locking assemblies.

E. Air Extractors: Provide air extractors constructed of aluminum capable of providing uniform air distribution and designed to minimize pressure drop and turbulence.

F. Duct Hardware: Provide duct hardware, manufactured by one manufacturer for all

items on project, for the following:

1. Quadrant Locks: Provide for each damper, a quadrant lock device on one end of the shaft; and an end bearing plate on the other end for damper lengths over 12 inches. Provide extended quadrant locks and end extended bearing plates for externally insulated ductwork.

2. Damper Remote Drives: Provide remote flexible drive where specified,

complete with flexible couplings, linkages and concealed type regulators for flush ceiling mounting.

G. Access Doors: Provide duct and plenum access doors of the size indicated, where

indicated and where necessary to service or replace equipment. Construct doors of the same or greater gauge as the ductwork or plenums served. Provide insulated doors for insulated ductwork and plenums. Provide insulated doors as double wall type insulated with 1-inch 6-pound density glass fiber, with suitable reinforced edges, closing into structurally framed openings with 1/2-inch neoprene-lined channels. Provide door panels with double diagonally cross breaks, hinged with two or more butt hinges and secured with two or more compression latches. Provide plenum doors with latch handles on both the inside and outside. Provide flush frames for uninsulated ductwork, and extended frames for externally insulated duct. Provide one side hinged and the other side with one handle-type latch for doors 12 inches high and smaller or 2 handle-type latches for larger doors.

AARHIP 15820-5

H. Test Holes: Provide instrument test holes in the ducts and plenums at appropriate

locations for insertion of 3/4-inch pitot tubes and similar air measuring instruments. Equip the openings with removable, tight fitting caps or covers.

I. Gravity Backdraft Dampers: Provide counterbalanced interlinked backdraft

dampers as shown and as specified. Construct the dampers of 0.90-inch thick extruded aluminum with extruded aluminum 0.025-inch blades, complete with extruded vinyl blade seals, nonmetallic bearings, 1/8-inch by 1/2-inch aluminum tie bars and adjustable zinc plated counterbalance bars on each blade. Provide dampers suitable for operation at -40 to 200 degrees F and a pressure drop not exceeding 0.02 inches w.g.

J. Fire Dampers: Provide, where shown and required Type A fire dampers, of the

sizes indicated, complete with necessary sleeves, chains and fusible links, and in compliance with NFPA and UL listed. Construct casings and sleeves of Type 316 stainless steel. Provide fusible links rated at 160 to 165 degrees F unless otherwise indicated. Provide dampers with a positive lock in the closed position, and with the following additional features:

1. Damper Blade Assembly: Curtain type.

2. Blade Material: Steel, match casing.

Provide an access door constructed of the same gauge metal as the duct, complete with suitable hinges, latches and gaskets, to permit link replacement at each fire damper.

K. Barometric Dampers: Provide interlinked heavy duty barometric dampers with

double flanged channel frame and streamlined airfoil blades constructed of Type 304 stainless steel. Provide dampers complete with blade counter balance and adjustable pressure setting weights. Provide silicone rubber blade seals. Provide dampers suitable for operation at pressure to 4 inches w.g. Testing and ratings to be in accordance with AMCA Standard 500-D.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine areas and conditions under which ductwork accessories will be installed. Do not proceed with the Work until unsatisfactory conditions have been corrected.

AARHIP 15820-6

3.2 INSTALLATION

A. General: Install ductwork accessories in accordance with the manufacturer's installation instructions, with applicable portions of details of construction as shown in SMACNA standards, and in accordance with recognized industry practices to ensure that products serve intended function. Make all necessary adjustments to provide a complete and satisfactory operation upon completion of the installation.

B. Turning Vanes: Install turning vanes in square or rectangular 90 degree elbows in

supply, return and exhaust air systems, and elsewhere as indicated.

C. Volume Dampers: Install volume dampers in main ducts and branch ducts and at all return and exhaust air branch duct take off connections and all other locations where shown.

D. Splitter Dampers: Install manually operated splitter dampers in all supply air

branch duct connections for volume distribution.

E. Extractors: Install air extractors behind all supply registers and all other locations where shown.

F. Duct Hardware: Install locking quadrant controls for each volume damper.

Provide remote flexible drives for dampers located above ceilings or where manual damper operators are inaccessible.

G. Access Doors: Install access doors to open against system air pressure, with

latches operable from either side, except outside only where the duct is to small for a person to enter. Provide access doors, amply sized to suit their function, in ducts and plenums, for inspection and cleaning, before and after filters, coils, fans, automatic dampers, fire dampers, and where indicated and necessary to service or required to replace equipment.

H. Instrument Test Holes: Provide instrument test holes in ducts and plenums where

required for testing and balancing purposes.

I. Gravity Backdraft Dampers: Install backdraft dampers at gravity relief locations and where shown.

J. Fire Dampers: Install fusible link fire dampers in all ducts passing through fire

rated building walls, floors and partitions indicated on the architectural drawings and where shown.

K. Coordination: Coordinate as necessary to interface installation of ductwork

accessories properly.

AARHIP 15820-7


A. Tests: Operate installed ductwork accessories to demonstrate their compliance with the specified requirements. Test for air leakage while the system is operating. Repair or replace faulty accessories, as required to obtain proper operation and leakproof performance.

B. Manufacturer's Field Services: Provide the services of a qualified representative of

the manufacturer as specified in Division 1 to inspect the installation of equipment, certify that it meets the manufacturer's recommendations, and instruct the operating personnel in its operation and maintenance.

3.4 ADJUSTING AND CLEANING

A. Adjusting: Adjust ductwork accessories for proper settings, install fusible links in fire dampers and adjust for proper action.

1. Final positioning of manual dampers is specified in Section 15950.

B. Cleaning: Clean factory-finished surfaces. Repair any marred or scratched

surfaces with the manufacturer's touch-up paint.

END OF SECTION

AARHIP 15820-8


AARHIP 15830-1

SECTION 15830

FANS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: The following types of fans:

1. Centrifugal fans 2. Roof-mounted fans 3. Propeller fans 4. In-line fans 5. Toilet fans

In hazardous locations provide equipment and wiring meeting the requirements for National Electric Code Class I, Group D, Division 1.


Following:

1. Section 09900 - Painting 2. Section 11395 - Odor Control Equipment 3. Section 15072 - Vibration Isolation 4. Section 15720 - Air Handling Units 5. Section 15810 - Ductwork 6. Section 15820 - Ductwork Accessories 7. Section 15900 - HVAC Controls 8. Section 15950 - Testing, Adjusting and Balancing 9. Section 16055 - Electrical Requirements for Shop Assembled Equipment 10. Section 16220 - Electric Motors 11. Section 16445 - Motor Control Centers

1.2 REFERENCES


1. AMCA 99 - Standards Handbook

2. AMCA 210 - Laboratory Methods of Testing Fans for Rating Purposes

3. AMCA 300 - Reverberant Room Method for Sound Testing of

Fans

AARHIP 15830-2

4. AMCA 301 - Method of Calculating Fan Sound Ratings from

Laboratory Test Data

5. AFBMA 9 - Load Ratings and Fatigue Life for Ball Bearings

6. AFBMA 11 - Load Ratings and Fatigue Life for Roller Bearings

7. ASTM A 27/A27M- Specification for Steel Castings, Carbon, for General Application

8. ASTM D 4167 - Specification for Fiber-Reinforced Plastic Fans

and Blowers

9. ASTM E 84 - Test Method for Surface Burning Characteristics of Building Materials

10. NEC - National Electrical Code

11. NEMA - National Electrical Manufacturers Association

12. SMACA - HVAC Duct Construction Standards

13. SSPC-SP3 - Power Tool Cleaning

1.3 SUBMITTALS


B. Product Data: Submit complete catalog product data, including the following:

1. Dimensions

2. Assembly

3. Weights

4. Specialties and accessories

5. Rated capacities

6. Performance ratings

7. Controls

AARHIP 15830-3

8. Certified fan performance curves with system operating conditions indicated, including brake horsepower, static pressure, and static efficiency plotted against air volume for the duty scheduled

9. Certified fan sound power ratings, for both fan outlet and casing radiation at

rated capacity

10. Motor ratings and electrical characteristics plus motor and fan accessories

11. Wiring diagrams that detail power, signal, and control wiring. Differentiate between manufacturer-installed wiring and field-installed wiring

12. Materials gauges and finishes, including color charts

13. Dampers, including housings, linkages, and operators

C. Shop Drawings: Submit shop drawings detailing equipment assemblies and

indicating locations, dimensions, weights, required clearances, construction details, and location and size of field connections.

D. Operation and Maintenance Manuals: Submit manufacturers descriptive literature,

as specified in Division 1, including operation instructions, lubrication instructions, motor and drive replacement instructions, wiring diagrams, controls, accessories maintenance and repair data, and parts listing. Include this data and product data in the operation and maintenance manual.


A. Performance Ratings: Conform to AMCA 210 and place the AMCA Certified Rating Seal on the equipment.

B. Sound Ratings: Conform to AMCA 301, test to AMCA 300 and place the AMCA

Certified Sound Rating Seal on the equipment.

C. Fabrication: Conform to AMCA 99.

D. Fans and Components: Provide UL listed and labeled fans and components.

E. Motors and Electrical Accessories: Comply with NEMA standards and NEC.

F. Manufacturer: Provide equipment from a company regularly engaged in design and manufacture of fans, of types and capacities required, whose products have been in satisfactory use in similar service for not less than 5 years documented experience, and which issues complete catalog data on these products.

AARHIP 15830-4



B. Delivery and Handling: Deliver products to site in factory fabricated protective

containers. Handle products properly to prevent damage, breaking, denting and scoring. Do not install damaged equipment, replace damaged units with new. Comply with manufacturer's instructions for unloading and transporting equipment to final location.

C. Storage and Protection: Store equipment in its original containers with labeling in

place until the time of installation and as specified in Division 1. 1.6 SEQUENCE AND SCHEDULING

A. Equipment Roof Supports: Coordinate the installation of roof curbs, equipment supports, and roof penetrations.

B. Structural Supports: Coordinate the size and location of structural steel support

members. 1.7 SPARE PARTS

A. Furnish spare parts wrapped or boxed, indexed and tagged with complete information for use and reordering. Provide the following spare parts.

1. One complete set of belts for each belt-driven fan.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Protective Coatings

a. Baked phenolic coating

(1) Heresite - P-413

2. Fiberglass Centrifugal Fans

a. Hartzell Fan Inc. b. New York Blower

AARHIP 15830-5

3. Roof-Mounted Louver Face Fans

a. Greenheck Fan Corp. b. Penn Ventilator Co.

4. Roof Curbs

a. Penn Ventilation Co. b. Thybar Corp. c. Pate

5. Aluminum Propeller Fans

a. Hartzell Fan Inc. b. Penn Ventilator Co. c. Greenheck Fan Corp.

6. In-Line Centrifugal Fans (Belt Drive)

a. Hartzell Fan Inc. b. Greenheck Fan Corp.

7. Toilet Fans

a. Broan

2.2 FANS GENERAL

A. General Design: Factory fabricate, assemble, test, and finish fans of the arrangement, minimum size, capacities and characteristics scheduled.

B. Fan Performance: Provide fans tested and rated in accordance with Air Movement

and Control Association, Inc. (AMCA) test procedures, bearing the AMCA rating seal. Provide certified performance curve for each fan.

C. Fans and Shafts: Provide fans statically and dynamically balanced at the factory.

Design fans for continuous operation at the maximum rated fan speed and motor horsepower. Provide turned, ground, and polished steel fan shafts designed to operate at no more than 70 percent of the first critical speed at the top of the speed range of the fan's class.

D. Belt Drives: Provide drives of a V-belt type, factory mounted, with final

alignment and belt adjustment made after installation. Provide V-belt drives which have a minimum service factor of 1.5 based on motor horsepower.

AARHIP 15830-6

E. Belts: Provide V-belt type belts in matched sets. Provide oil-resistant, nonsparking, and nonstatic belts.

F. Motor and Fan Wheel Pulleys: Use adjustable pitch motor sheaves with motors

through 15 hp; use fixed pitch motor sheaves on larger than 15 hp motors with adjustable pitch fan sheaves. Select pulley so that pitch adjustment is at the middle of the adjustment range at fan design conditions. Include an allowance to replace motor and fan wheel pulleys as required to obtain required airflow during final air balance of system.

G. Motor Guards: Provide steel motor guards for motors mounted on the outside of

the fan housing.

H. Shaft Bearings: Provide self-aligning grease lubricated bearings of the type indicated having a median life "Rating Life" (AFBMA L(50)) of 200,000, calculated in accordance with ANSI/AFBMA Standard 9 for ball bearings and ANSI/AFBMA Standard 11 for roller bearings.

I. Lubrication: Provide fan lubrication fittings extended to the service side with

aluminum tubes and secured accessibly outside the fan housing.

J. Protective Coating: Provide protective coating where indicated meeting the following requirements:

1. Baked Phenolic Coating: Where a baked phenolic corrosion-resistant

coating is required, thoroughly clean by sand-blasting, prepare and protect against corrosion all metal parts of the unit with one coat of primer and at least two coats of a baked phenolic corrosion-resistant coating to obtain a minimum total dry film thickness of 4 to 6 mils.

2. Manufacturer Recommendation: Perform cleaning and coating procedures

as specified and in accordance with the coating manufacturers published recommendations. As a minimum provide SSPC-SP3 Power Tool Cleaning.

K. Controls: Provide controls furnished with equipment meeting the requirements of

Sections 15900 and 16055.

L. Motors: Provide TEFC high energy efficient type motors as specified in Section 16220. Provide motors, electrical equipment and wiring located in hazardous areas or in airstreams exhausted from these areas meeting NEC electrical hazard classification requirements shown and as specified.

M. Electrical Equipment: Provide all electrical equipment and materials, including

combination motor starters, circuit breakers and disconnect circuit breakers meeting the requirements of Section 16445.

AARHIP 15830-7

2.3 FIBERGLASS CENTRIFUGAL FANS

A. General: Provide fiberglass centrifugal fans of the nonoverloading type and of fiberglass reinforced plastic (FRP) construction. Provide fans of the arrangement, minimum size and capacity as scheduled.

B. General Components: Provide each fiberglass centrifugal fan complete with

housing, inlet and drive side stands, flange drilling, spark-resistant construction, inspection port, flanged drain with PVC ball valve, pillow block bearings, bearings bases, motor, adjustable frequency drives where shown, adjustable motor mount with positive screw adjustment, flanged inlet and outlet, V-belts, fan sheave, adjustable motor sheave permitting adjustment of at least 5 percent above rated cfm, belt guard, shaft seal, unitary structural steel subbase and spring vibration isolators.

C. Performance: Provide fans which have a sharply rising pressure characteristic

extending throughout the operating range to assure quiet and stable operation. Provide fans with brake horsepower equal to or less than the bhp specified in the schedule at the listed static pressure and cfm.

D. Corrosion-Resistance Requirements: Construct the fan such that all surfaces in

contact with the corrosive gas stream are made of corrosion-resistant FRP. Provide FRP construction to resist the chemical environment specified for "Fiberglass Reinforced Plastic Ductwork-Type B" in Section 15810. Provide all nuts, bolts and fasteners in contact with gas stream of Type 316 stainless steel and encapsulated in FRP.

E. Construction: Provide fans constructed in accordance with the ASTM D 4167

standard specification for fiber-reinforced plastic fans and blowers for structural integrity.

F. Housings: Construct fan housings of a fire-retardant vinylester resin with an

ASTM E 84 Class I flame spread rating. Provide smooth airstream surfaces to minimize resistance and prevent build up of airborne contaminants. Provide fans with drilled flanged inlet and outlet. Furnish fans with lubricatable, double-lip, Teflon or Viton shaft seal. Provide bolted inlet assembly to permit wheel removal.

G. Wheels: Provide wheels of backwardly inclined nonoverloading design for

increased efficiency. Fabricate wheels of a fire-retardant vinylester resin with an ASTM E 84 Class II flame spread rating no greater than 30. Provide wheel hubs permanently bonded to the shaft and completely encapsulated in FRP for corrosion-resistant integrity. Steel wheels coated with FRP, or wheels with taper-lock hubs are not acceptable.

H. Spark Resistance: Make fans to be spark resistant by incorporating graphite flakes

in the wheel and housing surfaces to make them conductive and grounding the surface layers of the housing.

AARHIP 15830-8

I. Shaft: Provide ASTM A 27 steel shaft, Grade 1040/1045 with and FRP sleeve

fixed securely and bonded to the wheel backplate. Extend the sleeve out through the housing shaft hole for corrosion protection. A Hastelloy C276 shaft or shaft sleeve is acceptable in lieu of FRP sleeve. Design the shaft first critical speed to be at least 125 percent of the fan's maximum operating speed. Provide countersunk shafts for tachometer readings.

J. Bearings: Provide grease-lubricated bearings, precision antifriction ball, self-

aligning, pillow block design. Design bearings for a minimum life of 150,000 hours when rated at the fan's maximum, cataloged operating speed. Provide split pillow block type bearings on 40-inch diameter wheel fans and larger. Provide fan bearings visible and accessible for inspection and maintenance. Bearings enclosed within the fan housing where they can be exposed to the corrosive gas stream are not acceptable.

K. Corrosion Protection of Steel/Finish Coating: Thoroughly clean all steel fan

surfaces prior to painting using a combination of washing and power tool cleaning per SSPC-SP3 standard. After cleaning, treat all fan exterior surfaces with a coat of alkyd primer and finish coat of epoxy enamel to a thickness of 2 to 3 mils dry film thickness. Coat surfaces of bolted components and allow to dry prior to final assembly. Plate all fasteners external to the gas stream for extra corrosion protection.

2.4 ROOF-MOUNTED LOUVER FACE FANS

A. General: Provide all aluminum construction roof-mounted louver face fans of a centrifuge type with housing, weatherproof hood and curb cap; incorporate following specified features, unless scheduled otherwise.

B. Entire Assembly: Bear AMCA Certified Rating Seal.

C. Louvered Penthouse Hood: Provide heavy gauge extruded aluminum housing

braced where necessary to prevent vibration; provided with anti condesation coating. Provide lifting lugs. Provide hinged aluminum cover for quick access to motor and drive assembly.

D. Drive: Provide V-belt drives, sized for minimum of 150 percent of driven

horsepower.

E. Motors: Provide motors equipped with permanently factory lubricated bearings guaranteed for normal operation without further lubrication.

F. Openings: Provide openings equipped with bird screens for exhaust fans.

G. Fan Wheel: Provide backward curved aluminum blade wheel, non-overloading

design.

AARHIP 15830-9

H. Fan Bearings: High quality ball or roller type mounted in cast iron pillow blocks

with grease fittings. Provide pulleys of the fully machined cast iron type, keyed and securely attached to the wheel and motor shafts.

I. Vibration: Provide the entire fan and motor assembly mounted on vibration

isolators.

J. Disconnect Switch: Provide an integral disconnect switch for each fan.

K. Prefabricated Curbs: Provide fans complete with roof curbs as specified.

L. Protective Coating: Furnish fans with manufacturers standard primer and rustproof baked phenolic finish, as specified in Section 09900.

2.5 ROOF CURBS

A. Provide prefabricated roof curbs of types as required and shown. Provide curbs of monolithic construction, 18 or 14 gauge as required, galvanized steel with baked phenolic finish, with continuous arc-welded corner seams, galvanized epoxy coated steel inner liner, factory-installed wood nailer and insulated with 1-1/2-inch thick, 3-pound density rigid fiberglass board insulation. Provide curbs with a minimum height of 14 inches above the finished roof deck and of the style and design to mate the deck. Provide all curbs with tops leveled, with pitch built into curb where roof slopes 1/4 inch per foot or more.

2.6 ALUMINUM PROPELLER FANS

A. General: Provide propeller fans which meet the minimum size, capacity and arrangement as scheduled, and are belt driven unless shown otherwise.

B. Construction: Provide each propeller fan comprised of a heavy-gauge aluminum

panel with folded edges and integral venturi, rigid steel motor and drive assembly frame, motor, adjustable pitch motor sheave, V-belts, fan sheave and a dynamically and statically balanced propeller blade assembly. Bolt fan guards fabricated of heavy-gauge aluminum wire to the panel at the motor and discharge sides unless noted otherwise.

C. Damper: Provide a gravity operated back draft damper as noted, comprised of a

heavy-gauge aluminum frame with aluminum interlinked blades with neoprene edge seals, and linkage. Refer to Section 15820.

D. Protective Coatings: Provide propeller fans with factory painted one-coat primer

and finished with baked phenolic, as specified in Section 09900.

AARHIP 15830-10

2.7 IN-LINE CENTRIFUGAL FANS (BELT DRIVE)

A. General: Provide in-line centrifugal fans of the nonoverloading airfoil type and of heavy steel construction unless otherwise specified. Provide fans of the arrangement, minimum capacity and size as scheduled.

B. Assembly: Provide in-line centrifugal fans complete with welded steel flanged

housing, aluminum wheel, streamlined inlet cone, mounting feet or brackets as required, fans safety guard screen where scheduled, inlet and outlet companion flanges, plate access door with quick lock handles, shaft seal when scheduled, motor, adjustable motor mount, V-belt drive with adjustable motor sheave permitting adjustment of at least 5 percent above rated cfm, drive guard and spring vibration isolators.

C. Housing: Provide the fan housing constructed of heavy-gauge carbon steel.

Provide totally enclosed inner housing to protect the fan bearings and belts, supported to the outer housing by means of air straightening guide vanes. Provide continuously welded housing and wheels.

D. Wheels: Provide centrifugal nonoverloading aluminum airfoil type wheels with

backward curved blades, having nonoverloading horsepower characteristics. Mount statically and dynamically balanced wheels to the fan shaft with a split taper bushing.

E. Bearings: Provide motors with permanently lubricated bearings mounted out of

the airstream. Provide the drive shaft with self-aligning ball bearings and external grease fittings.

F. Protective Coating: Clean, phosphatize, and prime internal and external surfaces

with a rust-inhibiting primer, and finish with baked phenolic, as specified in Section 09900.

G. Vibration Isolation: Suspend fans with hanger rods and spring type isolators.

Provide spring vibration isolators meeting the requirements specified in Section 15072.

2.8 TOILET FANS

A. General: Provide fans of the arrangement, minimum size and capacity as scheduled. Provide fan AMCA rated for sound and air performance, UL listed, and HVI certified.

B. Housing: Provide rugged 26 gage galvanized steel construction housing with

integral mounting brackets. Provide housing with tapered, polymetric duct fitting with built-in backdraft damper.

AARHIP 15830-11

C. Blower: Provide plug-in permanently lubricated, totally enclosed motor and centrifugal blower designed for continuous operation.

D. Grille: Provide architectural metal grille finished with white acrylic paint. Provide

torsion spring grille mounting mechanism.

E. Wall Cap: Provide wall cap complete with spring-loaded backdraft damper and bird screen. Provide 22 gage steel cap electrically-bonded epoxy finish.


A. Tests: Perform the following factory tests:

1. Sound Power Level Ratings: Comply with AMCA Standard 301 "Method for Calculating Fan Sound Ratings from Laboratory Test Data." Test fans in accordance with AMCA Standard 300 "Test Code for Sound Rating." Provide fans which are licensed to bear the AMCA Certified Sound Ratings Seal.

2. Units Fan Performance Ratings: Establish flow rate, pressure, power, air

density, speed of rotation, and efficiency by factory tests and ratings in accordance with AMCA Standard 210/ ASHRAE Standard 51 - Laboratory Methods of Testing Fans for Rating.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Examine equipment and field conditions as follows.

1. Examine fans at the time of delivery for damaged or missing components.

2. Examine areas and conditions for compliance with requirements for installation tolerances, housekeeping pads, and other conditions affecting performance of fans.

3. Do not proceed until unsatisfactory conditions have been corrected.

B. Power Supply: Verify that the proper power supply is available.

3.2 INSTALLATION

A. General: Install equipment in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1. Make all necessary adjustments to equipment to provide complete and satisfactory operation upon completion of the installation.

AARHIP 15830-12

B. Support: Support fans as described below.

1. Support floor-mounted units on concrete equipment bases using housed

spring isolators. Secure units to anchor bolts installed in concrete equipment base.

2. Install prefabricated roof mounting curbs for roof-mounted fans, watertight

in accordance with the prefabricated curb manufacturer's recommendations. Secure roof-mounted fans to roof curbs. Set each fan on a continuous 2- by 1/2-inch sponge neoprene gasket. Flange connecting ducts over the wood mounting frame attached to the fan curb. Provide roof openings in accordance with approved manufacturers shop drawing submittals.

3. Suspend overhead mounted units from structural steel support frame using

threaded steel rods and vibration isolation springs.

C. Vibration Correction: If undesirable vibration occurs in the fan after installation, rebalance the fan in the field or replace to achieve operation within acceptable limits.

D. Access Space: Provide access space around fans and motors for service. Provide

no less than minimum as recommended by the manufacturer. Allow space for motor removal.

E. Electrical Leads: Install fans, as shown and specified, with flexible electrical

leads.

F. Flexible Connections: Provide flexible connections at inlet and discharge of fans where shown. Ensure metal bands of flexible connectors are parallel with minimum 1-inch flex between ductwork and fan while running. Flexible connections are not to be in tension while fan is running.

G. Drain Piping: Pipe fan scroll drains to nearest floor drain.

H. Backdraft Dampers: Provide backdraft dampers on discharge of exhaust fans and

as indicated.

I. Operating Requirements: Do not operate fans for any purpose until ductwork is clean, bearings are lubricated, and fans have been test run under observation.

J. Access Doors: Provide access doors for all fans, for inspection and maintenance.

K. Lubrication: Properly lubricate all pieces of equipment, furnished with lubrication

fittings, prior to start-up and at recommended intervals before turning equipment over to the OWNER. Attach a linen tag or heavy-duty shipping tag to each piece of equipment showing the date of lubrication and the name and number of

AARHIP 15830-13

lubricant used. Furnish typewritten list, in triplicate, of each item lubricated and the type of lubricant used.


A. Adjustment and Cleaning: Perform adjusting and cleaning as follows:

1. Align, adjust and balance each belt drive to prevent noise and vibration.

2. Adjust damper linkages for proper damper operation.

3. Start fan system and check for excessive leaks and vibration and correct.

4. Remove all loose materials and obstructions from interior of equipment.

5. Remove debris and waste materials resulting from installation.

6. Clean tar, adhesive, dirt or marks from exterior of unit.

B. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to inspect the installation of equipment, and certify that it meets the manufacturer's recommendations as specified in Division 1. Make any necessary adjustments, test and place the equipment in satisfactory operating condition and instruct the operating personnel in its operation and maintenance.

3.4 PAINTING

A. Paint fans as specified in Section 09900.

END OF SECTION

AARHIP 15830-14


AARHIP 15850-1

SECTION 15850

AIR OUTLETS AND INLETS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing ceiling air diffusers, registers, grilles, and all accessories and appurtenances necessary for complete installation.


Following:

1. Section 09900 - Painting 2. Section 10210 - Wall Louvers 3. Section 15810 - Ductwork 4. Section 15820 - Ductwork Accessories

1.2 REFERENCES


1. SSPC-SP3 - Power Tool Cleaning 1.3 SUBMITTALS


B. Product Data and Information: Submit manufacturer's technical product data for

air outlets and inlets including the following:

1. Data sheet for each type of air outlet and inlet, and accessory furnished, indicating construction, finish and mounting details.

2. Performance data for each type of air outlet and inlet furnished, including

aspiration ability, temperature and velocity traverses, throw and drop; and noise criteria ratings. Indicate selections on data.

C. Shop Drawings: Submit shop drawings for air outlets and inlets including the

following:

AARHIP 15850-2

1. Manufacturer's assembly-type shop drawing for each type of air outlet and inlet, indicating materials and methods of assembly of components.

2. Schedule of outlets and inlets indicating type, size, location, application, and

noise level.

D. Quality Control: Review requirements of outlets and inlets as to size, finish, and type of mounting prior to submitting product data and schedules.

E. Operations and Maintenance Manuals: Submit maintenance data, including

cleaning instructions for finishes, and spare parts lists. Include this data, product data, and shop drawings in maintenance manuals, in accordance with requirements of Division 1.


A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of air outlets and inlets of types and capacities required, whose products have been in satisfactory use in similar service for not less than 5 years.



B. Shipping and Packing: Deliver air outlets and inlets wrapped in factory-fabricated

fiberboard type containers. Identify on outside of container, the type of outlet or inlet, and location to be installed. Provide complete information for use and reordering, including supplier's name, address and phone number.

C. Storage and Protection: Store air outlets and inlets in original cartons and protect

them from weather and construction Work traffic. Where possible, store indoors. When necessary to store outdoors, store above grade and enclose with waterproof wrapping. Avoid crushing or bending, and prevent dirt and debris from entering and settling in devices.

D. Inspection: Inspect all air outlets and inlets against approved shop drawings at the

time of delivery.

Return for replacement all air outlets and inlets damaged or not meeting the requirements of the approved drawings.

1.6 SPARE PARTS


AARHIP 15850-3

1. Three sets of operating keys for each type of air outlet and inlet that require them.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Ceiling Air Diffusers:

a. Titus Products; Division of Philips Industries, Inc. b. Carnes Co.; Division of Wehr Corp. c. Krueger; Division of Philips Industries, Inc. d. Tuttle & Bailey

2. Registers and Grilles:

a. Titus Products; Division of Philips Industries, Inc. b. Carnes Co.; Division of Wehr Corp. c. Krueger; Division of Philips Industries, Inc. d. Tuttle & Bailey

2.2 MATERIALS, GENERAL

A. General: Except as otherwise indicated, provide manufacturer's standard ceiling air diffusers, registers and grilles, where shown, of size, shape, capacity, and type indicated, constructed of materials and components as indicated, and as required for complete installation.

B. Ceiling/Surface Compatibility: Provide diffusers, registers and grilles with border

styles that are compatible with adjacent construction systems, and that are specifically manufactured to fit into ceiling module or wall construction with accurate fit and adequate support. Refer to general construction drawings and specifications for types of ceiling systems and surfaces which will contain each type of air diffuser, register and grille.

C. Protective Coating: Provide protective coatings for each piece of equipment as

specified meeting the following requirements:

1. Primer and Enamel Finish: Provide standard factory applied rustproof primer and baked enamel finish on units that do not require corrosion-resistant coatings.

AARHIP 15850-4

2. Manufacturer Recommendation: Perform cleaning and coating procedures in accordance with the coating manufacturer's published recommendations. As a minimum provide SSPC-SP3 Power Tool Cleaning.

2.3 CEILING AIR DIFFUSERS

A. General: Provide ceiling air diffusers materials and coatings as follows:

1. Materials

a. Aluminum in galvanized steel ducts b. Aluminum in aluminum ducts c. Coated aluminum in FRP ducts

2. Coating

a. Semigloss enamel of color selected by the Architect.

B. Square and Rectangular Ceiling Diffusers: Provide square and rectangular ceiling

diffusers where shown and specified meeting the following requirements.

1. Provide square or rectangular, adjustable pattern, louvered face type ceiling diffusers to discharge air in 4 direction pattern with sectorizing baffles where indicated; Aluminum - Model TDC-AA, manufactured by Titus Products.

2. Provide frames to fit ceiling style.

3. Provide opposed blade dampers with equalizing grid, with damper

adjustable from diffuser face. 2.4 REGISTER AND GRILLES

A. General: Provide registers and grilles materials and coatings as follows:

1. Materials:

a. Aluminum in galvanized steel ducts b. Aluminum in aluminum ducts c. Coated aluminum in FRP ducts

2. Coating

a. Semigloss enamel of color approved by the Architect.

B. Supply Registers and Grilles: Provide supply registers and grilles where shown

and specified meeting the following requirements.

AARHIP 15850-5

1. Provide supply air registers and grilles as double deflection type, with

individually adjustable vertical front blades, flanged and gasketed; Aluminum - Model 272FS, manufactured by Titus Products.

2. Fabricate one inch margin frames with countersunk screw mounting.

3. Provide air extractors and integral, gang-operated opposed blade dampers

with a removable key operator, operable from the face.

C. Exhaust and Return Registers and Grilles: Provide exhaust and return registers and grilles where shown and specified meeting the following requirements.

1. Provide exhaust and return air registers and grilles as single deflection type,

with fixed horizontal blades set at 45 degrees, flanged and gasketed; Aluminum - Model 3FL manufactured by Titus Products.

2. Fabricate one inch margin frames with countersunk screw mounting.

3. Provide integral, gang-operated opposed blade dampers with a removable

key operator, operable from the face. 2.5 SOURCE QUALITY CONTROL

A. Performance: Provide air inlets and outlets meeting the following performance requirements.

1. Provide ceiling air diffusers, registers and grilles that have, as minimum,

temperature and velocity traverses, throw and drop, and noise criteria ratings for each size device as listed in manufacturer's current data.

PART 3 EXECUTION

3.1 INSPECTION

A. General: Examine areas and conditions under which air outlets and inlets are to be installed. Do not proceed with installation Work until unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. General: Install air outlets and inlets, in accordance with the manufacturers recommendations and approved shop drawings and as specified in Division 1.

AARHIP 15850-6

B. Coordination: Coordinate with other work, including ductwork and duct accessories, as necessary to interface installation of air outlets and inlets with other work.

C. Location: Locate ceiling air diffusers, registers and grilles, as indicated on general

construction "Reflected Ceiling Plans". Unless otherwise indicated, locate units in center of acoustical ceiling module.

D. Painting: Paint visible exterior duct surfaces behind grilles and registers flat black

in accordance with Section 09900.

END OF SECTION

AARHIP 15900-1

SECTION 15900

HVAC CONTROLS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing electronic/electric temperature control systems for heating, ventilating, and air conditioning systems as indicated. Provide systems complete in all respects, including thermostats, smoke detectors, thermometers, timers, control valves, relays and switches, automatic dampers, damper and valve operators, signal selectors, transmitters, miscellaneous accessories, temperature control panels (TCP), and alarm systems. Provide all control panels to be rated NEMA 4X.


1. Section 01730 - Operation and Maintenance Manual 2. Section 01820 - Training 3. Section 13410 - Field Instruments 4. Section 13430 - Programmable Logic Control (PLC) Systems 5. Section 15060 - Supports and Anchors 6. Section 15072 - Vibration Isolation 7. Section 15446 - Sump Pumps 8. Section 15670 - Condensing Units 9. Section 15720 - Air Handling Units 10. Section 15740 - HVAC Pumps 11. Section 15765 - Terminal Heat Transfer Units 12. Section 15830 - Fans 13. Section 15950 - Testing, Adjusting and Balancing 14. Section 16050 - Basic Electrical Material and Methods 15. Section 16055 - Electrical Requirements for Shop Assembled Equipment 16. Section 16075 - Electrical Identification 17. Section 16121 - Wires and Cables - 600 Volts and Below 18. Section 16220 - Electric Motors 19. Section 16445 - Motor Control Centers

1.2 REFERENCES


1. AMCA 500 - Test Methods for Louvers, Dampers and Shutters

AARHIP 15900-2

2. ASME B16.22 - Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

3. ASTM B 32 - Solder Metal

4. NEMA 250 - Enclosures for Electrical Equipment (1,000 Volts

Maximum)

5. NFPA 90A - Installation of Air Conditioning and Ventilation Systems

6. ASTM B 280 - Seamless Copper Tube for Air Conditioning and

Refrigeration Field Service

7. NEMA DC 3 - Residential Controls - Electric Wall-Mounted Room Thermostats

1.3 SUBMITTALS


B. Product Data: Provide complete catalog data for all proposed control components

including manufacturer's descriptive and technical literature, performance charts and curves, catalog cuts and installation instructions.

C. Shop Drawings: Provide shop drawings for the following:

1. Complete data on all proposed control components

2. Dimensioned external and internal control panel layouts, with components

identified

3. Bills of material for all control components

4. Control sequence description for each system

5. Control diagrams

6. Factory and field test Procedures

7. Valve schedule including sizes, material, trim, pressure drop and Cv calculations

8. Damper schedule including sizes, trim, operator sizes and pressure drop

calculations

AARHIP 15900-3

9. Water temperature sensor schedule including range, element type, accuracy, hysteresis, linearity, power requirements and mounting details

10. Air temperature sensor schedule including range, element type, element

length accuracy, hysteresis, linearity, power requirements and mounting details

11. Water flow sensor schedules including range, element type, accuracy,

hysteresis, power requirements and mounting details

12. Detailed operating instructions

13. Complete plan wiring, riser and schematic diagrams, and terminal connection diagrams

14. Calculations and all other details required to demonstrate the system design

has been coordinated and will properly function as a system. Submit all sensor range calculations.

15. Water flow (GPM) sensor schedule including range, element type, accuracy,

power requirements, mounting details and mounting location.

D. Field and Panel Instruments: Provide instruments which contain the following information, as a minimum.

1. Tag number per the Specifications and Contract Drawings

2. Product (item) name used herein and on the Contract Drawings

3. Name of manufacturer or supplier

4. Manufacturer's complete model number

5. Location of the device

6. Range, size, graduations and the operating power requirement

7. Physical size with dimensions, NEMA enclosure classification and

mounting details

8. Materials of construction of all components

9. Instrument or control device sizing calculations, where applicable

10. Certified calibration data on all flow metering devices, where applicable

11. Environmental requirements during storage and operation

AARHIP 15900-4

The Contractor to verify the process data with the equipment manufacturers and to submit completed data sheets for OWNER’s review. The Contractor is responsible for developing process data on remaining instruments.

E. Catalog Cuts: Submit for review, the name of the manufacturer, identifying trade

name and/or model designation, and catalog cuts for all equipment and material proposed under this Division. Provide catalog cuts certified for the tag numbers and ratings of the equipment being supplied. Highlight all the selected options.

F. Operation and Maintenance Manuals: Provide operation and maintenance manuals

covering the function, operation and maintenance of all control components and systems as specified in Section 01730.


A. Manufacturer: Provide equipment from a company specializing in manufacturing the products specified in this Section which has substantial documented experience and which issues complete catalog data on these products.

B. Installer: Provide company specializing in installing the Work of this Section

which has substantial years documented experience. 1.5 DELIVERY, STORAGE AND HANDLING

A. General: Deliver, store, and handle all products and materials as specified in Division 1 and as follows.

B. Acceptance: Accept products on-site in factory-fabricated protective containers,

with factory-installed shipping skids and lifting lugs. Inspect products for damage.

C. Storage and Protection: Store products in clean dry place and protect from weather and construction traffic. Handle carefully to avoid damage to components, enclosures, and finish.

1.6 SPARE PARTS

A. Provide all of the individual manufacturers recommended spare parts and tools for all equipment specified herein. In addition to the recommended spares, furnish all of the following minimum spare parts, tools and devices. Provide spare parts and special tools in accordance with the requirements of the General Conditions.

1. General: Provide 10% (minimum of ten (10)) spare fuses, indicating lights,

etc., for each size and type provided.

2. Electronic Field Instruments: Provide one (1) complete spare instrument for every ten (10), or part thereof, installed instruments (minimum of one (1)).

AARHIP 15900-5

Include any integral indicators, adapters, converters and modules needed to provide a complete functional replacement. Where similar units have been provided having different characteristics or ranges, the aforementioned quantities pertain to each type.

3. Primary Sensing Elements: One (1) spare of each size and type, complete

with housing and appurtenances for each ten (10) or part thereof installed.

4. Pressure and Temperature Switches: One (1) spare of each size, type and range, complete with housing and appurtenances for each ten (10) or part thereof installed.

5. Relays, Circuit Breakers, etc.: Provide minimum of two (2) spares of each

size, type and configuration for each ten (10) or part thereof installed.

6. Panel Mounted Switches and Indicating Lights: Provide minimum of two (2) spares of each size, type and configuration for each ten (10) or part thereof installed.

7. Gauges, Indicators and Thermometers: One (1) spare gauge and

thermometer of each size, type and range, complete with appurtenances for each ten (10) or part thereof installed.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below.

1. Temperature Control Equipment

a. Johnson Controls, Inc. b. Siemens

2. Control Dampers

a. Aluminum Dampers

(1) Ruskin - Model CD50 (2) Air Balance - Series 500

b. Fiberglass Reinforced Plastic (FRP) Damper

(1) Swartwout - Model 1108 Rectangular Dampers

AARHIP 15900-6

3. Damper Operators

a. Electric/Electronic Damper Operators

(1) Johnson Controls - Series M-100 (2) Belimo Aircontrols

4. Control Valves

a. Johnson Controls b. Siemens

5. Solenoid Valves

a. Automatic Switch Co. b. Skinner Valve Div., Honeywell Inc.

6. Time Delay Relays

a. Agastat - Cat. No. SSC12ABA b. ISSC - Cat. No. 1017-B-1

7. Differential Pressure Switches

a. Dwyer Instruments Inc. - Series 1900

8. Flow Switches

a. Dwyer Instruments Inc.

9. Current Switches

a. Veris Industries Inc.

10. Thermostats

a. General Use Thermostats

(1) Johnson Controls (2) Siemens

b. Corrosion-Resistant Thermostats

(1) Indeeco - Cat. No. C211-040

AARHIP 15900-7

11. Time Clocks

a. AMF Paragon b. Tork

12. Alarm Annunciators

a. Panalarm - Series 70 b. Ronan - Series X12

2.2 HVAC CONTROLS, GENERAL

A. General: Provide temperature control systems as specified and complete in all respects. Provide control components subject to mechanical strain of metallic construction. Provide all electric and electronic control components to be UL listed.

B. Equipment power wiring, control wiring and communication wiring, associated

conduit, transformers and appurtenances all under this section:

1. Damper Actuators 2. Valve Actuators 3. Limit Switches 4. HVAC Protection Devices 5. Air Flow Switches 6. Temperature Control Panel mounted electrical equipment and devices

Provide all wiring and conduit that conform to the requirements of Division 16 and to applicable codes.

C. Equipment control wiring, communication wiring and associated conduit,

transformers and appurtenances under this section; power wiring and conduit to equipment under Division 16:

1. Temperature Control Panels 2. Water Make-up Systems 3. Air Handling Units 4. Air Cooled Condensing Units 5. Unit Heaters 6. Pumps

D. Wiring: Provide electrical wiring and conduit for the following.

1. Control and interlock wiring from remote heating, ventilating and air

conditioning control components to identified terminals on TCPs, and to control panels supplied with the heating, ventilating and air conditioning equipment.

AARHIP 15900-8

2. Power wiring and alarm wiring from the control components initiating

alarms to the TCPs.

3. Motor starters and power wiring wired to terminal connections in the TCP for HVAC and plumbing motors less than 1/2 horsepower. Include motor starters.

4. Wiring of safeties required for sequences of operation including, but not

limited to, air and water flow switches, static pressure switches, high temperature thermostats, damper end switches, etc.

5. Power wiring to electric actuators from respective TCP.

Provide electrical power feeders to the TCPs, and interlock wiring from terminal strips in the TCPs to motor control centers, multiplexers and like equipment under Division 16. Provide a 120-volt single-phase electrical power source to the TCPs, under Division 16 sufficient for all control equipment and single phase motors.

Provide all wiring and conduit to meet the requirements of applicable Division 16 sections.

2.3 CONTROL DAMPERS

A. General: Provide multiple blade control dampers of the sizes shown at locations shown and specified. Furnish control dampers of the low leakage type designed to give not more than 15 cfm leakage per square foot of a 48-inch square damper at 4-inch w.g. pressure differential when tested in accordance with AMCA 500. Provide FRP dampers designed for leakage rates as specified.

B. Construction: Provide dampers for proportional mixing of converging airstreams

of the multiple parallel blade type with blades positioned to direct air into the converging branch, and dampers for throttling of the multiple opposed blade type, unless otherwise shown. Provide control damper meeting the following requirements:

1. Construct dampers (blades and frames) of the same type of material as the

ductwork in which they are installed.

2. Construct dampers connected to FRP ductwork constructed of FRP with accessories and appurtenances compatible with the specified ductwork.

3. Except where specified otherwise, provide damper blades which do not

exceed 6 inches in width and 48 inches in length and are rigidly constructed. Supply blades suitable for high velocity performance. Connect multiple section dampers with epoxy coated steel jackshaft.

AARHIP 15900-9

4. Provide damper bearings made of noncopper-bearing corrosion-resistant materials, molded synthetic. Do not use stainless steel bearings on FRP dampers. Provide EPDM rubber blade seals along with the damper. Provide jamb seals of the spring type of materials specified resulting in a tight closing, low leakage damper.

C. Aluminum Dampers: Provide aluminum dampers constructed of 6063 T5 extruded

aluminum. Construct frames of 5-inch wide, 1/8-inch thick extruded aluminum with mounting flanges, reinforced corners and flexible aluminum jamb seals. Supply blades of double wall airfoil type extruded aluminum with extruded replaceable blade seals locked in extruded blade slots. Furnish axles and linkage in the air stream of epoxy coated steel.

2.4 DAMPER AND VALVE OPERATORS

A. Electric Operators: Furnish electric damper and valve operators with oil-immersed motors and of the two-position or proportional modulating type as required. Furnish modulating operators which operate on the balance bridge principle with position feedback potentiometers and control transformers or electronic actuator drive accepting 4-20 mA or 2 to 12-volt dc signal input as required. Equip two-position operators with return springs. Provide damper operators that revert to their initial position upon power interruption. Supply damper operators of sufficient size and number to operate their respective dampers, and valves. Provide dampers with dimensions larger than 48 inches wide or 72 inches high, or area greater than 32 square feet, with multiple operators. Furnish electric damper operators conforming to Section 16055 which accept control signal inputs through a suitable transducer to drive the damper operators. Furnish damper operators with and powered by 24-volt ac transformers powered by an external 120-volt ac power source. Provide NEMA 4X FRP actuators.

B. Electronic Actuators: Furnish electronic damper actuators of two position or

modulating type as required. Provide actuators which have electronic overload or digital rotation sensing circuitry to prevent damage throughout rotation. Provide the torque required for proper close-off and be capable of being mechanically or electrically paralleled to increase torque where required. Provide a mechanical spring return mechanism for “Fail safe” operation. Non mechanical forms of fail safe are not acceptable. Provide all spring actuators capable of both clockwise and counterclockwise operation by changing the mounting orientation. Provide Proportional actuators designed to accept a 2 to 10 VDC or 4-20 mA input signal and provide and independent 2 to 10 VDC position feedback signal. Provide proportional actuators powered by 24 VAC or VDC and 2 position spring return actuators powered by 24 or 120 VAC. Power consumption not to exceed 15 VA per actuator. Provide actuators with an external manual gear release or crank to allow manual positioning when the actuator is not powered. Provide all modulating actuators with an external direction of rotation switch and a 3 foot electrical cable. Provide actuators with the capability of adding auxiliary switches

AARHIP 15900-10

or a feedback potentiometer. Provide all actuators with NEMA 4X FRP, UL listed enclosures.

C. Corrosion-Resistant Operators: Provide corrosion-resistant damper operators

which match or exceed corrosion resistance of the dampers or associated ductwork to which the operators are installed. Provide damper operators which have a cast-aluminum body complete with travel stops for rotational adjustment, Namur solenoid mounting pad and solenoid switching valves, limit switches, position indicator, valve mounting bracket, switches and positioner mounting bracket. Provide a finish of Di-aluminum Tri-oxide, a hard corrosion-resistant ceramic-like coating, for all damper operators. Provide damper operators protected against corrosion and furnished with the following:

1. Epoxy coating - 1 coat primer and 2 finish coats.

2. Electrical feed through connectors sealed gastight with silicone rubber after

wiring is completed.

3. Cover mounted 24-volt ac transformers (as an extension of the damper motor housing) or transformer mounted in a NEMA 4X FRP enclosure.

4. Gastight gasketing.

2.5 CONTROL VALVES

A. Construction: Provide automatic control valves with contoured plug and disc inner valve construction and constructed of materials to insure tight seating against the working fluid pressures and temperatures involved. Furnish valves 2 inches and smaller with screwed or union end bodies, and valves 2-1/2 inches and larger with flanged ends. Provide water valves with equal percentage operating characteristics.

B. Sizing: Provide control valves sized by the temperature control manufacturer

according to the required capacities and actual terminal device pressure drops. Where pressure drops through valves are not shown, provide valves sized for pressure drops not to exceed 3 psi for hot water heating valves, and 2 psig for steam valves.

2.6 SOLENOID VALVES

A. Design: Provide solenoid valves as the pilot piston-pressure actuated type, full ported for maximum flow and minimum pressure drop, and normally closed when de-energized.

B. Construction: Provide solenoid valves suitable for operating at a minimum

working pressure of 30 psi and a maximum temperature of 125 degrees F. Furnish

AARHIP 15900-11

the valve construction materials suitable for the medium in contact with the internal surfaces of the valve.

2.7 SWITCHES AND RELAYS

A. General: Provide electric relays necessary to accomplish specified control functions installed in the appropriate temperature control panels. Provide electric switches and relays complying with applicable requirements specified in Division 16.

B. Construction: Provide electric relays of the plug-in solid-state type with

compatible current and voltage ratings.

C. Time Delay Relays: Provide adjustable time delay relays with automatic reset, with ranges as specified and electrical rating of at least 10 amperes rms at 115 volts.

2.8 FLOW AND DIFFERENTIAL PRESSURE SWITCHES

A. General: Provide each flow switch with a solid-state "ON delay" time delay relay, either integral with the flow switch, or separately mounted in the related temperature control panel. In either case, wire the time delay relay from the temperature control panel and incorporate a delay of about 5 seconds (5 to 60 seconds adjustable) except where specified otherwise, to prevent false alarm until fluid flow is established during start-up. Mount separate time delay relays in the temperature control panel. Furnish the electrical rating for flow switches and time delay relays as at least 10 amperes rms at 115 volts, single phase.

B. Flow Switches: Provide flow switches for water and other liquid systems suitable

for operating a maximum pressure of 150 psi and a maximum temperature of 250 degrees F. Design the switch to be operated by a segmented epoxy coated steel or similar corrosion-resistant metal paddle. Furnish the bearing as hardened steel, and the switch complete with a sensitivity adjusting screw.

C. Functions: Unless otherwise noted, provide each switch to accomplish the

following functions:

1. De-energize the respective pump starter

2. Energize an audible alarm and an identified pilot light at the related temperature control panel.

3. Close a pair of dry contacts wired to a terminal strip in the related

temperature control panel to complete a remote alarm circuit.

AARHIP 15900-12

2.9 CURRENT SWITCHES

A. General: Unless Sequence of Operation indicate the application of flow switches, provide all three-phase motor operated systems with electric current switches. Provide electric current switches to accomplish specified control functions and comply with applicable requirements specified in Division 16.

B. Construction: Provide current switches of a solid state type with compatible

current and voltage ratings. Provide sensors complete with in-rush time delay, single set joint adjustment, power and status LED’s, and adjustable trip set point with accuracy of ∀ 2 percent of range. UL listing and NEMA 4X sealing required.

C. Design: Provide switches designed for 5 to 185 degrees F and 0 to 95 percent

humidity, and of a power induced type. Sensors with external power supply are not acceptable.

D. Functions: Unless otherwise noted, provide each switch to accomplish the


1. De-energize the respective fan starter.

2. Energize an audible alarm and an identified pilot light at the related temperature control panel.

2.10 DIFFERENTIAL PRESSURE INDICATORS

A. The case, dial, pointer glass, overrange protection, zero adjustment of pulsation dampeners, mounting requirements etc., are as specified under pressure gauges.

1. Use Bourdon tube gauge assembly encapsulated in a pressure chamber for

differential pressure measurement above 10 psid.

2. For measurement of differential pressure below 10 psid multiple diaphragm use assembly supported on bulkhead plate housed in pressure chamber.

3. Consider piston operated differential gauges as an alternate to measure

pressure drop across filters, valves and equipment.

4. Material for measuring element to be generally epoxy coated steel as a minimum except for gauges used on air service and gauges used with diaphragm seals.

AARHIP 15900-13

2.11 TEMPERATURE MEASUREMENT

A. Temperature Elements

1. Thermowells: Provide thermowells (3/4" NPT minimum) for each temperature measurement system (temperature switch, RTD, etc.) and to comply with SAMA RC17-10. Provide lagging-type units on all insulated vessels or pipes. Provide bushings and wells to be corrosion resistant. Provide corrosion resistant unions to allow sensor removal without rotating sensor or sensor wiring.

2. RTD=s: Provide the resistance temperature detectors to be single type, each

of the 100 ohm, platinum, 3-wire type having a stability of better than 0.2 percent of maximum exposed temperature for one year of service, or 0.25ΕC, whichever is greater. The repeatability to be better than 0.05% of the maximum exposed temperature, or 0.13ΕC, whichever is greater. Provide RTD=s to be complete assemblies which include the thermowell, connection head and sensor. Provide the connection head of NEMA 4X construction with screw on cover as a minimum, but to comply with any hazardous area classifications. Submit sensor calibration curve with the shop drawings. Accuracy to be ∀0.20ΕF and NIST traceable. Install RTD with corrosion resistant unions sensor/transmitter wiring with a flexible service loop sufficiently long to allow sensor removal without disconnecting any wiring. RTD=s must be spring loaded type Rosemount Series 68.

B. Temperature Transmitters

1. General: Mount temperature transmitters for RTD inputs in an enclosure

that is wall or stand mounted adjacent to the temperature element assembly or as indicated on the contract drawings. Provide the enclosure to be weatherproof or circuits classified as intrinsically safe as appropriate for the environment. Provide transmitters to be loop powered from Temperature Control Panel or I/O panel with 24 VDC and which have an isolated current output range of 4 to 20 mA 24V DC.

2. RTD Input

a. Provide transmitters which have an accuracy of 0.2 percent of full

scale, an ambient temperature coefficient better than plus or minus 0.01 percent/degree F total for factors of zero shift, span shift and suppression shift for calibration spans as low as 3.0 millivolts.

b. Equip room temperature transmitters with epoxy coated steel covers.

AARHIP 15900-14

c. Provide duct-type transmitters with insertion probe or using capillary averaging elements in systems or ductwork with greater than 8 feet perimeter (or circumference) length.

2.12 FREEZESTATS

A. Provide freezestats complete with SPDT snap acting switch, manual reset lever, 1/8" OD x 20' long capillary tube and capillary mounting clips. Provide the freezestats which have a range between 30ΕF and 60ΕF. Provide freezestat which respond to lowest temperature sensed by any one foot portion of capillary. Where required for adequate protection, supply multiple freezestats. Locate the freezestats downstream of the heating coil. Provide one 20 feet freezestat element for each 15 sq. ft of coil.

2.13 THERMOSTATS

A. Electric Thermostats: Provide electric thermostats as two-position type of fully modulating type as required. Furnish electric thermostats with bimetallic sensing elements and concealed adjustable set point. Supply electric thermostats with field adjustable sensitivity and with thermometers in covers of approved standard finish. Equip electric modulating type thermostats to operate on the balanced bridge principle. Provide thermostats sensing the temperature of rooms, when located outside of the room, of the remote bulb type with stainless steel bulb and capillary not exceeding 20 feet in length.

B. Insertion and Immersion Type Thermostats: Provide insertion and immersion type

thermostats with adjustable sensitivity and adjustable set point, and a proper stainless steel thermal element to meet the specific requirements. Equip immersion thermostats with union connections and a stainless steel immersion well packed with a heat conducting material. Furnish insertion thermostats with a capillary system of the proper length to meet the application.

C. Corrosion-Resistant Thermostats: Provide all thermostats to be electric, corrosion-

resistant type in a NEMA 4X FRP enclosure with a nickel-plated or stainless steel bulb.

2.14 TEMPERATURE CONTROL PANELS

A. General: Furnish temperature control panels with suitable brackets for wall mounting, each prewired to integral identified terminal strips. Provide interior panel wiring color coded and numbered conductors, neatly bundled and secured. Furnish panels as of the NEMA 4X FRP enclosed type, equipped with hinged doors and locks, and constructed of heavy-gauge sheet metal or aluminum with baked enamel finish. Provide a disconnect switch mounted inside the panel for each 120-volt circuit connected to the temperature control panel. Provide a power "ON" pilot light mounted on the face of the panel to be energized when the electric circuits feeding the panel are energized. Number each panel and provide a

AARHIP 15900-15

nameplate identifying the system or systems controlled. Conform panels to Section 16055. Multiple control panels are acceptable if a single panel size is to large to accommodate all control functions as determined by the CONTRACTOR.

B. Panel Components: Furnish the temperature control panels with switches, alarm

annunciators and pilot lights mounted on the front of the panel. Mount controllers, control relays, timing relays, terminal strips and other components inside the panel. Equip the panels with manual starters with thermal overload for associated HVAC and plumbing equipment motors 1/3 hp and smaller. Provide an identified RUN pilot light for each fan. Provide red RUN indication pilot light.

C. Alarm Annunciator: Provide the alarm annunciator as solid-state suitable for flush

panel mounting or mounting adjacent to the temperature control panel. Provide the annunciator window engraved with black lettering and illuminated blue for ALARM. Provide a panel-mounted lamp test push button such that when pressed all alarm lights are illuminated.

D. Alarm Module Function: Provide the alarm module such that when an alarm

occurs, the alarm module causes a horn to sound and the corresponding alarm light to flash. Provide a panel-mounted SILENCE push button to silence the horn and change the flashing light to a steady light when pressed. Provide the alarm module such that another alarm occurring in the system repeats the above sequence. When the alarm condition returns to normal, the alarm module automatically causes the corresponding steady alarm light to turn off. Provide each annunciator module with a lock/nonlock feature.

E. Auxiliary Contacts: Include in each alarm module auxiliary isolated dry contacts

which repeat the field contact function. Provide alarm circuits as double pole, prewired to a terminal strip for remote signaling. Provide, in addition, the annunciator with an auxiliary contact which closes upon loss of power to the annunciator.

F. Alarm Horn: Furnish the annunciator with a variable volume alarm horn powered

by 115-volt ac, 60 hertz, and suitable for panel mounting.

G. Identification: Identify devices mounted on the front of the panel by engraved bakelite or formica tags. Identify all equipment as scheduled and as shown on the control diagram. Permanently mount the control diagrams provided under suitable protective cover adjacent to the local control panel.

H. Electrical Diagrams: Consult the schematic diagrams shown for control relays,

timing relays and other accessory equipment to be provided, and mounted and prewired to terminal strips in the temperature control panels. Provide control relays, timing relays, reset timers, manual motor starters and remote control stations meeting applicable requirements of Division 16.

I. Controllers: Provide controllers meeting requirements specified in Section 13430.

AARHIP 15900-16

2.15 POWER SUPPLIES AND CIRCUIT PROTECTION

A. All 120 VAC power feed for all instrument and control equipment are provided under Electrical Division 16. Power supplies located inside the panels to be furnished under this contract complete with filtering, power conditioning, and surge suppressors, etc.

B. Alternating current power supplies to panel mounted equipment to be through a

main circuit breaker and branch breakers located inside the panel. All 24 V DC transmitters to be powered from the panel. All 24 volt instrument, signal and control circuits to be protected by individual draw-out fuses, located in the panel.

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Verify that systems are ready to receive control component Work. Beginning of installation means that the installer accepts the existing conditions.

3.2 INSTALLATION

A. General: Install required control components in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1. Adjust and test to meet the required control performance. Coordinate prior to control installation the proposed controls with electrical plans and interfacing equipment for compatibility. Install the systems by experienced competent mechanics employed by a firm with an established controls service organization.

B. Electrical Requirements: Provide electrical material and installation in accordance

with applicable requirements of Division 16.

C. Testing: Prove operation of all pumps, supply, exhaust and return air fans by current switches. If a fan or pump has been commanded on and the current switch indicates a no-flow status, initiate an individual identified audible and visual alarm and close remote alarm contacts at the temperature control panel annunciator for the fan and pump in alarm. Provide an adjustable time delay function for each flow switch to lock out the alarm during fan start-up.

D. Selector Switches: Provide a HAND/OFF/AUTO selector switch for each pump,

supply, exhaust and return air fan at the temperature control panel, or as specified otherwise:

1. Operate fans and pumps through their safety devices, as specified, when the

selector switch is in the HAND or AUTO position.

AARHIP 15900-17

2. Provide the selector switch which permits continuous operation of each fan

and pump when placed in the HAND position. When the selector switch is in the HAND position, provide dampers which function as specified for the AUTO position.

E. Test Button: Provide an OFF/LOCK-ENABLE switch with a momentary contact

TEST push button at each fan and pump. Provide and wire the TEST push button to test the fan motor with the selector switch in the AUTO position and to bypass the fan's safety devices.

F. Signals: Provide signals as follows

1. All electronic instruments (transmitters) to provide a linear 4 to 20 milliamp

signal at a nominal 24VDC. The signal to be proportional to the process variable indicated. Signal conditioning (such as square root extraction or frequency conversion), if needed, to be done by the transmitter electronics.

G. Painting: Provide painting in accordance with Section 09900.

H. Control Sensors: Check and verify locations of thermostats, and other exposed

control sensors with plans and room details before installation. Locate room thermostats 48 inches above floor. Align with lighting switches.

1. Mount freeze protection thermostats using flanges and element holders.

2. Mount outdoor thermostats and outdoor sensors indoors, with sensing

elements outdoors with sun shield.

3. Provide separable sockets for liquids and flanges for air bulb elements.

4. Provide thermostats in aspirating boxes in front entrances, and where indicated.

5. Provide guards on thermostats in entrance hallways and other public areas

and where indicated.

I. Control Valves: Provide valves with position indicators and with pilot positioners where sequenced with other controls.

J. Thermometers: Locate a thermometer adjacent to each rigid stem thermostat.

Mount a dial thermometer, minimum 2-1/2-inch diameter, with a liquid-filled remote system adjacent to each remote bulb thermostat, and remote sensor. Supply averaging bulb thermometers where averaging bulb thermostats and sensors are required. Provide duct-type thermometers in all fresh air intakes, mixed air and return air main ducts, and all supply fan discharges. Furnish thermometers with proper range scales for the locations where they are installed.

AARHIP 15900-18

K. Flow Switches: Mount a flow switch in the discharge of each pump unless

otherwise noted, to give a failure alarm on no flow only when that pump or fan starter is energized.

L. Control Dampers: Provide mixing dampers of opposed or paralled blade

construction arranged to mix streams.

M. Damper Operators: Provide pilot positioners on damper operators sequenced with other controls. Locate damper operators outside of the airstream wherever possible.

N. Temperature Control Panels: Mount control panels adjacent to associated

equipment on vibration-free walls or freestanding angle iron supports.

O. Conduit and Wiring: Provide conduit and electrical wiring where required meeting requirements of Division 16.

P. Lights, Switches, and Push Buttons: Provide pilot lights, selector switches, and

push buttons located on face of control panels to be heavy duty oil tight in accordance with Specification Section 16445.

Q. Current Switches: Mount current switches in associated Motor Control Centers, to

give a failure alarm on no flow only when that fan starter is energized. Provide all required conduit and wiring. Coordinate with Electrical Work

3.3 GENERAL SEQUENCES OF OPERATION AND CONTROL

REQUIREMENTS

A. Electrical and Equipment Ratings

1. Review ALL documents for required electrical ratings

2. The more stringent ratings apply (e.g., minimum rating for all panels and equipment is NEMA 4X.)

B. Detailed Sequences of Operation: Many sequences contained herein are general or

typical in form. Edit to fit the specific application.

C. Provide temperature, GPM, static pressure, time delay, dead band, offset, CFM, etc., set points and alarm points that are easily and clearly adjustable.

D. All temperatures listed are in degrees F.

AARHIP 15900-19

E. HOA Switches

1. Provide panel face HOA switches at the appropriate TCP for all HVAC motors.

2. Clearly and permanently identify the system served by the switch.

3. Provide local and system-wide alarm of switches not placed in the Auto

position.

F. Manual control of dampers and valves

1. Provide override of two position and modulating valves and dampers, either at the actuator or in the associated TCP

2. Provide means of adjusting modulating valves from inside the associated

TCP. Provide adjustment means with 0 to 100 percent position scale.

G. Equipment flow status

1. Provide all three-phase HVAC equipment with a means of proving flow

2. Single speed pump and fan motors use current switches in lieu of hardware flow switches mounted in the motor control centers provided under electrical work:

a. Coordinate with the test and balance work performed in Section

15950 to properly set the upper and lower operating current ranges of normal operation.

b. Use the work performed in Item a to determine the threshold for free

running (e.g., broken belt) current.

H. Lead Lag Control

1. Include with Control Submittal individual sequences of operation for Lead-Lag controlled equipment.

2. If the selected Lead pump or fan fails to start or fails in normal Auto

operation, the Lag equipment starts.

3. Failure is as determined by starter status and current (or flow) switch status.

I. Sequence of Operation Controls Submittal Requirements

1. Organize the submitted in the following order:

a. By Building ID letter and Name

AARHIP 15900-20

b. By TCP ID number

c. By system

2. Submit specific sequences for all equipment. Where the Specification sequences show only an equipment (or system) listing, provide complete sequences of operation based on similar sequences shown elsewhere in this Specification Section, based on sequences implied from other Specification Sections or based on normal control engineering practice. If equipment (or systems) are not included in a Building’s sequences of operation listing but are included in Equipment Schedules, provide complete sequences as in the foregoing.

3. Include summary of system type at start of each individual sequence, e.g., 2

speed- 100% Outdoor Air, etc.

J. Fan Interlock Schedule

1. General

a. In the following paragraphs, the unit listed first is the one being controlled and the unit(s) listed after is the one controlling it.

b. Include interlock schedules with control submittals organized

separately for the Building, TCP and System Sequences of Operation with which they are associated.

c. Where a unit is shown interlocked to a space temperature sensor,

indicate the sensor ID Number in Control Submittals. Units controlled by space sensors typically require a make up (outdoor) air damper or dampers to open. Also indicate in the damper ID Numbers in Control Submittals

d. Hard-wire interlock starting of 100 percent outdoor air AHUs and

ACUs to their outdoor air damper position limit switch.

e. Interlock starting of exhaust air fans with two position motorized exhaust air dampers to the damper position

3.4 SEQUENCES OF OPERATION

A. Normal Control Positions: Normal positions of controlled devices must be position device returns to on power failure. Include all interlocks and safeties. Provide normal positions as follows:

1. Outside air damper: Closed. 2. Return air damper: Open. 3. Exhaust fan dampers: Closed.

AARHIP 15900-21

B. Smoke Detection: When the Smoke Alarm signal is received at any temperature

control panel (TCP) from the Fire Alarm Control Panel (provided under Electrical Work) all fans throughout the facility stop.

3.5 SEQUENCES OF OPERATION

A. CF2-AHU-1: 100 Percent Outdoor Air-1 Speed - Heating Only (CF2-TCP-1)

1. Safeties

a. General: Safeties are hard wired through motor controls and work in all control modes.

b. Freezestat: If the freezestat senses a temperature below 38°F, the fan

stops.

c. Outdoor air damper: The fan does not start until the outdoor air damper limit switch makes contact. If the fan is commanded to start and this safety has prevented it from doing so, limit switch alarm is issued.

2. Fan start/stop- single speed

a. H-O Switch: A TCP Hand-Off switch selects control of the supply

fan.

b. Hand: The fan runs continuously

c. When the supply fan runs, the interlocked exhaust fans CF1-EAF-1, 2, 3 and 5, and CR1-EAF-1 run if their mode selector switches are in the Auto position.

3. Damper Control

a. Fan off: Damper goes to its normal position (CF2-AHU-1-D1 =

closed)

b. Fan on: Damper opens before supply fan starts.

4. Temperature Control

a. Space thermostat: The space thermostat is used for heating control set point (55°F).

AARHIP 15900-22

b. Space temperature control: As space temperature falls below the heating set point, the heating coil control valve modulates open to the coil.

5. Heating Pump Control CF2-HSP-1

a. H-O-A Switch: Hand-Off-Auto switch selects Auto or Hand control

of the heating coil pump.

b. Hand: The pump runs continuously.

c. Auto: The pump runs whenever the supply fan runs and outdoor air is below 65�F.

B. CF2-AHU-2: 100 Percent Outdoor Air-1 Speed - Heating Only (CF2-TCP-1)

1. Controls for CF2-AHU-2, CF2-EAF-1, 2, 8 and CF2-HSP-2 are similar to

controls for air handling system described in paragraph A above.

C. CF2-AHU-3: 100 Percent Outdoor Air-2 Speed – Heating Only (CF2-TCP-1)

1. Safeties


b. Freezestat: If the freezestat senses a temperature below 38°F, the fan

stops.

c. Outdoor air damper: The fan does not start until the outdoor air damper limit switch makes contact. If the fan is commanded to start and this safety has prevented it from doing so, limit switch alarm is issued.

2. Fan start/stop- two speed

a. H-L-O Switch: A TCP High-Low-Off switch selects high or low

speed operation of the supply fan.

b. High or Low: The fan runs continuously at the speed selected

c. When the supply fan runs in low speed mode, its interlocked exhaust fans CF3-EAF-1 and 8 run if their mode selector switches are in the Auto position.

AARHIP 15900-23

d. When the supply fan runs in high speed mode, its interlocked exhaust fans CF3-EAF-1, 8 and 9 run if their mode selector switches are in the Auto position.

3. Damper Control

a. Fan off: Damper goes to its normal position (CF2-AHU-3-D1=

closed)

b. Fan on: Damper opens before supply fan starts.


a. Space Thermostat: The space thermostat is used for heating control set point (55°F).

b. Space temperature control: As space temperature falls below the

heating set point, the heating coil control valve modulates open to the coil.

5. Heating Pump Control CF2-HSP-3

a. H-O-A Switch: A TCP Hand-Off-Auto switch selects Auto or Hand

control of the heating coil pump.

b. Hand: The pump runs continuously

c. Auto: The pump runs whenever the supply fan runs and outdoor air is below 65°F.

D. CR3-AHU-1: 100 Percent Outdoor Air-1 Speed - Heating Only (CR3-TCP-1)

1. Controls for CR3-AHU-1, CR4-EAF-1, CR3-EAF-1 and CR3-HSP-1 are

similar to controls for air handling system described in paragraph A above.

E. CR3-AHU-2: 100 Percent Outdoor Air-1 Speed - Heating Only (CR3-TCP-1)

1. Controls for CR3-AHU-2, DL1-EAF-1, DL1-EAF-2, DL2-EAF-1, DL2-EAF-2 and CR3-HSP-2 are similar to controls for air handling system described in paragraph A above.

F. CR3-AHU-3: 100 Percent Outdoor Air-1 Speed - Heating Only (CR3-TCP-1)

1. Controls for CR3-AHU-3, DL3-EAF-1 and CR3-HSP-3 are similar to

controls for air handling system described in paragraph A above.

AARHIP 15900-24

G. CR3-ACU-1- Return Air – Heating/Cooling (CR3-TCP-1)

1. Safeties


b. Freezestat: If the freezestat senses a temperature below 38�F, the fans stop.

2. Fan start/stop

a. H-O Switch: H-O switch selects control of the supply fan.

b. Hand: The fan runs continuously.

c. When the supply fan runs in any mode, its interlocked exhaust/return

fan CR3-RAF-1runs if its mode selector switch is in the Auto position.

3. Damper Control

a. Fan off: Dampers go to their normal positions (CR3-ACU-1-D1 and -

D3= closed, CR3-ACU-1-D2= open).

b. Fan on: Dampers are positioned by temperature control.


a. Space Thermostat: The space thermostat is used for heating and cooling control (720F and 780F).

b. Heating control: When the space temperature falls below the heating

set point, the heating coil control valve modulates open to the coil.

c. Cooling control: When the space temperature rises above the cooling set point, CR4-ACCU-1 refrigeration cooling cycles on.

5. Heating Pump Control CR3-HSP-4

a. H-O-A Switch: H-O-A switch selects Auto or Hand control of the

heating coil pump.


c. Auto: The pump runs whenever the supply fan runs and outdoor air is below 65°F.

AARHIP 15900-25

H. CR3-ACU-2- Return Air – Heating/Cooling (CR3-TCP-1)

1. Controls for CR3-ACU-2, CR3-RAF-2 and CR3-HSP-5 are similar to controls for air conditioning system described in paragraph G above.

I. CR4-ACU-1- Return Air – Heating/Cooling (CR3-TCP-1)

1. Controls for CR4-ACU-1and CR4-HSP-1 are similar to controls for air

conditioning system described in paragraph G above.

J. CF1-EAF-4 and 6, CF2-EAF-3, 4, 5, 6 and 7, CF3-EAF-6, 7, and 10, Summer Ventilation (CF2-TCP-1)

1. Fans are controlled by space thermostats and H-O-A selector switches

located at TCP.

2. When in the Auto mode the exhaust fans start by space temperature set at 85°F.

3. When exhaust fans are called to start, their normally closed outdoor air

dampers open.

4. Where two exhaust fans serve the same space, they start in sequence by thermostats set 5°F apart.

K. CF3-EAF-11 and 12, CR4-EAF-2 and 3, and DL3-EAF-2 Summer Ventilation

(CR3-TCP-1)

1. Controls are similar to controls for exhaust fans described in paragraph J above.

L. CF3-EAF-2, 3, 4 and 5, and CR2-EAF-1 Toilet/Break Room Ventilation

1. Room ON-OFF light switches control exhaust fans.

2. In the ON mode the fans start and when placed in OFF position the fans

stop.

M. CR1-HPP-1A and 1B- Primary Heating Pumps-Variable Speed (CR1-TCP-1)

1. Number of existing and new buildings are heated by hot water delivered by the primary heating loop.

2. Pump start/stop

a. H-O-A Switch: Hand-Off-Auto switch selects control of the pump.

AARHIP 15900-26

b. L-L-A Switch: Lead-Lag-Auto switch selects lead-lag controls.

c. Hand: The lead pump runs continuously.

d. Auto: The lead pump runs whenever the outdoor air temperature is below 65°F.

e. Speed control: The lead pump speed is controlled to maintain hot

water return temperature set point 180°F. On a fall in water temperature below the set point, lead pump speed is increased. On a rise, speed is reduced.

f. GPM Measurement: Provide primary heat flow indication resulting

from the control loop in “e”. Limit the GPM to 600 minimum and 1500 maximum. Provide magnetic flow meters specified in Section 13410.

N. CR1-HSP-7 Secondary Heating Pump Terminal Units (CR1-TCP-1)

1. Pump start/stop



c. Auto: The pump runs whenever the outdoor air temperature is below

65°F.

d. As supply water temperature falls below the heating set point, the heating three way control valve modulates open to heating loads.

O. CR1-HSP-3 and 4 Secondary Heating Pumps Variable Speed (CR1-TCP-1)

1. Number of new and existing buildings are heated by hot water delivered by

the secondary heating loop.

2. Pump start/stop





AARHIP 15900-27

e. Speed control: The lead pump speed is controlled to maintain hot water return temperature set point 1950F. On a fall in water temperature below the set point, lead pump speed is increased. On a rise, speed is reduced.

P. CR1-HSP-5 and 6 Secondary Heating Pumps (CR1-TCP-1)

1. Number of existing buildings are heated by hot water delivered by the

secondary heating loop.

2. Pump start/stop





Q. Hot Water Cabinet Unit Heaters

1. Unit mounted speed and thermostat controls are integral with cabinet

heaters. Thermostats control hot water supply valves to maintain set point temperatures.

R. Hot Water Unit Heaters

1. Space mounted thermostat cycles unit fan to maintain space temperature set

point.

S. Hot Water Fin Tube Radiation

1. Space mounted thermostat controls hot water solenoid valve to maintain space temperature set point.

T. Pressure Fill for Hydronic System, Fill Pump CR1-GFP-1

1. System start/stop

a. Pressure switches control operation of CR1-GFP-1.

b. Mechanical float controls make-up water to the fill system break tank.

AARHIP 15900-28

2. Alarms

a. Make-up water flow.

b. Low water level in the system break tank.

c. Each of the above conditions generates visual and audible alarms at the unit control panel.

3. Indications

a. Amount of make-up water is monitored through water meter.

U. Combustion Air Control

1. There are two combustion air dampers, one dedicated to each boiler.

2. When a boiler control panel begins its start sequence, its combustion air

damper fully opens.

3. Provide hard-wired control from boiler control panels.

4. If Code or the boiler manufacturers require proving of combustion air damper opening, provide end switch control through the boiler control panels for this function.

V. Boiler Control CR1-HWB-1 and CR1-HWB-2 (CR1-TCP-1)

1. General

a. The boilers are controlled from LOCAL-REMOTE selector switches

at TCP.

b. When the selector switches are in the LOCAL mode, boilers run from switches at their control panels.

c. When the selector switches are in the REMOTE mode, boilers are

controlled from the Boiler Sequencing Control.

d. The boilers are operating on natural gas (NG).

e. The lag boiler is set to operate when the lead boiler fails and when the load demand exceeds the heating capacity of the lead boiler.

f. Each Boiler has boiler panel switches and functions listed in the

Specification Section 15510, Boilers and Boiler Room Equipment.

AARHIP 15900-29

2. Boiler Start/Stop Control

a. Manual Control - When a boiler is set to local control, start-stop and capacity are controlled through its boiler control panel.

b. Boilers normally run by Boiler Sequencing Control. Local control

requires attended operation.

c. Lead- Lag Control

(1) Provide Lead-Lag boiler selection.

(2) If the Lead Boiler fails operation, the Lag Gas Boiler is started.

(3) If Boiler Sequencing Control requires a second boiler to operate, the next boiler in sequence starts.

d. When a boiler is commanded to start, its circulating pump CR1-HSP-

1/CR1-HSP-2 starts.

3. Boiler Sequencing Control

a. Provide boiler sequencing control incorporating controllers, relays, switches, indicating and alarm lights, and other devices required, and providing specified sequencing of burners.

b. Provide boiler temperature controller with adjustable differential and

with sensing element located in primary hot water supply piping as shown to automatically sequence boilers in their preprogrammed firing order to maintain hot water supply point, 210°F (adjustable).

c. Provide adjustable dead band between Lead and Lag boiler

sequencing.

d. Provide boiler sequencing control to perform the following functions:

(1) Design system such that when a boiler is brought on-line, its associated glycol hot water pump starts and when flow is proved by a flow switch in circuit, a solenoid valve on glycol hot water branch main at the next boiler programmed to operate opens, allowing hot water to flow through the standby boiler and bring it up to temperature, and burner to operate subject to its safety controls.

(2) Provide indicating lights on control panel to give visual

indication of cut in and cut out for each boiler.

AARHIP 15900-30

(3) Design system such that each burner starts at low fire and modulates to high fire before the next boiler starts. As the load is satisfied, each burner recycles to low fire position ready for restarting.

(4) Provide control equipment, required to modulate each boiler

burner. Provide 0- to 10-minute adjustable timer to prevent undue recycling of each lag boiler due to load changes.

4. Boiler Low Temperature Protection

a. The control valve is normally open to boiler recirculation.

b. When a boiler and its circulating pump start, the valve modulates to

maintain minimum water/glycol temperature entering the boiler, or minimum temperature difference between water/glycol entering and leaving the boiler.

W. Interlocks

1. CF1-EAF-1, 2, 3, 5 and CR1-EAF-1 to CF2-AHU-1

2. CF2-EAF-1, 2, and 8 to CF2-AHU-2

3. CF3-EAF-1, 8 and 9 to CF-AHU-3

4. CR4-EAF-1 and CR3-EAF-1 to CR3-AHU-1

5. DL1-EAF-1, 2 and DL2-EAF-1, 2 to CR3-AHU-2

6. DL3-EAF-1 to CR3-AHU-3

7. CR3-RAF-1 and CR4-ACCU-1 to CR3-ACU-1

8. CR3-RAF-2 and CR4-ACCU-2 to CR3-ACU-2

9. CR4-ACCU-3 to CR4-ACU-1

10. CF1-D1 to CF1-EAF-6


12. CF2-D1 and D2 to CF2-EAF-7

13. CF2-D3 to CF2-EAF-3 and 4


AARHIP 15900-31

15. CF3-D1 and D2 to CF3-EAF-10




19. CR4-D1 to CR4-EAF-2

20. CR4-D2 to CR4-EAF-3

21. DL3-D1 to DL3-EAF-2

X. Switches, Pilot Lights and Push Buttons (CF2-TCP-1)

1. CF2-AHU-1 H-O

2. CF2-AHU-2 H-O

3. CF2-AHU-3 H-L-O

4. CF1-EAF-1 H-O-A

5. CF1-EAF-2 H-OA

6. CF1-EAF-3 H-O-A

7. CF1-EAF-4 H-O-A

8. CF1-EAF-5 H-O-A

9. CF1-EAF-6 H-O-A

10. CR1-EAF-1 H-O-A

11. CF2-EAF-1 H-O-A

12. CF2-EAF-2 H-O-A

13. CF2-EAF-3 H-O-A

14. CF2-EAF-4 H-O-A

15. CF2-EAF-5 H-O-A

AARHIP 15900-32

16. CF2-EAF-6 H-O-A

17. CF2-EAF-7 H-O-A

18. CF2-EAF-8 H-O-A

19. CF3-EAF-1 H-OA

20. CF3-EAF-6 H-O-A

21. CF3-EAF-7 H-O-A

22. CF3-EAF-8 H-O-A

23. CF3-EAF-9 H-O-A

24. CF3-EAF-10 H-O-A

25. CF2-HSP-1 H-O-A

26. CF2-HSP-2 H-O-A

27. CF2-HSP-3 H-O-A

28. CF2-AHU-1 RUN (RED)

29. CF2-AHU-2 RUN (RED)

30. CF2-AHU-3 RUN LO (RED)

31. CF2-AHU-3 RUN HI (RED)

32. CF1-EAF-1 RUN (RED)






38. CR1-EAF-1 RUN (RED)


AARHIP 15900-33














53. CF2-HSP-1 RUN (RED)



56. CF2-TCP-1 POWER ON (GREEN)

57. PILOT LIGHTS TEST PUSH BUTTON

58. ALARM (LIGHTS/HORN) TEST PUSH BUTTON

59. ALARM SILENCE PUSH BUTTON

Y. Alarm Annunciation (Visual and Audible, CF2-TCP-1)

1. CF2-AHU-1 Fan Failure


AARHIP 15900-34


4. CF1-EAF-1 Fan Failure






10. CR1-EAF-1 Fan Failure















25. CF2-HSP-1 Pump Failure


AARHIP 15900-35


28. ELEC. RM NO.1 High Temp



31. CENTR. OPER. RM High Temp

32. CF1-SMP-1A/1B High Water Alarm

33. CF1-SMP-2A/2B High Water Alarm

34. CF1-SMP-3 High Water Alarm

35. HEATING SYS Make Up Water

36. AHUs, EAFs Smoke Alarm (Signal from Fire

Alarm Control Panel provided under Electrical Work)

37. CF1-ESE-1 Emergency Shower Alarm




41. Spare

42. Spare

43. Spare

44. Spare

Z. Indication/Adjustments (CF2-TCP-1) AHUs and ACUs (Individual)

1. Discharge Temperature

2. Space Temperature

3. Heating Coil Valve Position

AARHIP 15900-36

4. Heating Set Point Adjustment

5. Cooling Set Point Adjustment

6. Cooling ON/OFF

7. Heating ON/OFF

AA. Remote Alarm Contacts to PICS (CF2-TCP-1)

1. CF2-TCP-1 General Alarm (Any alarm listed in paragraph Y)

2. CF1-ESE-1 and 2, CF2-ESE-1 Emergency Shower/Eyewash Alarm and CF3-ESE-1 (Any ESE alarm listed in Paragraph

Y)

BB. Switches, Pilot Lights and Buttons (CR3-TCP-1)

1. CR3-AHU-1 H-O

2. CR3-AHU-2 H-O

3. CR3-AHU-3 H-O

4. CR3-ACU-1 H-O

5. CR3-ACU-2 H-O

6. CR4-ACU-1 H-O

7. CR4-EAF-1 H-O-A

8. CR4-EAF-2 H-O-A

9. CR4-EAF-3 H-O-A

10. CR3-EAF-1 H-O-A

11. DL1-EAF-1 H-O-A

12. DL1-EAF-2 H-O-A

13. DL2-EAF-1 H-O-A

14. DL2-EAF-2 H-O-A

AARHIP 15900-37

15. DL3-EAF-1 H-O-A

16. DL3-EAF-2 H-O-A



19. CR3-RAF-1 H-O-A

20. CR3-RAF-2 H-O-A

21. CR3-HSP-1 H-O-A

22. CR3-HSP-2 H-O-A

23. CR3-HSP-3 H-O-A

24. CR3-HSP-4 H-O-A

25. CR3-HSP-5 H-O-A

26. CR4-HSP-1 H-O-A

27. CR3-AHU-1 RUN (RED)



30. CR3-ACU-1 RUN (RED)





35. CR4-EAF-3 RUN (Red)


37. DL1-EAF-1 RUN (RED)


AARHIP 15900-38







45. CR3-RAF-1 RUN (RED)

46. CR3-RAF-2 RUN (RED)

47. CR3-HSP-1 RUN (RED)






53. CR3-TCP-1 POWER ON (GREEN)




CC. Alarm Annunciation (Visual and Audible, CR3-TCP-1)

1. CR3-AHU-1 Fan Failure



4. CR3-ACU-1 Fan Failure

AARHIP 15900-39







11. DL1-EAF-1 Fan Failure








19. CR3-RAF-1 Fan Failure

20. CR3-RAF-2 Fan Failure

21. CR3-HSP-1 Pump Failure






27. AHUs, EAFs. RAFs Smoke Alarm (Signal from Fire Alarm Control Panel provided under Electrical Work)

AARHIP 15900-40

28. CR2-EE-1 Emergency Eyewash Alarm

29. Make-up Water Storage Tank Low Level

30. Make-up Water Water Flow

31. Spare

32. Spare

33. Spare

DD. Indication/Adjustments (CR3-TCP-1) AHUs and ACUs (Individual)

1. Discharge Temperature

2. Space Temperature

3. Hating Coil Valve Position

4. Heating Set Point Adjustment

5. Cooling Set Point Adjustment

6. Cooling ON/OFF

7. Heating ON/OFF

8. Make-up Water Meter/GAL

EE. Remote Alarm Contacts to PICS (CR3-TCP-1)

1. CR3-TCP-1 General Alarm (Any alarm listed

in paragraph CC)

2. CR2-EE-1 Emergency Eyewash Alarm (EE alarm listed in paragraph CC)

FF. Switches, Pilot Lights and Push Buttons (CR1-TCP-1)

1. CR1-HPP-1A H-O-A

2. CR1-HPP-1B H-O-A

3. CR1-HPP-1A/1B CR1-HPP-1A-1B-AUTO

AARHIP 15900-41

4. CR1-HSP-3 H-O-A

5. CR1-HSP-4 H-O-A

6. CR1-HSP-3/4 CR1-HSP-3-4-AUTO

7. CR1-HWB-1 L-R

8. CR1-HWB-2 L-R

9. CR1-HWB-1/2 CR1-HWB-1-2-AUTO

10. CR1-HSP-1 H-O-A

11. CR1-HSP-2 H-O-A

12. CR1-HPP-1A RUN (RED)

13. CR1-HPP-1B RUN (RED)



16. CR1-HWB-1 RUN (RED)

17. CR1-HWB-2 RUN (RED)



20. CR1-HSP-5 H-O-A

21. CR1-HSP-6 H-O-A

22. CR1-HSP-7 H-O-A




26. CR1-TCP-1 POWER ON (GREEN)


AARHIP 15900-42



GG. Alarm Annunciation (Visual and Audible, CR-1-TCP-1)

1. CR1-HPP-1A Pump Failure

2. CR1-HPP-1B Pump Failure



5. CR1-HWB-1 Boiler Failure







12. Spare

13. Spare

14. Spare

HH. Indication/Adjustment (CR1-TCP-1) CR1-HSP-7

1. Hot Water Supply Temperature

2. Hot Water Return Temperature

3. Set Point Adjustments

II. Remote Alarm Contacts to PICS (CR1-TCP-1)

1. CR1-HWB-1 Boiler Status

AARHIP 15900-43

2. CR1-HWB-2 Boiler Status



5. CR1-HPP-1A Pump Status

6. CR1-HPP-1B Pump Status

7. CR1-HPP-1A Pump Failure

8. CR1-HPP-1B Pump Failure

9. CR1-TCP-1 General Alarm (Any alarm listed in paragraph GG except alarms listed above)

JJ. Selected equipment to run from the Emergency Generator upon power failure

regardless of Lead/Lag switches setting. The Generator is provided under Electrical Work (Coordinate with Division 16)

1. CR1-HWB-1

2. CR1-HPP-1A

3. CR1-HSP-1

4. CR1-HSP-3

5. CR1-HSP-5

6. CR3-ACU-1

7. CR3-ACU-2

8. CR3-HSP-4

9. CR3-HSP-5

10. CR3-RAF-1

11. CR3-RAF-2

12. CR4-ACU-1

13. CR4-HSP-1

AARHIP 15900-44


A. Manufacturer's Field Services: Furnish the services of a qualified representative of the manufacturer to provide instruction on proper installation of the equipment, inspect the completed installation, make any necessary adjustments, participate in the startup of the equipment, participate in the field testing of the equipment and place the equipment in trouble-free operation, as specified in Division 1. Provide training in accordance with Section 01820.

B. Training: Provide training to the operating personnel in the operation and

maintenance of the temperature control system as required by Section 01820, Training and as follows:

1. Provide basic operator training for data display, alarm and status descriptors,

requesting data, execution of commands and request of logs.

2. Provide on-site hands-on operator instruction to the operating personnel, during system commissioning and at such time that acceptable performance of the hardware has been established.

3. Provide operator instruction at an agreed upon time, during normal working

hours by competent representatives familiar hardware and accessories.

C. Tests: After installation of the equipment, control equipment and all appurtenances, subject each unit to a field running test as specified in Division 1, under actual operating conditions.

1. Perform prefinal inspection/test as follows:

a. Carry out test with controls operating as near as possible to service

conditions.

b. Correct all defects in the controls.

2. Final inspection/test:

a. Prior to the acceptance test, completely adjust and operate properly all controls.

b. Notify the Owner when the installation is ready for acceptance tests.

At least two weeks prior to scheduled acceptance tests, deliver copies of record internal panel layouts and detailed schematic and wiring diagrams to the Owner. At the acceptance test, demonstrate the complete functions and proper operation of each control system to the Owner. Simulate conditions of off-season temperature and alarms as required for a complete demonstration.

AARHIP 15900-45


A. General: Approximately ten months after substantial completion submit for the Owner’s consideration a maintenance agreement on the entire temperature control system for the succeeding year. Include, at least, an annual checkout and recalibration of all controls, and prompt repair or replacement of controls which malfunction during the contract period. Include necessary replacement parts, labor and travel expense in the proposed maintenance contract amount.

END OF SECTION

AARHIP 15900-46


AARHIP 15950-1

SECTION 15950

TESTING, ADJUSTING AND BALANCING

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing and installing the following:

1. Testing, adjustment and balancing of air systems. 2. Testing, adjustment and balancing of hydronic systems. 3. Measurement of final operating conditions of HVAC systems.


Following:

1. Section 15072 - Vibration Isolation 2. Section 15183 - Hydronic Piping, Valves and Specialties 3. Section 15184 - Refrigerant Piping and Specialties 4. Section 15187 - Chemical (Water) Treatment 5. Section 15510 - Boilers and Boiler Room Equipment 6. Section 15670 - Condensing Units 7. Section 15720 - Air Handling Units 8. Section 15740 - HVAC Pumps 9. Section 15761 - Air Coils 10. Section 15765 - Terminal Heat Transfer Units 11. Section 15810 - Ductwork 12. Section 15820 - Ductwork Accessories 13. Section 15830 - Fans 14. Section 15850 - Air Outlets and Inlets 15. Section 15900 - HVAC Controls

1.2 REFERENCES


1. AABC - National Standards for Field Measurement and Instrumentation, Total System Balance.

2. ASHRAE - Most Recent Systems Handbook: Chapter 57, Testing,

Adjusting and Balancing.

3. NEBB - Procedural Standards for Testing, Balancing and Adjusting of Environmental Systems.

AARHIP 15950-2

1.3 SUBMITTALS


B. Testing and Balancing Agency: Submit the name and qualifications of the testing,

adjusting and balancing agency and their personnel for approval within 30 days after the award of the contract.

C. Test Reports: Submit a complete set of all approved tests prior to final acceptance.

D. System Testing and Balancing: Submit a detailed account of the proposed

methods and sequence to carry out system testing and balancing.

E. Draft Reports: Prior to commencing the Work, submit draft reports indicating adjusting, balancing and equipment data required.

1. Submit three draft copies of the report for review prior to final acceptance.

Provide three final copies for the OWNER and for inclusion in the operation and maintenance manuals.

F. Reports Quality: Provide reports in soft cover, letter size, 3-ring binder manuals,

complete with index page and indexing tabs, with cover identification at front and side. Include a set of reduced drawings with air outlets and inlets, and equipment identified to correspond with the data sheets, and indicating thermostat locations.

G. Testing and Balancing Equipment: Submit data sheets of specific instruments to

be used, listing their most recent calibration dates prior to commencing system balance.

H. Other Requirements: Include detailed procedures, agenda, sample report forms

and copy of AABC National Project Performance Guarantee, prior to commencing the system balance.

1.4 REPORT FORMS

A. General: Submit reports on AABC National Standards for Total System Balance or NEBB forms.

B. Format: Include the following information on the report forms:

1. Title Page

a. Company name b. Company address c. Company telephone number

AARHIP 15950-3

d. Project name e. Project location f. Project ENGINEER g. Project CONTRACTOR h. Project altitude

2. Instrument List

a. Instrument b. Manufacturer c. Model d. Serial number e. Range f. Calibration date

3. Air Handling Equipment

a. Identification/Location b. Manufacturer c. Model/Size d. Air flow, design and actual e. Return air flow, design and actual f. Outside air flow, design and actual g. Total static pressure (total external), design and actual h. Inlet pressure i. Discharge pressure j. Fan RPM

4. Exhaust Fan Data

a. Identification/Location b. Manufacturer c. Model/Size d. Air flow, design and actual e. Total static pressure (total external), design and actual f. Inlet pressure g. Discharge pressure h. Fan RPM

5. Supply Fan Data

a. Identification/Location b. Manufacturer c. Model/Size d. Air flow, design and actual e. Total static pressure (total external), design and actual f. Inlet pressure

AARHIP 15950-4

g. Discharge pressure h. Fan RPM

6. Return Air/Outside Air Data

a. Identification/Location b. Design air flow c. Actual air flow d. Design return air flow e. Actual return air flow f. Design outside air flow g. Actual outside air flow h. Return air temperature i. Outside air temperature j. Required mixed air temperature k. Actual mixed air temperature l. Design outside/return air ratio m. Actual outside/return air ratio

7. Electric Motors

a. Manufacturer b. HP/BHP c. Phase, voltage, amperage; nameplate, actual, no load d. RPM e. Enclosure f. Service factor g. Starter size, rating, heater elements

8. V-Belt Drive

a. Identification/Location b. Required driven RPM c. Driven sheave, diameter and RPM d. Belt, size and quantity e. Motor sheave, diameter and RPM f. Center to center distance, maximum, minimum and actual

9. Duct Traverse

a. System zone/branch b. Duct size c. Area d. Design velocity e. Design air flow f. Actual velocity g. Actual air flow

AARHIP 15950-5

h. Duct static pressure i. Air temperature j. Air correction factor

10. Air Distribution Test Sheet

a. Air terminal number b. Room number/location c. Terminal type d. Terminal size e. Area factor f. Design velocity g. Design air flow h. Actual velocity i. Actual air flow j. Percent of design air flow

11. Terminal Unit Data

a. Identification/Location b. Manufacturer c. Model/Size d. Maximum design air flow e. Maximum actual air flow

12. Pump Data

a. Identification/Location b. Manufacturer c. Model/Size d. Impeller e. Service f. Design flow rate, pressure drop, BHP g. Actual flow rate, pressure drop, BHP h. Discharge pressure i. Suction pressure j. Total operating head pressure k. Shut off, discharge and suction pressures l. Shut off, total head pressure

13. Air Cooled Condenser

a. Identification/Location b. Manufacturer c. Model/Size d. Entering DB air temperature, design and actual

AARHIP 15950-6

e. Leaving DB air temperature, design and actual f. Number of compressors

14. Cooling Coil Data

a. Identification/Location b. Manufacturer c. Service d. Air flow, design and actual e. Entering air DB temperature, design and actual f. Entering air WB temperature, design and actual g. Leaving air DB temperature, design and actual h. Leaving air WB temperature, design and actual i. Air pressure drop, design and actual

15. Heating Coil Data

a. Identification/Location b. Manufacturer c. Service d. Air flow, design and actual e. Entering air temperature, design and actual f. Leaving air temperature, design and actual g. Air pressure drop, design and actual h. Water flow, design and actual i. Water pressure drop, design and actual j. Entering water temperature, design and actual k. Leaving water temperature, design and actual

16. Sound Level Report

a. Location b. Octave bands - equipment off c. Octave bands - equipment on

17. Vibration Test

a. Location of points

(1) Fan bearing, drive end (2) Fan bearing, opposite end (3) Motor bearing, center (if applicable) (4) Motor bearing, drive end (5) Motor bearing, opposite end (6) Casing (bottom or top) (7) Casing (side)

AARHIP 15950-7

(8) Duct after flexible connection (discharge) (9) Duct after flexible connection (suction)

b. Test readings

(1) Horizontal, velocity and displacement (2) Vertical, velocity and displacement (3) Axial, velocity and displacement

c. Normally acceptable readings, velocity and acceleration d. Unusual conditions at time of test e. Vibration source (if noncomplying)

18. Duct Leak Test

a. Description of ductwork under test b. Duct design operating pressure c. Duct design test static pressure d. Duct capacity, air flow e. Maximum allowable leakage duct capacity times leak factor f. Test apparatus

(1) Blower (2) Orifice, tube size (3) Orifice size (4) Calibrated

g. Actual static pressure h. Actual orifice differential pressure i. Leakage

19. Boiler Combustion Test

a. Identification/location b. Boiler manufacturer c. Model/Size d. Firing rate e. Overfire draft f. Gas meter timing dial size g. Gas meter time per revolution h. Gas pressure at meter outlet i. Gas flow rate j. Heat input k. Burner manifold gas pressure l. Percent carbon monoxide (CO) m. Percent carbon dioxide (CO2) n. Percent oxygen (O2)

AARHIP 15950-8

o. Percent excess air p. Flue gas temperature at outlet q. Ambient temperature r. Net stack temperature s. Percent stack loss t. Percent combustion efficiency u. Heat output

1.5 PROJECT RECORD DOCUMENTS

A. General: Submit record documents as specified in Division 1.

B. Location Record: Accurately record actual locations of flow measuring stations balancing valves and rough setting.


A. Provide services from a company specializing in the testing, adjusting and balancing of systems specified in this Section with minimum 5 years documented experience certified by AABC or NEBB.

1. Perform Work under supervision of AABC Certified Test and Balance

Engineer or NEBB Certified Testing, Balancing and Adjusting Supervisor.

2. Perform the total system balance in accordance with ASHRAE most recent issue Systems Handbook.


A. Sequence the Work to commence after completion of systems and schedule completion of Work before Substantial Completion. Schedule and provide assistance in final adjustment and test of life safety system with the Fire Authority.

1.8 PRE-INSTALLATION

A. Conference: Convene a conference 1 week prior to commencing testing.

PART 2 PRODUCTS

Not Used

AARHIP 15950-9

PART 3 EXECUTION

3.1 EXAMINATION

A. General: Before commencing Work, verify that the systems are complete and operable. Verify the following:

1. Equipment is operable and in a safe and normal condition

2. Temperature control systems are installed complete and operable

3. Proper thermal overload protection is in place for electrical equipment

4. Final filters are clean and in place. If required, install temporary media in

addition to final filters

5. Duct systems are clean of debris

6. Fan rotations are correct

7. Fire and volume dampers are in place and open

8. Coil fins have been cleaned and combed

9. Access doors are closed and duct end caps are in place

10. Air outlets are installed and connected

11. Duct system leakage has been minimized

12. Hydronic systems have been flushed, filled and vented

13. Pump rotations are correct

14. Proper strainer baskets are clean and in place

15. Service and balance valves are open

16. All required fittings and valves, including balancing cocks, flow control valves, pressure gauges and gauge cocks with snubbers, thermometers with wells, P&T plugs, and air vents are properly installed as specified

B. Defects and Deficiencies: Report any defects or deficiencies noted.

C. System Imbalance: Promptly report abnormal conditions in mechanical systems or

conditions which prevent system balancing.

AARHIP 15950-10

D. Acceptance of Existing Conditions: Beginning of testing means acceptance of existing conditions.

3.2 PREPARATION

A. Additional Balancing: Provide additional balancing devices as required.

B. Instruments: Provide instruments required for testing adjusting and balancing operations. Make these instruments available to facilitate spot checks during testing.

3.3 INSTALLATION TOLERANCES

A. Air Systems: Adjust the air handling systems to plus or minus 5 percent for supply systems and plus or minus 10 percent for return and exhaust systems from the design figures indicated.

B. Hydronic Systems: Adjust the hydronic systems to plus or minus 10 percent of the

design conditions indicated. 3.4 ADJUSTING

A. General: Adjust Work as specified in Division 1.

B. Completion: Properly install, inspect and confirm proper operation of each individual component of the system before giving notice to proceed with testing, adjusting and balancing. Do not perform testing, adjusting and balancing until all mechanical equipment is properly installed and is 100 percent operational, all temperature controls are installed and calibrated and all systems are cleaned and clean filters installed.

C. Deficiency and Correction: Assist in the system testing, adjusting and balancing.

Adjust the system and make corrections of any deficiencies found such as: motor starters and horsepower; improper sheave and belt sizes; missing, improperly installed or malfunctioning volume control dampers, air extractors, power wiring, controls and any other items that prevent the completion of the system testing, adjusting and balancing.

D. Recorded Data: Record data representing actually measured, or observed

conditions.

E. Settings: Permanently mark settings of valves, dampers and other adjustment devices the allow the balanced settings to be restored. Set and lock memory stops.

F. Balance Verification: After adjustment, take measurements to verify that the

balance has not been disrupted or that such disruption has been rectified.

AARHIP 15950-11

G. Operating Systems: Leave systems in proper working order, replacing belt guards, closing access doors, closing doors to electrical switch boxes, and restoring thermostats to the specified settings.

H. Final Inspection: At final inspection, recheck random selections of data recorded

in the report. Recheck points or areas as selected and witnessed by the OWNER.

I. Checking: Check and adjust the systems approximately six months after final acceptance and submit report.

3.5 AIR SYSTEM TESTING AND BALANCING

A. Perform air system balancing as follows:

1. Check filters for cleanliness and minimum bypass leakage, dampers (both volume and fire) for correct position, and temperature controls for completeness of installation.

2. Prepare test report sheets for fans, and air inlets and outlets. Obtain the

manufacturer's flow factors and follow the recommended procedure of testing.

3. Open all supply dampers, and place all fans in specified operation.

4. Check motor amperage and voltage for each motor, fan rotation, and

automatic dampers for proper position.

5. Check air and water temperature controls and verify that they are operating to deliver design temperatures. Adjust the system with mixing dampers positioned under the minimum outdoor air condition.

6. Using pitot tube and calibrated manometer, traverse the main duct and all

main branches and ascertain the total air being delivered. Adjust or replace pulleys and belts and install additional dampers if required to obtain the design airflow. Make adjustments so that all finally adjusted air quantities are at least equal to, but more than 10 percent above, the air quantities noted on the drawings.

7. Adjust branch dampers until the proper air volume is obtained in each

branch duct.

8. Commence terminal outlet balancing beginning with the outlets nearest the fan. Use branch dampers for major adjusting and terminal dampers for minor adjustments only.

9. Make additional test and adjustment passes through entire systems as

necessary to obtain the noted outlet values.

AARHIP 15950-12

10. Read and record amperage readings for each motor lead, fan static and

velocity pressures and the static pressure drop across each major component (i.e., intake, filters, coils).

11. Reposition system dampers to supply maximum outdoor air and record the

amperage and pressure readings in this position.

12. Adjust air terminal outlets for proper distribution pattern.

13. Inspect and test all electrical protective devices and circuits for proper motor protection, including properly sized starter overload heater elements, for all equipment furnished.

14. Provide a system schematic with the required and actual air quantities

recorded at each outlet or inlet.

15. When modulating dampers are provided, take measurements and balance the system at extreme conditions.

16. Measure building static pressure and adjust the supply, return and exhaust

air systems to provide the required relationship to maintain approximately 0.05 inches positive static pressure for each zone near building entries.

17. Permanently mark the balance position of all manual volume dampers, and

replace all access covers. 3.6 HYDRONIC SYSTEM TESTING AND BALANCING

A. The following is a suggested procedure for testing hydronic systems:

1. Use calibrated (Venturi tubes, orifices or other metered) fittings and pressure gauges to determine flow rates for system balance.

2. Adjust make-up water pressure controls to obtain the design system

pressure.

3. Verify that heating coils and cooling coils are clean and unobstructed, that balancing cocks and valves, both manual and automatic, are in the correct position, and that the temperature control system is complete and adjusted.

4. Prepare test report sheets for pumps.

5. Obtain the manufacturer's pump curves, and the pressure drops at design

flow rates through water coils, and balancing valves.

AARHIP 15950-13

6. Place balancing cocks and shutoff valves in the open position and pumps in normal operation. Check motor amperage and voltage for each motor lead, pump rotation and the proper position of automatic valves.

7. Check total head at each pump and adjust the discharge balancing valve to

obtain the design gpm water flow.

8. Commence balancing of coils and heating water circuits, beginning with those nearest the main pump, and adjust balancing valves to obtain the design flow in each circuit. Adjust the water flow through each unit heater to obtain design water temperature drop as measured by a contact pyrometer. Make additional passes through the entire systems as necessary to obtain water flows within +10 percent of design values.

9. Inspect and test electrical protective devices and circuits for proper motor

protection, including properly sized starter overload heater elements for all equipment.

10. Finally balance amperage draw, total head in feet and gpm for each pump.

List gpm flows through each heating coil, and each main pipe branch containing a specified flow measuring device.


A. General: When each system has been completed and proved functional, demonstrate its intended operation in each of its operating modes. Simulate in an acceptable manner functions dependent upon parameters such as weather, process or emergency conditions which are unavailable at the time of test, or separately demonstrate when those parameters exist, to assure proper functioning under all operating conditions. Immediately after testing, properly reset control settings temporarily modified for such simulations.

B. Final Acceptance: Final acceptance of the Work will be contingent upon the

operation of all equipment and systems meeting the specified requirements.

END OF SECTION

AARHIP 15950-14


AARHIP 16050-1

SECTION 16050

BASIC ELECTRICAL MATERIALS AND METHODS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: General requirements for providing basic electrical materials and methods.


Following:

1. Certain equipment, control devices, conduit and wiring are shown on electrical drawings, but are specified in other sections pertaining to plumbing, heating, ventilating, air conditioning, temperature control systems, process equipment, process control systems and instrumentation. Install and connect these items to the electrical system as indicated or required in accordance with the Contract Documents.

C. Overall Application of Specifications: This Section applies to all Division 16

sections and to other sections that include requirements for electrical equipment. Irrespective of where the electrical requirements are specified, provide and install all materials necessary for a complete operational system.

D. Temporary Requirements: This Section applies to any temporary circuits,

overcurrent devices, conduit, wiring, and other equipment required during changeover from the existing electrical system to a new electrical system. This Section also applies to temporary rewiring of lighting circuits, power circuits, instruments and devices.

1.2 DEFINITIONS

A. Hazardous Areas: Hazardous areas as defined by the NEC as Class I, Division 1, Group D, or Class I, Division 2, Group D. The following areas are designated hazardous:

1. Class 1, Division 1, Group D

a. Scum Room and Well in Gravity Thickener Building. b. Blend and Gravity Thickening Tanks. c. Sludge Holding Tanks. d. WAS Tanks and Mixer Room.

AARHIP 16050-2

2. Class 1, Division 2, Group D

a. Scum Pumping Area in Gravity Thickener Building. b. Odor Control Fan Room and Area.

B. Corrosive Areas: The following areas are designated corrosive areas: 1. Gravity Belt Thickener Area. 2. Outdoors Above Grade


A. Design Requirements: Design requirements are specified in the applicable sections.

B. Performance Requirements: Performance requirements are specified in the

applicable sections. 1.4 SUBMITTALS

A. General: Furnish all submittals, including the following, as specified in Division 1.

B. Product Data and Information: Furnish a complete list of electrical equipment and

materials to be furnished that shows the manufacturer, catalog number, size, type, capacity, voltage rating and other pertinent information related to each item on the list.

1. Furnish catalog data on the manufacturer's standard equipment and

materials. Clearly indicate on the catalog data the equipment and devices specifically being proposed.

2. Identification: Furnish a complete schedule or listing of system and

equipment identification labels with legends.

C. CONTRACTOR's Shop Drawings: Furnish shop drawings on items manufactured for the Contract.

1. Furnish a connection diagram and schematic for each piece of electrical

equipment. A manufacturer's standard connection diagram or schematic showing more than one method of wiring is not acceptable unless, the intended method is clearly marked.

2. Furnish diagram that show connections to field equipment. Clearly

differentiate between manufacturer's wiring and field wiring.

AARHIP 16050-3

3. Furnish raceway layout drawings that show conduits, boxes, and panels which contain the conductors to be provided. Include schedules listing conduit sizes and conductor content and identification.

4. Where additions and modifications are made to existing equipment, furnish

drawings which clearly identify the existing equipment that remains and the new Work.

D. Coordination Drawings: Furnish coordination drawings that have a scale of

1/4"=1'-0" or larger; that show major elements, components, and systems of electrical equipment as they relate to other systems, installations, and building components. Indicate locations where access space is limited and where sequencing and coordination of installations are required for the efficient flow of the Work, including (but not limited to) the following:

1. Indicate the proposed locations of major raceway systems, equipment, and

materials. Include the following:

a. Clearances for servicing equipment, including space for equipment disassembly as required for periodic maintenance.

b. Exterior wall and foundation penetrations.

c. Fire-rated wall and floor penetrations.

d. Equipment connections and support details.

e. Sizes and location of required concrete pads and bases.

2. Indicate scheduling, sequencing, movement, and positioning of large

equipment into the building during construction.

3. Prepare floor plans, elevations, and details to indicate penetrations in floors, walls, and ceilings and their relationship to other penetrations and installations.

4. Prepare reflected ceiling plans to coordinate the installation of air outlets and

inlets, light fixtures, communications systems components, sprinklers, and other ceiling-mounted devices.

E. Record Documents: Furnish record documents, and in addition to the

requirements specified in Division 1, indicate installed conditions for:

1. Interior and exterior raceway systems’ sizes and locations; locations of control devices; distribution and branch electrical circuitry; and fuse and circuit breaker sizes and arrangements.

AARHIP 16050-4

2. Exposed and concealed equipment locations dimensioned from prominent building lines.

3. Approved substitutions, and actual equipment and materials installed.

F. Maintenance Manuals: Furnish maintenance manuals, and in addition to the

requirements specified in Division 1, include the following information for equipment items:

1. Functional description, normal operating characteristics and limitations,

performance curves, engineering data and tests, and complete nomenclature and catalog numbers of replacement parts.

2. Manufacturer's printed operating procedures to include start-up, break-in,

and routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; and summer and winter operating instructions.

3. Maintenance procedures for routine preventative maintenance and

troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions.

4. Servicing instructions and lubrication charts and schedules.

5. Manufacturers installation instructions.


A. Codes: Provide all electrical Work in accordance with applicable local codes, regulations and ordinances. If there is a conflict between the requirements specified in the Contract Documents and the codes, follow the more stringent requirements as determined and approved.

B. Testing: As a minimum, provide standard factory and field tests for each type of

equipment. Other tests may be specified in the applicable equipment section.

C. Labeling: Provide electrical equipment and materials that are listed and approved by Underwriters Laboratories or other OSHA recognized testing laboratories with the testing agency’s label attached.

D. Standard Products: Unless otherwise indicated, provide electrical materials and

equipment which are the standard products of manufacturers regularly engaged in the production of such materials and equipment. Provide the manufacturer's latest standard design that conforms to these Specifications. Provide the products of the same manufacturer when two or more units of the same class of material and equipment are required.

AARHIP 16050-5


A. General: Deliver, store and handle all products and materials as specified in Division 1 (and as follows:)

B. Shipping and Packing: Provide materials and equipment suitably boxed, crated or

otherwise completely enclosed and protected during shipment, handling, and storage. Clearly label such boxes, crates or enclosures with manufacturer's name, and name of material or equipment enclosed.

C. Acceptance at Site: Conform to acceptance requirements as required in Division 1.

1. Repair or replace all materials and equipment damaged by handling and

storage as directed at no additional Contract cost.

D. Storage and Protection: Protect materials and equipment from exposure to the elements and keep them dry at all times. Handle and store to prevent damage and deterioration in accordance with manufacturer's recommendations.

1.7 PROJECT CONDITIONS

A. General: The Drawings indicate the extent and general arrangement of the principal electrical elements, outlets, devices and circuit layouts. Install and connect all electrical elements and devices to form a complete workable system as required by the Contract Documents, regardless of whether all system components are specifically stated in the Specifications or shown. Provide necessary materials and installation wherever required to conform to the specific requirements of the furnished equipment and for proper installation of the Work.

B. Schematics: In general the runs of feeders are shown schematically and are not

intended to show exact routing and locations of raceways. Verify actual and final arrangement, equipment locations, and prepare circuit and raceway layouts before ordering materials and equipment. Equipment locations are approximate and are subject to modifications as determined by approved equipment dimensions.

C. Coordination of Work: Coordinate the Work so that the electrical equipment may

be installed without altering building components, other equipment or installations.

D. Departure from Design: If departures are deemed necessary due to structural conditions, obstructions or other problems, provide details of such departures and the reasons for requesting approval as soon as practicable but not later than the submittal of the raceway layout drawings. Do not make any departures without written approval.

AARHIP 16050-6

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

3.1 ROUGH-IN

A. Final Location: Verify final locations for rough-ins with field measurements and with the requirements of the actual equipment to be connected.

3.2 ELECTRICAL INSTALLATIONS

A. General: Sequence, coordinate, and integrate the various elements of electrical systems, materials, and equipment. Comply with the following requirements:

1. Coordinate electrical systems, equipment, and materials installation with

other building components.

2. Verify all dimensions by making field measurements.

3. Arrange for chases, slots, and openings in other building components as construction progresses to provide for electrical installations.

4. Coordinate the installation of required supporting devices and sleeves to be

set in cast-in-place concrete and other structural components, as they are constructed.

5. Sequence, coordinate, and integrate installations of electrical materials and

equipment for efficient flow of the Work. Give particular attention to large equipment requiring positioning prior to closing in the building.

6. Where mounting heights are not detailed or dimensioned, install systems,

materials, and equipment to provide the maximum possible headroom.

7. Coordinate connection of electrical systems with exterior underground and overhead utilities and services. Comply with requirements of governing regulations, franchised service companies, and controlling agencies. Provide all required connections for each service.

8. Install systems, materials, and equipment to conform with approved

submittal data, including coordination drawings, to greatest extent possible. Conform to arrangements indicated by the Contract Documents, recognizing that portions of the Work are shown only in diagrammatic form. Where coordination requirements conflict with individual system requirements, refer conflict to the ENGINEER for resolution.

AARHIP 16050-7

9. Where installed exposed in finished spaces, install systems, materials, and

equipment level and plumb, parallel and perpendicular to other building systems and components.

10. Provide electrical equipment to facilitate servicing, maintenance, and repair

or replacement of equipment components. As much as practical, connect equipment for ease of disconnecting, with minimum of interference with other installations.

11. Provide access panels or doors where units are concealed behind finished

surfaces.

12. Install systems, materials, and equipment providing right-of-way priority to systems required to be installed at a specified slope.

3.3 CUTTING AND PATCHING

A. General: Perform cutting and patching as specified in Division 1. In addition to the requirements specified in Division 1, the following requirements apply:

1. Perform cutting, fitting, and patching of electrical equipment and materials

required to:

a. Uncover Work to provide for installation of ill-timed Work.

b. Remove and replace defective Work.

c. Remove and replace Work not conforming to requirements of the Contract Documents.

d. Remove samples of installed Work as specified for testing.

e. Install equipment and materials in existing structures.

f. Locate existing structural reinforcing with a pachometer where core

drilled penetrations are required so as not to cut the steel reinforcing.

2. Cut, remove, and properly dispose of selected electrical equipment, components, and materials as indicated. Included are the removal of electrical items indicated to be removed and items made obsolete by the new Work. Deliver all removed serviceable apparatus to the OWNER as directed.

3. Protect the structure, furnishings, finishes, and adjacent materials not

indicated or scheduled to be removed.

AARHIP 16050-8

4. Provide and maintain adequate temporary partitions or dust barriers that prevent the spread of dust and dirt to adjacent areas.

5. Protection of Installed Work: During cutting and patching operations,

protect adjacent installations.

6. Patch finished surfaces and building components using new materials that are compatible with the original installation and applied by experienced installers

END OF SECTION

AARHIP 16055-1

SECTION 16055

ELECTRICAL REQUIREMENTS FOR SHOP-ASSEMBLED EQUIPMENT

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing, installing and testing shop-assembled equipment as indicated, in accordance with the Contract Documents. Shop-assembled equipment panels and other items are specified under the driven equipment sections and may require external field connection to ancillary devices and other system components for interlocks and alarms. Provide all field wiring as required by the system and equipment specified under the driven equipment sections. This field wiring may not be specified or shown. This equipment includes but is not limited to the following:

1. Air compressors 2. Air conditioning units 3. Belt filter presses 4. Belt thickeners 5. Boilers 6. Centrifuge equipment 7. Chemical feed equipment 8. Electric hoists and cranes 9. Electric water coolers 10. Electric water heaters 11. Elevators 12. Grinding equipment 13. Miscellaneous control equipment 14. Odor control equipment 15. Overhead doors 16. Plate and frame presses 17. Pump and fan equipment 18. Sump pump equipment 19. Temperature control systems 20. Valve and gate operators

B. Related Work Specified in Other Sections, But is Not Limited to, the Following:

1. Section 03310 - Cast-in-Place Concrete 2. Section 09900 - Painting 3. Section 16050 - Basic Electrical Materials and Methods 4. Section 16130 - Electrical Raceway Systems 5. Section 16121 - Wires and Cables - 600 Volts and Below

AARHIP 16055-2

6. Section 16140 - Wiring Devices 7. Section 16220 - Electric Motors 8. Section 16075 - Electrical Identification 9. Section 16060 - Grounding 10. Section 16491 – Control Components and Devices

1.2 REFERENCES


1. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

2. UL 486A - Wire Connectors and Soldering Lugs for Use with Copper Conductors.


A. Design Requirements: Provide the Shop Assembled equipment using the Components and Appurtenances meeting the requirements specified in Division 16.

1.4 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's data on all equipment and

devices in the assembly, including voltages, number of phases, current ratings, capacities and other relevant data.

C. Shop Drawings: Furnish shop drawings for the shop-assembled equipment,

including the following:

1. Layout drawings of the assembly showing accurately scaled basic equipment sections, auxiliary compartments and combination sections. Show special relationships of assemblies to associated equipment, including plan and front views of the equipment. Furnish a device summary.

2. Furnish wiring diagrams for assemblies that show connections to electrical

power. Clearly differentiate between shop-installed portions of wiring and field installed portions.

3. Furnish construction drawings for equipment requiring field assembly.

Clearly differentiate between shop-assembled portions and field assembled portions.

AARHIP 16055-3

4. A manufacturer’s standard connection diagram or schematic showing more than one method of connection is not acceptable unless the intended method is clearly identified.

D. Quality Control: Furnish manufacturer's test reports and certified performance

records of all equipment installed. Furnish field test reports after equipment is installed.


A. Codes: Comply with local codes and all other applicable codes.

B. Regulatory Requirements: Comply with applicable Regulatory Agency requirements.



PART 2 PRODUCTS

2.1 FABRICATION

A. General: Provide shop-assembled equipment as standard products manufactured by companies regularly engaged in the manufacture of such equipment.

B. Factory Assembled Requirements: Provide control panels for shop-assembled

equipment as complete factory assembled units that require only external connections for installation including main disconnect and all electrical features necessary for the proper operation of the units.

C. Controls:

1. Motors 1/2 Hp and Larger:

a. Provide motors suitable for 480-volt, 3-phase, 60-hertz operation,

with all controls at 115 volts or less.

b. Provide a combination circuit breaker along with all required control transformers, relays, timers, heaters and other necessary incidentals to form a complete functioning unit.

c. Provide NEMA Size 1 or larger starters.

AARHIP 16055-4

2. Motors less than 1/2 Hp:

a. Provide motors suitable for 120-volt, single phase operation.

b. Provide manual motor starter with neon pilot light.

3. Provide all controls and equipment as specified in Section16491.

D. Control Components: Install principal control components in NEMA 250 rated enclosures as follows:

AREA ENCLOSURE

Above grade indoor NEMA 12 - Industrial

Outdoor and below grade elevation indoor NEMA 4 - Watertight

Corrosive areas as defined in Section 16050 or as shown.

NEMA 4X - Watertight and corrosion-resistant (stainless steel) (fiberglass-reinforced thermal setting polyester formulation) with stainless steel external hardware. Provide all external operators made of the same materials as that of the enclosures

All areas listed Class I, Division 1 or 2, Group D as defined in Section 16050 or as shown.

NEMA 7 - Explosion-proof

E. Miscellaneous Controls:

1. Provide float switches, pressure switches, limit switches, thermostats and

other auxiliary control devices to satisfy the intended service.

2. Provide contacts rated at 10-amperes, 120 volts, 60-hertz ac, unless otherwise specified.

3. Provide limit switches that function in accordance with contact development

charts.

AARHIP 16055-5

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install shop-assembled equipment as indicated, in accordance with manufacturer's written instructions.

B. Coordination: Coordinate cabling and wiring as necessary to interface installation

of shop-assembled equipment.

C. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with equipment manufacturer's published torque tightening values for equipment connectors. Where manufacturer's torque requirements are not indicated, tighten connectors and terminals in accordance with UL Standard 486A.

D. Grounding Connections: Make equipment grounding connections for the shop-

assembled equipment as specified and shown. Tighten connections in accordance with UL Standard 486A to assure permanent and effective grounding.

E. Adjustments: Make all necessary adjustments to the equipment to provide

complete and satisfactory operation upon completion of the Contract. 3.2 CLEANING AND PAINTING

A. Shop Painting: Paint the shop-assembled equipment enclosures as specified in Section 09900.

B. Field Painting: Clean and touch up scratched and marred surfaces to match

original finish.

END OF SECTION

AARHIP 16055-6


AARHIP 16060-1

SECTION 16060

GROUNDING

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing a complete grounding system as specified and shown. Grounding includes but is not limited to: electric equipment enclosures, transformers, unit substations, switchgears, switchboards, motor control centers, ground grid systems, grounding rods, grounding conductors, bonding jumpers, water pipe connections, and structure metal frames as required.


Following:

1. Section 16050 - Basic Electrical Materials and Methods 2. Section 16130 - Electrical Raceway Systems 3. Section 16121 - Wires and Cables - 600 Volts and Below 4. Section 16080 - Electrical Testing Requirements

1.2 REFERENCES

A. Codes and Standards: The following codes and standards are referred to in this Section:

1. NEC - National Electrical Code.

1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's catalog data for the

following:

1. Grounding and grounded conductors 2. Grounding connectors, clamps and bushings 3. Grounding rods 4. Bonding jumpers

C. Shop Drawings: Furnish shop drawings showing the locations and length of

grounding bus external to enclosures and rods. Label the size and material used for grounding bus and rods. Furnish details pertaining to grounding electrode

AARHIP 16060-2

conductors, grounding and grounded conductors, grounding connections and the ground grid for buildings, structures, lighting units, manholes and handholes.

D. Quality Control: Furnish a field report of the system ground impedance test

results. 1.4 QUALITY ASSURANCE

A. Codes and Standards: Construct a complete grounding system in accordance with applicable ANSI, IEEE Standards and the NEC and local codes.



PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Acceptable manufacturers are listed below. Other manufacturers of equivalent products may be submitted for review.

1. Grounding and Grounded Conductors

a. American Insulated Wire Corporation b. Rome Cable Corporation

2. Ground Plates

a. Burndy Corporation b. OZ/Gedney Company c. Erico Products d. Thomas & Betts

3. Grounding Rods

a. Harger Lightning Protection, Inc. b. Thomson Industries, Inc. c. Carolina Galvanizing Utility Products Division d. Erico Products e. Superior Grounding Systems

4. Electrolytic Grounding System and Grounding Enhancement Material

a. Lyncole XIT Grounding

AARHIP 16060-3

b. Superior Grounding Systems

5. Ground Rod Access Box

a. Strongwell – Quazite b. Hartford Concrete Products, Inc.

2.2 MATERIALS

A. General: Provide conductor sizes as shown or required.

B. Materials: Provide conductors in accordance with the requirements specified in Section 16121.

C. Bare conductors: Provide bare copper conductor where embedded in concrete or

exposed.

D. Insulated Conductors: Provide copper conductor with green color insulation rated at 600 volts where buried in earth, installed in conduits or other enclosed raceways.

2.3 CONNECTORS

A. Grounding Clamps and Bolted Connectors: Provide grounding clamps and bolted connectors suitable for devices or cables being connected.

B. Ground Plates: Provide two-hole, cast, copper alloy, ground plates suitable for

installation in concrete. Fabricate the ground plates with two ½-inch diameter threaded holes and a 4/0 stud for connection to the grounding system.

C. Welding: Provide the exothermic welding process for buried, concealed and

accessible connections to structural members, ground rods, and case grounds. Clean and paint welds embedded in the ground or encased in concrete with asphalt base paint.

D. Bolted Connectors: Provide bolted connectors for grounding to ground buses and

equipment.

E. Pipe Grounding: Provide copper, brass, or bronze grounding clamps for grounding pipes. Do not provide strap type clamps.

F. Grounding Bushings: Provide grounding bushings for conduits where conduits are

not effectively grounded by firm contact to the grounded enclosure.

AARHIP 16060-4

2.4 GROUNDING RODS

A. Length and Size: Provide grounding rods 3/4-inch in diameter and 10 feet long.

B. Grounding Rod Material: Stainless steel.

PART 3 EXECUTION

3.1 INSTALLATION

A. General:

1. Install conductors to preclude exposure to physical damage. 2. Install connections firm and tight.

3. Arrange conductors and connectors without placing strain on the

connections.

4. Bury equipment grounding conductors as shown, or at a minimum of 12 inches below grade.

5. Bring loops or taps up for connection to equipment or other items to be

grounded.

6. Install an insulated grounding conductor in all conduits.

7. When raceways are used to contain and protect grounding conductors, install in accordance with Section 16130 and NEC.

8. Where conductors are installed in nonmetallic raceway, provide the

grounding conductor in addition to the neutral wire, sized in accordance with NEC or as scheduled.

9. Perform exothermic welding with properly sized molds and in dry locations.

B. Grounding Rod Installation:

1. Install grounding rods as shown with the top of the rod a minimum of 12

inches below grade.

2. Drive grounding rods into permanently moist soil.

3. Provide additional ground rod sections as required to reach permanently moist soil.

AARHIP 16060-5

4. Provide cast iron junction box without bottom for access to grounding rod and conductor where shown.

C. Grounding Rod Installation (Alternative installation for dry climate locations)

1. Install grounding rods as shown with the top of the rod a minimum of 12 inches below grade.

2. Auger a 4-inch diameter hole to a depth of 1 foot less that the length of the

ground rod at the installed elevation.

3. Drive the grounding rod 1 foot into the bottom of the hole.

4. Pour the grounding enhancement material into the void around the ground rod using the dosage recommended by the manufacturer.

5. Fill remaining void with excavated material.

6. Provide junction box without bottom, for access to grounding rod and

conductor where shown.

D. Equipment Grounding: Ground each piece of electrical equipment using a conductor in the raceway feeding the equipment in accordance with NEC.

1. Unless specified otherwise, connect transformer enclosures and neutrals to

the grounding system. Connect the neutral ground connection at the transformer terminal. Make the connection from the ground grid to the ground bus and enclosures of switchboards, switchgears and motor control centers, lighting and distribution panelboards, and control, relay and instrumentation panels.

2. Provide two separate, independent, diagonally opposite connections for

power transformers so removal of one connection will not impair continuity of the ground system. Provide ground plates that are imbedded in the concrete pad so that transformers can be removed without damaging grounding system. Install a copper ground connect between ground plates and the transformers.

E. Grounding Conductors: Connect the grounding conductor between the equipment

and the grounding system. Where a ground bar is furnished with the panelboard, connect the grounding conductor to the bar.

F. Miscellaneous Grounding: Provide grounding for the following:

1. Ground receptacles and switches and their metal plates through positive

ground connection to the yoke/strap, outlet box and grounding system grounding wire installed in the conduit.

AARHIP 16060-6

2. Ground racks, supports, frames, covers and metal parts in manholes or

handholes, controllers, motor frames, surge capacitors, arrestors, lighting fixtures, metal structures, exposed noncurrent carrying metal, mechanical equipment, hoist beams, cranes and similar items.

3. Provide ground connections to equipment using ground plates imbedded in

the concrete pad so that the equipment can be removed without damaging grounding system. Provide a copper ground connection between ground plates and the equipment.


A. Tests: Conduct a witnessed test to determine the ground impedance for the entire system using a ground loop impedance tester. Provide a maximum impedance of 2 ohms at any point of the test. Add additional grounding rods if necessary to meet this requirement.

END OF SECTION

AARHIP 16075-1

SECTION 16075

ELECTRICAL IDENTIFICATION

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing materials for the identification of electrical equipment, components, conduits, cables and wiring, and furnishing and installing safety signs.


1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods

1.2 REFERENCES


1. ANSI C2 - National Electrical Safety Code (NESC) 2. ANSI Z535.1 - Safety Color Code 3. ANSI Z535.2 - Environmental and Facility Safety Signs 4. ANSI Z535.3 - Criteria for Safety Symbols 5. OSHA - Occupational Safety and Health Act

1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's catalog data for safety

signs, nameplates, labels and markers.

1. Furnish manufacturer's instructions indicating application conditions and limitations of use; and storage, handling, protection, examination and installation of product.

C. CONTRACTOR's Record Drawings: Furnish CONTRACTOR's record drawings

accurately showing actual location of markers for underground ducts, handholes and manholes, at completion of the Project.

AARHIP 16075-2



1.5 SPARE PARTS


1. Ten safety signs of each size and wording.

B. Packaging: Package spare parts in containers bearing labels clearly designating contents. Identify all spare parts with information needed for reordering. Deliver spare parts in original factory packages.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. W. H. Brady Company 2. Seton 3. Thomas & Betts

2.2 MATERIALS AND COMPONENTS

A. General: Provide identification materials listed and classified by UL or tested by an acceptable Electrical Testing Company certifying the equivalence of the materials to UL listing requirements and OSHA approved.

B. Laminated Plastic Nameplates: Provide engraved three layer laminated plastic

nameplates with black letters on white background and fastened with corrosion-resistant screws. Do not use mounting cement for fastening nameplates.

1. Provide nameplates with 1-inch high lettering for switchgears, switchboards,

motor control centers, control panels, relay panels, contactor panels, panelboards, and similarly grouped equipment, transformers and disconnect switches.

2. Provide nameplates with 1/2-inch high lettering for individual components

of a group such as main breakers, switchgear units, switchboard units, motor control center units and similar devices.

AARHIP 16075-3

3. Provide nameplates with 1/2-inch high lettering for remote motor controllers, control stations, relays and similar equipment.

4. Provide nameplates with 1/2-inch high lettering for each motor identifying

service or function and lettering of an appropriate size to suit each motor.

5. Provide approved laminated directories of circuits with typewritten designations of each branch circuit in each panelboard.

C. Wire Markers: Identify wire bundles and each individual wire.

1. Wire bundles: Provide a brass or rigid fiber identifying tag attached with nylon self locking "Ty-Raps".

2. Wire identification markers: Provide a printed white, heat-shrink, seamless

tubing type with black bold lettering for wires size No. 10 AWG and smaller. Provide a printed self-laminating white, vinyl type with black bold lettering for wires No. 8 AWG and larger.

D. Conduit Marking Paint: Provide conduit marking paint meeting the requirements

of Section 09900. E. Safety Signs: Provide safety signs in accordance with OSHA standard meeting the

requirements of ANSI C2, ANSI Z535.1, ANSI Z535.2 and ANSI Z535.3.

1. Provide safety signs manufactured from vinyl having a minimum thickness of 60 mils with red and black letters and graphics on a white background.

2. Size: 10 inches by 14 inches except signs 7-inch by 10-inch may be

provided where the larger size cannot be applied. 3. Mount safety signs using corrosion-resistant screws. Do not use mounting

cement.

PART 3 EXECUTION

3.1 PREPARATION

A. Surface Preparation: Degrease and clean surfaces to receive nameplates, labels and marking paint.

AARHIP 16075-4

3.2 INSTALLATION

A. General: Install nameplates on the front of equipment, parallel to the equipment lines and secured with corrosion resistant screws. 1. Install laminated nameplates identifying:

a. Each electrical equipment enclosure b. Individual equipment and devices

B. Wire Markers: Identify wire bundles and each individual wire with identification tags as follows:

1. Wire Bundles: Install an identifying tag engraved with the conduit number

where conduits enter motor control centers, switchgear, switchboards, control panels, terminal boxes and the like.

2. Wire identification markers: Provide wire identification markers on each

wire at all termination points and where accessible at manholes, pull boxes, terminal boxes, etc.

a. On power and lighting circuits: The branch circuit or feeder number

as indicated on drawings

b. On control circuits terminated in motor control centers, switchgears, control panels and alike: The field device and terminal number of the opposite end connection.

c. On control circuits at each field device: The panel or compartment

number and terminal number of the opposite end connection.

3. Oversize wire markers so that after heat shrinking the wire marker can be rotated on the wire. Rotate wire markers so that wire identification number is visible.

C. Conduit Markers: Paint colored marking bands on each conduit that is longer than

6 feet at intervals of 20 feet on centers to identify the wiring voltage system contained in the conduit or for identifying the different conduit systems as follows:

1. 15,000-Volt System 2. 4,160-Volt System 3. 2,300-Volt System 4. 480-Volt System 5. 208/120-Volt System 6. 240/120-Volt System 7. 24/48/125-Volt dc System 8. Fire Alarm System

AARHIP 16075-5

9. Telephone System 10. Paging System 11. Security System

D. Safety Signs: Provide safety signs as follows or as shown:

1. Type DS-1 a. Wording: “DANGER - BATTERY CHARGING AREA, NO

SMOKING” b. Location: Within 3 feet of all station battery racks.

2. Type DS-2

a. Wording: “DANGER - ELECTRICAL EQUIPMENT, QUALIFIED

PERSONNEL ONLY” b. Location: At each entrance to electrical rooms, and enclosed outdoor

electrical equipment.

3. Type DS-3 a. Wording: “DANGER - HIGH VOLTAGE, KEEP OUT” b. Location: At each entrance to electrical rooms, and enclosed outdoor

electrical equipment operating at over 600 Volts. Also, on the sides of fences or walls which enclose outdoor equipment operating at over 600 Volts.

4. Type DS-4

a. Wording: “DANGER - HIGH VOLTAGE” b. Location: Outside all equipment operating at over 600 Volts.

5. Type DS-5

a. Wording: “DANGER - POWERED FROM MORE THAN ONE

SOURCE” b. Location: Outside all equipment that operates from more than one

power source.

AARHIP 16075-6

6. Type DS-6 a. Wording: “NOTICE - KEEP DOOR CLOSED” b. Location: On all doors with another safety sign installed.

7. Type DS-7

a. Wording: “CAUTION - CONTROLS & INTERLOCKS POWERED

FROM MULTIPLE SOURCES” b. Location: On all control panel doors.

END OF SECTION

AARHIP 16080-1

SECTION 16080

ELECTRICAL TESTING REQUIREMENTS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements of field acceptance testing of materials and equipment provided under various other sections to determine suitability for installation and energization. Requirements of field testing and certification of electrical equipment and materials provided under various other sections to assess their equivalence to UL Inc. listing/labeling.


Following:

1. All relevant electrical sections.

1.2 REFERENCES


1. NETA - InterNational Electrical Testing Association 2. NIST - National Institute of Standards and Technology

1.3 SUBMITTALS

A. General: Furnish all submittals including the following, as specified in Division 1 and Section 16050.

1. Acceptance Testing Reports: Furnish acceptance testing reports for all

equipment and materials including the following information:

a. Summary of the test b. Description of material or equipment tested c. Description of test including acceptable test values d. Test results e. Analysis of test results with recommendations

2. UL Testing: Furnish standard test parameters in accordance with the

acceptable codes and standards for all the equipment and materials tested for equivalence to UL listing.

AARHIP 16080-2

3. UL Test Reports and Certificates: Furnish test reports and certificates for all equipment and materials tested for equivalence to UL listing, for approval.

PART 2 PRODUCTS

2.1 TESTING COMPANIES

A. Acceptable Testing Companies: Acceptable testing companies are as listed below:

1. MET Electrical Testing Co., Inc. 2. ASET Power Systems Services, Inc.

3. Electric Power Systems, Inc.

4. Electro-Test, Inc.

5. High Voltage Maintenance Corp.

6. UL Underwriters Laboratories, Inc.

7. Other OSHA and NETA approved testing facilities


A. Tests: Furnish all testing and certification in accordance with the latest NETA, ANSI, IEEE and NEMA Standards to meet the UL requirements, NFPA Standards and NEC.

B. Test Equipment: Furnish all testing equipment, cables and appurtenances required

to perform all tests and certifications in accordance with the following:

1. Use instruments that have been calibrated, to assure that they are within rated accuracy in accordance with NIST.

2. Select test instruments that are appropriate for the variable being measured.

PART 3 EXECUTION

3.1 UL TESTING AND CERTIFICATION

A. General: Furnish the test reports and certifications for UL equivalence prior to acceptance of all materials and equipment requiring such tests and certifications.

AARHIP 16080-3

3.2 ACCEPTANCE TESTING

A. General: Furnish acceptance test reports prior to acceptance of all materials, equipment and installations requiring such tests.

END OF SECTION

AARHIP 16080-4


AARHI 16085-1

SECTION 16085

SHORT CIRCUIT AND COORDINATION STUDY

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Short circuit and coordination study and an are flash hazard study for the entire power distribution system.

B. Related work specified in other sections includes, but is not limited to, the

following:

1. Section 16430 - 480 Volt Switchgear 2. Section 16345 - Medium Voltage Interrupter Switches. 3. Section 16275 - Substation Transformers 4. Section 16445 - Motor Control Centers 5. Section 16080 - Electrical Testing Requirements

1.2 REFERENCES


1. IEEE 242, "IEEE Recommended Practices for Protection and Coordination of Industrial and Commercial Power Systems"

2. IEEE 399, "IEEE Recommended Practices for Industrial and Commercial

Power Systems Analysis"

3. IEEE 1584, “IEEE Guide for Arc Flash Hazard Calculation”


5. NFPA 70E – Standard for Electrical Safety in the Workplace

6. OSHA 29-CFR 1910, “OSHA General Industry Book” 1.3 SYSTEM DESCRIPTION

A. Requirements: Furnish a short circuit and coordination study for the entire distribution system. Include the following in the short circuit study:

1. One-line diagram of the entire distribution system identifying all

components considered and ratings of all power devices. Use ANSI device numbers to identify all protective devices.

AARHI 16085-2

2. Calculation of momentary and interrupting fault duties for each bus.

3. Calculation of bus-to-bus impedance values reduced to a common MVA base.

4. Individually consider all motors 100 horsepower and greater. Group motors

less than 100 horsepower into one equivalent motor at the motor control center bus or switchboard distribution section.

5. A table indicating the rating of each interrupting device related to the

calculated duty and suggest changes when appropriate.

6. A table showing settings for all adjustable devices. Furnish these settings as a practical compromise between protection of equipment and coordination of downstream devices.

7. Time-current coordination curves to illustrate the protection and

coordination achieved. Furnish curves that include:

a. Appropriate NEC protection points

b. Appropriate ANSI protection points

c. Transformer magnetizing inrush and through-fault protective curve

d. Motor starting characteristics

e. Cable damage limit levels

f. One-line diagram of system plotted

g. Short circuit current levels

8. Analysis and recommended settings for all adjustable overvoltage, undervoltage and voltage unbalance protective devices. Include voltage and time delay settings.

B. Provide an Arc Flash Hazard Study for the electrical distribution system installed

under this Contract. The intent of the Arc Flash Hazard Study is to determine hazards that exist at each piece of electrical equipment, rated greater than 240-volts. This includes switchgear, panelboards, motor control centers, unit substations, automatic transfer switches, adjustable frequency drives and transformers.

1. Develop scenarios for the arc flash hazard study that consider operation

during normal conditions alternate operations such as emergency power conditions, and any other operations, which could result in an arc flash hazard.

AARHI 16085-3

2. Perform an arc flash hazard study after the short circuit and protective

device coordination study has been updated to reflect installed equipment characteristics and wiring configurations.

3. Incorporate pertinent data, rationale employed, and assumptions in

developing the calculations in the introductory remarks of the study.

4. Perform the study in accordance with applicable NFPA 70E, OSHA 29-CFR, Part 1910 Sub part S and IEEE 1584. Base the results of the arc flash hazard study on IEEE 1584 method.

5. Determine the following for each bus

a. Flash Hazard Protection Boundary

b. Limited Approach Boundary

c. Restricted Boundary

d. Prohibited Boundary

e. Incident Energy Level

f. Required Personal Protective Equipment Class

g. Type of Fire Rated Clothing

1.4 SUBMITTALS

A. Short Circuit and Coordination Study: Furnish all submittals, including the following, as specified in Division 1.

1. An executive summary of the study results and data

2. A tabulation of all protective device ratings compared with calculated fault

duties

3. A tabulation of settings for all adjustable protective devices

4. Copies of all time-current coordination curves

5. Analysis of the data that led to the conclusions and recommendations included in the executive summary

6. The one-line diagram of the system studied, including all rating and

identifications

AARHI 16085-4

7. Copies of all computed results referenced to the one-line diagram and the impedance listing

8. Furnish six bound copies of the final report

B. Arc Flash Hazard Study. Furnish all submittals, including the following, as

specified in Division 1.

1. Provide an Arc Flash Hazard label containing the following information:

a. Flash Hazard Boundary

b. Call/cm^2 Flash Hazard at working distance

c. Class of PEE required

d. Shock Hazard when cover is removed

e. Limited Approach Boundary

f. Restricted Approach Boundary

g. Prohibited Approach Boundary

h. Equipment Identification and Study Date

i. Submit proposed label design for approval. Size and locate the labels so that they can be read by a person 5’-8” tall sanding 3’-0” away.

2. Produce Arc Flash Hazard Evaluation Summary Sheet listing the following

additional items:

a. Bus name

b. Upstream protective device name, type, and settings

c. Bus Line to line voltage

d. Bus bolted fault

e. Protective device bolted fault current

f. Arcing fault current

g. Protective device trip/delay time

h. Solidly grounded column

AARHI 16085-5

i. Equipment type

j. Arc flash boundary

k. Working distance

l. Incident energy

m. Required Protective Fire Rated Clothing Type and Class

3. The contractor shall submit the arc flash hazard study and arc flash warning labels at least 30 days prior to energizing the electrical equipment.

4. Submit three (3) copies of the power systems study and (1) set of warning

labels.

5. Furnish four CD-ROM containing the following:

a. Complete copy of the report in PDF format

b. Acrobat Reader

c. Distribution system one-line diagrams in AutoDesk AutoCAD latest version drawing format.

d. All short circuit and coordination study input data and component

library files in format suitable for input into SKM PowerTools.

e. All voltage data. 1.5 QUALITY ASSURANCE

A. Qualifications: Conduct the short circuit and coordination study using a power-system engineering, study or analysis organization with the following qualifications:

1. Five or more years experience on this type of work

2. A proven computer program for performing 3-phase fault-duty calculations

3. Demonstrated capability for calibrating and setting protective devices.

4. Furnish the services of a lead individual for the study who has a minimum of

five years experience in performing 3-phase, fault-duty calculations.

AARHI 16085-6

B. Conduct the arc flash study using a power-system engineering, study or analysis organization with the following qualifications:

1. Two or more years in performing arch flashing hazard studies of this type.

2. Registered Professional Electrical Engineer licensed in the state of

Michigan.

PART 2 PRODUCTS

Not used

PART 3 EXECUTION

3.1 PREPARATION

A. General: Gather the necessary data to complete the short circuit and protective curve coordination calculations and are flash hazard study. Obtain from field surveys and shop drawings informational data pertaining to product manufacturer, type and rating of PT's, CT's circuit breakers, fusing, relays, auxiliaries, and the like. Distribution equipment and shop drawing data may be reviewed at the site.

B. Data: Estimate the lengths and sizes of cables shown on the one-line diagrams

from the Contract Drawings or from field observations and measurements. 3.2 SHORT CIRCUIT STUDY AND PROTECTIVE DEVICE EVALUATION

STUDY

A. General: Include in the input data for the short circuit study the electric utility company's short circuit contribution, resistance and reactance components of the branch impedances, the X/R ratios, base quantities selected, and other source impedances.

B. Calculations: Calculate the three-phase, bolted, short circuit and single-phase,

line-to-ground short circuit current values. Calculate close and latch duty values and interrupting duty values on the basis of calculated three-phase, bolted, short circuit currents at each bus. Buses include, but are not limited to, transformers, switchgears, medium-voltage motor control centers, switchboards, low-voltage motor control centers, distribution panelboards, pertinent branch circuit panels and other significant locations throughout the system. Include in the short circuit tabulations symmetrical fault currents and X/R ratios. List for each fault location, the total duty on the bus, as well as the individual contribution from each connected branch, with its respective X/R ratio.

C. Protective Device Evaluation Study: Perform a protective device evaluation study

to determine the adequacy of circuit breakers, molded case switches, automatic transfer switches, fuses and cables by tabulating and comparing the short circuit

AARHI 16085-7

ratings of these devices with the calculated fault currents. Apply appropriate multiplying factors based on system X/R ratios and protective device rating standards.

3.3 PROTECTIVE DEVICE COORDINATION STUDY

A. General: Perform a protective device coordination study to provide the necessary calculations and logic decisions required to select or to check the selection of power-fuse ratings, protective-relay characteristics and settings, ratios and characteristics of associated current transformers, and low-voltage, breaker trip characteristics and settings.

B. Study Items: Include in the coordination study all medium and low voltage classes

of equipment from the building or plant service protective devices down to and including the highest rated device in the low-voltage motor control centers and panelboards. Include the phase and ground overcurrent protection as well as the settings of all other adjustable protective devices.

C. Plotted Data: Plot the time-current characteristics of the specified protective

devices on log-log paper. On the plots, include complete titles, representative one-line diagram and legends, significant motor starting characteristics, complete parameters of transformers, and the complete operating bands of low-voltage, circuit breaker, trip curves and fuses. Indicate the types of protective devices selected, proposed relay taps, time dial and instantaneous trip settings, transformer magnetizing inrush and ANSI transformer withstand parameters, cable thermal overcurrent withstand limits and significant symmetrical and asymmetrical fault currents. Adhere to all restrictions of the National Electrical Code and proper coordination intervals and maintain separation of characteristic curves. Furnish the coordination plots for phase and ground protective devices on a system basis. Use a sufficient number of separate curves to clearly indicate the coordination achieved.

D. Tabulation of Data: Furnish the selections and settings of the protective devices

separately, in tabulated form, listing circuit identification; IEEE device number; current transformer ratios and connection; manufacturer and type; range of adjustment and recommended settings. Furnish a tabulation of the recommended power fuse selection for the medium-voltage fuses where applied in the system.

E. Settings: Furnish the protective relay characteristics, tap and time dial settings

required by the coordination study to the switchgear manufacturer for selection of protective devices.

3.4 ARC FLASH HAZARD STUDY

A. General: Perform the arc flash hazard study utilizing data obtained from the Short Circuit and Protective Device Coordination Study. Follow procedures established by IEEE 1584.

AARHI 16085-8

B. Study Items: Include all electrical equipment greater than 240-volts furnished or modified under this Contract.

C. Tabulation of Data: Furnish in tabulated form, the results of the study, detailing

for each equipment the following:

1. Flash hazard boundary

2. Limited approach boundary

3. Restricted boundary

4. Prohibited boundary

5. Incident energy level

6. Required personal protective equipment class

7. Type of fire rated clothing

D. Labels: Provide labels as specified 3.5 STUDY REPORT

A. General: Summarize the results of the power system studies in a final report.

B. Presentation of Short Circuit and Coordination Report: Include the following sections in the short circuit and coordination report.

1. Executive Summary

2. Description, purpose, basis and scope of the study and a one line diagram of

that portion of the power system which is included within the scope of the study

3. Tabulations of circuit breaker, fuse and other protective device ratings

versus calculated short circuit duties, and commentary regarding the same

4. Protective-device, time–versus-current, coordination curves; tabulations of relay and circuit breaker trip settings; fuse selections, and commentary regarding the same

5. Fault current calculations including a definition of terms and guide for

interpretation of computer printout

AARHI 16085-9

C. Presentation of the Arc Flash Hazard report. Include the following sections in the arc flash hazard study report:

1. Introduction

2. Executive summary 3. Recommendations and assumptions

4. One line drawing.

5. Arc flash evaluations summary spreadsheet

6. Bus detail sheets

7. Arc flash hazard warning labels printed in color on adhesive backed labels.

D. Recommendations: Analyze the short circuit, protective device coordination, and

arc flash calculations and highlight any equipment that is determined to be underrated or causes an abnormally high incident energy calculation. Propose approaches to reduce the energy levels. Proposed major corrective modifications will be taken under advisement by the Engineer, and the Contractor will be given further instruction.

END OF SECTION

AARHI 16085-10


AARHIP 16121-1

SECTION 16121

WIRES AND CABLES - 600 VOLTS AND BELOW

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing all wires and cables rated at 600 volts and below for complete electrical systems as shown.


Following:

1. Section 16050 - Basic Electrical Materials and Methods 2. Section 16075 - Electrical Identification 3. Section 16080 - Electrical Testing Requirements

1.2 REFERENCES


1. ASTM B 3 - Standard Specifications for Soft or Annealed Copper Wire

2. ASTM B 8 - Standard Specification for Concentric-Lay-Stranded

Copper Conductors, Hard, Medium-Hard, or Soft

3. TIA/EIA 568-A - Commercial Building Telecommunications Cabling Standard

1.3 SUBMITTALS

A. General: Furnish all submittals, including the following, as specified in Division 1 and Section 16050.

B. Product Data and Information: Furnish manufacturer's catalog data for each type

of wire and cable furnished. 1.4 QUALITY ASSURANCE

A. General: Furnish wire and cable in accordance with applicable IEEE and NEMA standards, meeting the requirements of the NEC and UL listed.

AARHIP 16121-2

B. Tests: Furnish cables factory tested prior to shipment in accordance with ICEA standards for the insulation specified.


A. General: Deliver, store and handle wire and cable in accordance with the manufacturer's instructions and as specified in Division 1.

B. Storage: Store cable reels on concrete or other hard surface or on 2x4 wood

laggings.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Wire and Cable

a. American Insulated Wire Corporation b. Southwire Company c. Rome Cable Corporation

2. Instrumentation Cable

a. Belden b. Dekoron c. The Okonite Company

3. Data (Local Area Network), Data Highway Cable, and Fire Alarm Cables

a. Belden b. Alpha

4. Multiconductor Cable

a. The Okonite Company b. Rome Cable Corporation c. Southwire Company

5. Wire Connectors

a. Thomas & Betts b. 3 M/Electrical Products Division c. Ideal

AARHIP 16121-3

6. Color Coding Marker

a. W. H. Brady Company b. Thomas & Betts

2.2 MATERIALS

A. Conductors: Provide soft drawn or annealed copper conductors with 98 percent minimum conductivity, meeting requirements of ASTM B 3 (solid) or ASTM B 8 (stranded). Use stranded conductors except solid No. 12 and No. 10 AWG may be used in lighting fixture and convenience outlet wiring.

B. Insulation: Provide wires and cables with insulation as follows:

1. Power, control and lighting wiring

a. Single Conductor: Provide insulation as follows:

Conductor Size

NEC Type Letter

Insulation Material

Nos. 14, 12 and 10 AWG

XHHW Cross-linked Polyethylene

No. 8 AWG and Larger

RHW Cross-linked Polyethylene

b. Multiconductor Cables: Insulate individual conductors with 15 mils

of polyethylene or PVC and 4-mil nylon jacket. Wrap the conductors with type binder and an outer jacket not less than 45 mils of PVC. Use ICEA Method 1 for color coding wires.

2. Instrumentation Wiring: The manufacturers’ name and catalog number

shown below are for the purpose of establishing quality and general configuration.

a. Two conductor or single pair: Stranded No. 16 AWG wire, 600 volt

polyethylene insulation, twisted conductors, tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and outer jacket of PVC. Belden Cat. No. 8719.

b. Three Conductor: Stranded No. 16 wire, 600 volt polyethylene

insulation, twisted conductors, tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and outer jacket of PVC. Belden Cat. No. 8618.

AARHIP 16121-4

c. Multiple Pairs or Triads: Provide individually shielded pairs or triad of stranded No. 16 AWG wire with overall shield. Insulate each wire for 600 volts with 15 mils of PVC and a 4-mil nylon jacket. Assemble pairs or triads with tinned copper drain wire and metalized tape shield providing 100 percent shield coverage. Cable pairs or triads together with tinned copper drain wire and overall metalized tape shield.

3. Data (Local Area Network) Cable: The manufacturers’ name and catalog

number shown below are for the purpose of establishing quality and general configuration.

a. Category 5: Provide cable having third party verification to TIA/EIA

568-A Category 5 requirements and constructed of four pair of stranded No. 24 AWG solid copper wire, polyethylene or polypropylene insulation, stranded No. 24 AWG tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and outer jacket of gray PVC. Belden Cat. No. 1624R.

4. Data Highway Cable: The manufacturers’ name and catalog number shown

below are for the purpose of establishing quality and general configuration.

a. Twinaxial: Provide stranded No. 20 AWG tinned copper wire (9.5 ohms/mile), 78 ohm nominal impedance, 300 volt polyethylene insulation, tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and 55 percent tinned copper braid shield (4.1 ohms/mile) and outer jacket of blue PVC. Belden Cat. No. 9463.

5. Fire alarm Cable: Provide cables compatible with the fire alarm system

specified in Section 13851 - Signaling and Alarm. The manufacturers’ name and catalog number shown below are for the purpose of establishing quality and general configuration.

a. Plenum Cable: Provide NEC Type FPLP cable consisting of two

solid conductor No. 16 AWG, 300 volt PVC insulation, tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and red Flamarrest outer jacket. Belden Cat. No. 6220FK.

b. Riser Cable: Provide NEC Type FPLR-CIC cable consisting of two

solid conductor No. 16 AWG, 300 volt silicone rubber insulation with tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and red FRPE outer jacket. Belden Cat. No. 5220FZ.

AARHIP 16121-5

c. General Purpose Cable: Provide NEC Type FPL cable consisting of two solid conductor No. 16 AWG, 300 volt foom high-density polyethylene insulation with tinned copper drain wire, overlapped metalized tape overall shield providing 100 percent shield coverage and red PVC outer jacket. Belden Cat. No. 5220FJ.

d. Provide wire marking meeting the requirements of NFPA 70 Article

760.

C. Printed Data on Covering: Provide the following information printed on the surface of all wires and cables at regular intervals throughout the entire length.

1. Manufacturer or trade name. 2. Size of conductor. 3. Type of insulation. 4. Voltage classification.

2.3 WIRE CONNECTIONS AND CONNECTING DEVICES

A. Connectors for No. 10 AWG and Smaller: Provide insulated compression type butt connectors.

B. Connectors for No. 8 AWG and Larger: Provide UL, Inc. listed compression type

tube connectors for parallel or butt splices. Provide companion preformed plastic insulating covers or tape to provide insulation equal to conductor insulation.

C. Miscellaneous Connectors: Provide preinsulated spring connectors for lighting

and receptacle splices and pigtails.

D. Solderless Lugs: Provide solderless terminal lugs for stranded and multiple solid conductors at connection to terminals or use UL listed crimp tool compression style lugs.

E. Control Wire Terminations: Provide spade lug or pressure type control conductor

connection terminations for control wiring terminations. Provide lug bolting at devices or bus bars with a flat washer, a Belleville washer and a locknut.

2.4 COLOR CODING

A. General: Use a vinyl impregnated cloth tape resistant to oil, dirt and heat for conductor color coding.

AARHIP 16121-6

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Swab new and existing conduits to be used to clear debris and remove moisture before conductor installation. Install conductors in raceways with no splices between boxes.

B. Pulling Equipment: Pull conductors using proper equipment without exceeding

manufacturer's recommendation for maximum pulling tension. Protect conductor insulation jacket at all times from twists, kinks, scrapes, punctures and other damage. Replace damaged conductors. Pull wires and cables into ducts and conduit without the use of lubricants, except where such use is necessary and approved by the cable manufacturer and the ENGINEER. Use UL listed lubricating compound compatible with the conductor insulated jacket and with the raceway.

Use lines of nylon or polypropylene, propelled by carbon dioxide, or compressed air, to snake or pull wire and cable into conduits. Do not use flat steel tapes or steel cables.

C. Conductor Support: Support conductors in vertical risers with woven grips to

prevent loading on conductor connectors.

D. Seals: Provide a seal between the conductor and conduit for conduits entering buildings or from areas where the temperature change may cause condensation or moisture. Seal the conduits after the conductors are in place.

E. Identification: Identify all cables as specified in Section 16075.

F. Color Coded Tape: Apply color coding tape at all terminations and splices with

overlapping turns for a minimum length of two inches, starting two inches back from the termination point. Provide color code tape in all boxes and manholes.

Provide color coding throughout the entire network for service, feeder, branch, control and low energy signal circuit conductors. Use the following color code for conductors.

COLOR CODING

SYSTEM PHASE A PHASE B PHASE C NEUTRAL GROUND 208/120 three phase

Black

Red

Blue

White

Green

AARHIP 16121-7

COLOR CODING SYSTEM PHASE A PHASE B PHASE C NEUTRAL GROUND 480/277 three phase

Brown

Orange

Yellow

White

Green

Control and low- energy signal

Red

---

---

White

Green

Gas and Fire De-tection Systems

Pink

---

---

---

---

Instru-mentation

Tan

---

---

---

---

dc circuits

Olive

---

---

---

---

Fire Alarm System

Red --- --- --- ---

G. Terminations: Leave a minimum of six inches of free conductor at each connected

outlet and a minimum of nine inches at unconnected outlets.

H. NEC Requirements: Install wiring in accordance with applicable provisions of National Electrical Code, and as indicated.

I. Conductor Sizing: Size conductors in accordance with the NEC and the following:

1. Size for branch lighting circuits so that the greatest voltage drop between

lighting panel and center of load does not exceed two percent at rated load.

2. Size conductors to limit the maximum conductor temperature to less than 75 degrees C, except where specifically stated otherwise.

3. Use minimum conductor sizes as follows:

a. Power and lighting branch circuits, No. 12 AWG.

b. 120-volt control circuits, No. 14 AWG.

AARHIP 16121-8

c. Instrumentation and signal wiring, 2 or 3 conductors No. 16 AWG stranded shielded.

4. Conductor Derating: Derate the conductor ampacity for installation in an

ambient temperature of 40 degrees C.

5. Size conductors as shown or as required by the actual load to be served, whichever is larger.

J. Splicing: Install continuous cables without splices in all duct systems. K. Instrumentation wiring: Install instrumentation wiring as follows:

1. Wherever possible provide continuous instrumentation wiring without

splices from field device to instrument. Where connections are required, make all connections in terminal boxes.

2. Terminate instrumentation wiring at terminal blocks only.

3. Where instrumentation wire is required to be connected in a terminal box,

provide an isolated terminal for each shield.

4. Ground instrumentation shields and drain wires only at the panel end of loop.

5. Install clear, heat-shrink, seamless tubing over exposed shields and drain

wires in all terminal boxes, junction boxes, panels and field devices.

L. Hazardous Areas: Seal all conduits in hazardous areas before admission of possible hazardous gases to the area.

M. Accuracy of Information: The number and sizes of wires and conduits indicated

are for guidance only and are not necessarily the correct number and sizes necessary for actual equipment installed. Install as many wires and conduits of the required size as necessary for a complete electrical system, and provide adequately for the equipment actually installed.

3.2 CONDUCTOR IDENTIFICATION

A. Labeling: Label each wire at both termination points and at each splice point in junction boxes. Carry individual conductor or circuit identification throughout, with circuit numbers or other identification clearly stamped on terminal boards and printed on directory cards in distribution cabinets and panelboards.

B. Identification: Where the total number of control and signal wires is three or more

and no terminal board is provided, identify each wire in junction boxes and cabinets by means of plastic slip-on wire marker.

AARHIP 16121-9

C. Plastic Tags: In manholes, identify each wire by laminated plastic tag located so it

can be easily seen.

D. Color Coordination: Connect circuit conductors of the same color to the same phase throughout the installation.

3.3 WIRE AND CABLE CONNECTIONS TO EQUIPMENT

A. General: Provide electrical connections to all equipment in strict accordance with the manufacturer's approved wiring diagrams, the Plans, or as approved. Repair or replace any damaged equipment resulting from erroneous connections.

3.4 CONNECTOR AND TERMINAL LUG INSTALLATION

A. UL Requirements: Install all connectors and terminal lugs in accordance with UL requirements and manufacturer's recommendations.


A. Field Tests: Test the following 600-volt wires and cables after installation but before final connections are made up:

1. All secondary feeders from the substation transformers.

2. All feeders between and from the low voltage switchgear assemblies.

3. All feeders from motor control centers to motors 30 hp and larger.

4. All feeders from variable speed drive units.

5. All feeders from motor control centers, to lighting panels and dry-type

transformers.

6. For the above listed cables, apply a test voltage of 1,500 volts ac for a period of 1 minute between all conductors in the same conduit, and between each conductors and ground.

B. Test Results: Make all tests and submit certified test results. Replace any cables

that fail the tests.

C. Continuity Test: Perform continuity test to demonstrate proper cable connection.

END OF SECTION

AARHIP 16121-10


AARHIP 16122-1

SECTION 16122

MEDIUM VOLTAGE CABLES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing single conductor medium voltage cables and accessories as indicated, in accordance with the Contract Documents.


1. Section 16050 - Basic Electric Materials and Methods 2. Section 16075 – Electrical Identification 3. Section 16080 - Electrical Testing Requirements

1.2 REFERENCES


1. ASTM B 8 - Specification for Concentric Lay Stranded Copper Conductors, Hard, Medium-Hard, or Soft

2. ASTM B 496 - Standard Specification for Compact Round Concentric-

Lay-Stranded Copper Conductors

3. AEIC CS8 - Specifications for Extruded Dielectric Shielded Power Cables Rated 5 through 46 kV

4. UL 1072 - Medium Voltage Power Cables

5. IEEE 400 - IEEE Guide for Making High-Direct-Voltage Tests on

Power Cable Systems in the Field 1.3 SUBMITTALS


B. Product Data and Information: Furnish physical and electrical catalog data for all

cables and cable components and shop drawings for splice kits and terminations.

C. Quality Control: Furnish certified Shop Test Reports for all cable lengths shipped, and AEIC Qualification Test Reports.

AARHIP 16122-2

D. Number of Copies: Submit six copies of certification and warranties as described.



B. Handling: Handle the cables carefully to avoid twists and kinks or other damage

to the insulation.

C. Storage: Store cable reels on concrete or other hard surface or on 2 x 4 wood lagging.

1.5 WARRANTY

A. Written Warranty: Furnish a written 40-year minimum warranty from the cable manufacturer that the cable is free of any factory-incurred defects.

B. Replacement if Found Defective: In the event the cable is found defective in

design, material, or workmanship within the 40-year design life of the cable, remove and replace the defective portion of the cable with another cable meeting the original design specifications for the failed cable. Provide the replacement cable with the same warranty as the replaced cable and at no additional cost to the OWNER.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Medium voltage cable

a. The Kerite Company b. The Okonite Company

2.2 MATERIALS

A. General: Provide single medium voltage power cable consisting of stranded copper conductors, conductor screen, insulation, insulation screen, metallic shield and outer jacket, suitable for use in wet and dry locations in conduit, underground concrete encased ducts, directly buried, and aerial installation. Provide cables rated 105 degrees C for continuous operation, 130 degrees C for emergency overload operation and 250 degrees C for short circuit conditions, UL listed as

AARHIP 16122-3

Type MV-105 in accordance with UL 1072 and manufactured in accordance with AEIC CS8.

B. Conductors: Provide soft drawn, annealed and uncoated copper conductors with

98 percent minimum conductivity in accordance with the requirements of ASTM B 8, with Class B stranding or compact stranding meeting the requirements of ASTM B 496. Provide conductor sizes as scheduled and as required.

C. Conductor Screen (Shield): Provide conductor screen of an extruded layer of

semiconducting, thermosetting compound.

D. Insulation: Provide conductor insulation other than black or grey in color of a compound based on a thermosetting ethylene-propylene elastomer extruded in tandem with and inseparably bonded to the conductor screen. Provide insulation resistant to heat, moisture, impact, ozone and electrical discharge. Provide the insulation thickness as shown below:

1. For nominal 13.2 kV applications

a. Voltage rating15,000 volts b. Insulation thickness 220 mils c. Insulation level 133 percent

E. Insulation Screen (Shield): Provide insulation screen of an extruded

semiconducting compound. Provide insulation screen that is easily removed without requiring the use of heat or special tools.

F. Metallic Shield: Provide 5-mil thick helically applied coated copper tape shield

over insulation screen with a 20 percent minimum overlap.

G. Outer Jacket: Provide an outer jacket of heavy-duty thermoplastic black polyvinyl chloride (PVC).

2.3 COMPONENTS

A. Splice Kit: Provide splice kits and terminations specifically designed for the application as recommended by the cable manufacturer.

B. Connections: Provide splice and connections made up with closed end

compression connectors and terminal lugs. Provide fittings and compression tools of the circular or hexagonal compression type rated for the voltage of the cable.


A. General: Perform the following shop tests in accordance with the requirements of AEIC and furnish certified test reports for all cable lengths shipped.

AARHIP 16122-4

1. Qualification tests 2. High voltage ac and dc tests 3. Insulation resistance test 4. Partial discharge test

B. Test Reports: Furnish certified test report for all cable lengths shipped.

PART 3 EXECUTION

3.1 PREPARATION

A. Conduit Preparation: Mandrell all new and existing conduits and duct lines before installation and swab to remove accumulated moisture and debris before cables are pulled.

3.2 INSTALLATION

A. General: Install all medium voltage cables in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Initial Pulls: Use lines of limited stretch to pull wire and cable into conduits. Do

not use flat steel tapes and steel cables.

C. Lubricants: Provide cable lubricants recommended by the manufacturer when pulling the cables into ducts and conduits.

D. Pull Setup: Provide complete cable pulling setup, including winches, cable reel,

support frames, turning sheaves, guides and the like.

E. Tension Meters: Connect a pulling tension meter to the pulling setup. Arrange the pulling equipment and apply pulling methods so that pulling tensions do not exceed the manufacturer's permissible limits for the cable furnished.

F. Cable Groupings: Arrange cables securely tied, neatly bundled and racked in

manholes.

G. Splices: Do not make splices within the conduit system. Do not make splices within handholes or manholes unless approved.

H. Fireproofing (Arcproofing): Fireproof (arcproof) all medium voltage cables

installed in manholes and pullboxes. Provide fireproofing (arcproofing) with approximately 30 mils thick by 3 inches wide fireproofing tape and applied tightly around each cable spiral in one-half lapped wrapping or in a butt jointed wrapping with a second wrapping covering joints of the first wrapping. Smooth irregularities in cables, such as at splices, with insulating putty before applying

AARHIP 16122-5

fireproofing tape. Install the tape with coated side toward the cable to extend not less than one inch into conduit. Install a random wrapping of glass cloth electrical tape around installed fireproofing tape to prevent unravelling. Provide fireproofing (arcproofing) tape consisting of a flexible, conformable fabric with one side coated with a flame retardant, flexible, polymeric coating or a chlorinated elastomer. Provide tape that is noncombustive and noncorrosive to the cable sheath.

I. Terminators: Install medium voltage termination as recommended by the cable

manufacturer.

J. Lug Bolting: Provide connections at terminals, devices and bus bars made up of a flat Belleville or equal washer, and a locknut.

K. Unacceptable Connections: Do not use indentor type compression fittings.

Mechanical splices or lugs are not acceptable. 3.3 IDENTIFICATION OF CIRCUITS

A. General: Identify all cables in accordance with the requirements contained in Section 16075 and as follows.

B. Color Code: Color code the cables with the following color code scheme.

Phase A - Brown Phase B - Orange Phase C - Yellow Neutral - White Ground - Green

C. Coding Tape: When using color coding tape apply the tape with overlapping turns

for a minimum length of 2 inches starting 2 inches back from the termination point.


A. Inspection: Arrange inspection of the cable (including splices and terminations) installation by the manufacturer. Furnish manufacturer's certificate that the cable was installed property.

B. Field Tests: Arrange the performance of following field tests in presence of the

ENGINEER after terminations have been made up, but before final connections are made to equipment terminals.

1. Cable continuity test using a test light or a buzzer.

AARHIP 16122-6

2. Cable insulation level (high voltage dc) test using approved dc HI-POT equipment in accordance with IEEE 400 for the voltage rating and insulation thicknesses given below; by an independent testing agency:

Voltage Rating

Insulation Thickness

dc Test Voltage

Time of Application

15,000 volts 175 mil 55 kV 15 minutes 15,000 volts 220 mil 65 kV 15 Minutes

END OF SECTION

AARHIP 16130-1

SECTION 16130

ELECTRICAL RACEWAY SYSTEMS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing electrical raceway systems as indicated, in accordance with the Contract Documents.


Following:

1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16132 - Underground Electrical Distribution System

1.2 REFERENCES


1. ANSI C80.1 - Specifications for Rigid Steel Conduit, Zinc Coated

2. ANSI C80.3 - Specifications for Electrical Metallic Tubing, Zinc Coated.

3. ANSI C80.5 - Specifications for Rigid Aluminum Conduit

4. ANSI C80.6 - Intermediate Metal Conduit (IMC) - Zinc Coat

5. ANSI/NFPA 70 - National Electrical Code

6. NEMA RN1 - Polyvinyl Chloride (PVC) Externally Coated

Galvanized Rigid Steel Conduit and Intermediate Metal Conduit.

7. NEMA TC2 - Electrical Plastic Tubing (EPT) and Conduit (EPC-40

and EPC-80)

8. UL 1 - Flexible Metal Conduit

9. UL 6 - Rigid Metal Conduit

10. UL 360 - Liquid-Tight Flexible Steel Conduit

AARHIP 16130-2

11. UL 651 - Schedule 40 and 80 Rigid PVC Conduit

12. UL 797 - Electrical Metallic Tubing

13. UL 1242 - Intermediate Metal Conduit

14. Federal

Specification WW-C-540C - Conduits, Metal, Rigid (Electrical, Aluminum)

1.3 SUBMITTALS



A. Codes: Provide all materials and workmanship to meet the requirements of ANSI/NFPA 70 National Electrical Code.

B. Regulatory Requirements: Provide UL listed components.



PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Rigid steel and intermediate metal conduits and electrical metallic tubing:

a. Allied Tube and Conduit b. Wheatland Tube Company c. LTV Steel Tubular Products Company

2. PVC coated steel conduits fitting and boxes:

a. Robroy Industries b. Occidental Coating Company c. Perma-Cote Industries

AARHIP 16130-3

3. Rigid nonmetallic conduits:

a. Carlon Company b. Certainteed Corporation c. National Pipe Company

4. Aluminum Conduits:

a. Allied Tube and Conduit b. Wheatland Tube Company c. Easco Aluminum

5. Liquidtight flexible steel conduit:

a. Electri-Flex Company b. The International Metal Hose Co. c. Alflex Corp. d. Anamet, Inc.

6. Conduit Fitting and Connectors

a. Appleton Electric Company b. Thomas & Betts c. Crouse Hinds Company d. OZ/Gedney Company e. Killark f. Adalet-PLM

7. Boxes and Enclosures:

a. Appleton Electric Company b. Raco/Bell c. Crouse Hinds Company d. Thomas & Betts e. Hoffman f. Hope g. OZ/Gedney Company

8. Strut Channel and Fittings

a. Allied Tube and Conduit b. B-Line Systems, Inc. c. Kindorf d. Enduro e. Strut Tech f. Unistrut

AARHIP 16130-4

9. Fire Stop System

a. 3M/Electrical Products Division b. International Protective Coatings c. Nelson Electric

10. Terminal Blocks

a. Phoenix Contact b. Entrelec c. Weidmuller

2.2 RACEWAYS

A. General: Provide minimum 3/4-inch raceways.

B. Raceway Requirements: Provide raceways meeting the following requirements:

1. Provide rigid steel, heavy wall, hot-dip galvanized in accordance with the requirements of UL-6 and ANSI C80.1.

2. Provide electrical metallic tubing hot dip galvanized conduit in accordance

with the requirements of UL 797 and ANSI C80.3.

3. Provide PVC coated rigid steel in accordance with the requirements for rigid steel raceway herein and with 40 mils bonded PVC exterior coating meeting requirements of NEMA RN-1. Provide a nominal 2 mil urethane interior coating and a clear urethane coating over the galvanized threads.

4. Provide rigid nonmetallic Schedule 40 PVC in accordance with

requirements of NEMA TC2 and UL 651 with solvent cement joints.

5. Provide rigid nonmetallic Schedule 80 PVC electrical conduit in accordance with the requirements of UL Standard 651 and NEMA Standard TC2 with solvent cement joints.

6. Provide liquidtight flexible single strip steel, hot-dip galvanized conduit

with PVC jacket in accordance with requirements of UL 1. Provide a continuous copper bonding conductor wound spirally between convolutions on the inside of the conduit meeting requirements of UL 360 for conduit sizes 1-1/4-inch and smaller.

7. Provide explosion-proof, heavy duty construction, flexible conduit, with

internal insulation liner for Class I, Division 1, Group D hazardous areas.

AARHIP 16130-5

2.3 FITTINGS

A. General: Provide fittings of similar material as raceways.

B. Fittings Requirements: Provide fittings meeting the following requirements:

1. Set screw or indenter type fittings are not acceptable. Provide threaded connectors for all rigid or intermediate metal conduits.

2. Provide solvent cement connections for all rigid nonmetallic conduits.

3. Provide gland compression type fittings for all electrical metallic tubing.

Provide insulated type connectors.

4. Provide insulated connectors for liquidtight flexible conduit.

5. Expansion/Deflection Fittings:

a. Provide a deflection and expansion coupling for rigid and intermediate metal conduits that have a ¾ inch movement in all directions from normal and a 30 degree angular deflection. Provide coupling that includes internal bonding jumper.

b. Provide a nonmetallic expansion coupling for nonmetallic conduits

that have a 4-inch maximum expansion.

6. Bushings

a. Provide insulated nonmetallic bushing rated 105 degrees C for all installations where bonding is not required.

b. Provide insulated metallic grounding and bonding bushing rated 150

degrees C where bonding is required.

7. Fittings for Hazardous Locations:

a. Provide fittings that conform to the requirements of NEC Chapter 5 for Class I, Division 1or 2, Group D hazardous locations as defined in Section 16050 or as shown.

b. Provide seal fittings designed for 40 percent fill capacity suitable for

either horizontal or vertical installation.

AARHIP 16130-6

2.4 WALL AND FLOOR PENETRATIONS

A. Watertight:

1. For conduit penetrations in new exterior walls or floors provide watertight sealing sleeves consisting of a steel sleeve with pressure ring and clamps.

2. For conduit penetrations in existing walls or floors, provide watertight

sealing bushing consisting of a neoprene sealing ring between two PVC coated steel pressure discs. Provide stainless steel captive screws for sealing ring compression.

B. Fire-proofing Through Fire Rated Construction:

1. Provide a permanent fire stop system for all penetrations through fire-rated

walls, partitions and floors.

2. Design fire stop system to maintain the integrity of the wall or floor assembly for its rated time period.

3. Arrange fire stop system to allow normal pipe movement without being

displaced.

4. Do not utilize asbestos in fire stop systems.

5. Provide an intumescent fire stop system when exposed to flame or heat. 2.5 BOXES AND CABINETS

A. Outlet Box Requirements:

1. Provide galvanized cast iron boxes for galvanized rigid steel and intermediate metal conduit systems.

2. Provide nonmetallic boxes and covers in PVC conduit systems.

3. Provide PVC coated boxes and covers in PVC coated conduit systems.

4. Provide pressed steel boxes and covers in electrical metallic tubing conduit

systems.

5. Provide boxes located in Class I, Division 1 hazardous areas meeting NEMA 7 requirements.

6. Provide corrosion-resistant fiberglass reinforced polyester boxes with

stainless steel hardware in corrosive areas as defined in Section 16050 or as shown.

AARHIP 16130-7

7. Provide watertight gasketed covers held with nonferrous screws for all cast

metal boxes.

B. Junction and Pull Box Requirements:

1. Provide cast aluminum boxes with mounting lugs, threaded hubs and gasket covers for surface mounted boxes

2. Provide fabricated sheet metal boxes when cast metal box weight exceeds 50

pounds. Construct box from 1/8-inch thick galvanized sheet steel or aluminum with sides return channel flanged around cover opening. Provide angle or channel supporting frame. Provide continuously welded and ground smooth seams. Provide mounting lugs and threaded conduit hubs.

3. Provide cast steel or fabricated 10-gauge Type 316 stainless steel for boxes

either partially or fully encased in concrete. For partially encased boxes provide sides return channel flanged around cover opening. For fully encased boxes provide flush covers. Provide continuously welded and ground smooth seams. Provide mounting lugs and threaded conduit hubs.

4. Provide watertight gasketed covers held with stainless-steel captive screw

slot bolts.

5. Provide two padlocking hasps for boxes containing medium voltage cables.

6. Provide steel barriers in all boxes that isolates instrumentation wiring from all other wiring systems

7. Provide fabricated boxes located indoors meeting NEMA 13 requirements.

8. Provide all boxes located outdoors meeting NEMA 4 requirements.

9. Provide boxes located in Class I, Division 1 hazardous areas meeting

NEMA 7 requirements.

C. Terminal Box Requirements:

1. Provide minimum 12 gauge stainless steel fabricated box with mounting lugs, floor stand, and hinged doors.

2. Provide the door with continuous piano hinge and 3 point lockable latch.

Provide print pocket on inside of door.

3. Provide back plate fabricated from 12 gauge minimum steel with white enamel finish for mounting terminals and wire troughs.

AARHIP 16130-8

4. Provide wire troughs consisting of plastic ducts with snap slot design and removable covers. Run all wiring within wire troughs.

5. Furnish a schedule of terminals with the following information

a. Source b. Type of Signal c. Function

6. Provide removable jumpers to allow operation of the equipment.

7. Separate analog terminals from all other terminals.

8. Provide number of terminals shown. Where the number of terminals are not

shown, provide sufficient terminals for each wire entering the terminal box plus 20 percent but not less than 10 spare terminals.

9. Terminals:

a. All catalog numbers refer to Phoenix Contact Type for the purpose of

establishing the standard of quality and general configuration desired.

b. Provide symmetrical type steel mounting rails, DIN-EN50022.

c. Analog Signals: Provide terminals in enclosed housing suitable for wires from 22 to 12 AWG rated 600 volts with gray body, knife disconnect and test connection socket on both sides of disconnect, Phoenix Contact Type UK 5-MTK-P/P.

d. Control and Alarm Signals: Provide terminals suitable for wires

from 30 to 10 AWG rated 18 amperes at 600 volts, blue body, Phoenix Contact Type UK5N BU.

e. 120-Volt Power Wiring: Provide terminals suitable for wires from 18

to 10 AWG rated 30 amperes at 600 volts, hot (black body), neutral (white body), ground (green body) , Phoenix Contact Type UK5N BK, UK5N WH & UK5N GN, respectively.

2.6 SUPPORTING DEVICES

A. Raceway Supports: Provide raceway supports meeting the following requirements:

1. Do not use perforated straps or plumbers tape for conduit supports.

AARHIP 16130-9

2. Provide expansion bolts or inserts for fasteners in concrete, toggle bolts for hollow masonry or frame construction, and preset inserts for prestressed concrete.

3. Conduit Straps and Backs:

a. For metallic conduits, provide steel or malleable iron.

b. For nonmetallic and PVC coated conduits, provide PVC coated

malleable iron with stainless steel anchors and bolts.

4. Conduit Hangers

a. For metallic conduits, provide steel adjustable conduit hangers or clevis hangers.

b. For nonmetallic and PVC coated conduits, provide PVC coated

adjustable conduit hangers with stainless steel hardware.

5. Beam Clamps:

a. For metallic conduits, provide malleable iron with steel bolt.

b. For nonmetallic and PVC coated conduit, provide PVC coated malleable iron with stainless steel bolt.

6. Trapeze Hangers:

a. For metallic conduits provide 12 gauge 1-1/2-inch square steel

channels with steel channel straps to secure conduits.

b. For nonmetallic or PVC coated conduit, provide either PVC coated 12 gauge 1-1/2-inch square steel channels or 1-5/8-inch square fiberglass channels. Provide PVC coated straps with stainless steel bolts for securing conduits.

c. Provide addition channels welded together to limit the deflection to

1/240th of span.

7. Thread Rod

a. Provide thread rod with the minimum size as follows:

(1) Conduit Hangers

(a) 3/4-inch to 1-1/2-inch conduit: 1/4-inch thread rod

AARHIP 16130-10

(b) 2-inch to 3-1/2-inch conduit: 3/8-inch thread rod

(c) 4-inch and larger: 1/2-inch thread rod

(2) Trapeze Hangers: Provide thread rod of sufficient size to support the load. Provide a minimum of 3/8-inch thread rod.

b. For Metallic Conduit Systems: Provide continuous threaded

galvanized steel rod.

c. For Nonmetallic or PVC Coated Conduit Systems: Provide continuous threaded PVC coated galvanized steel rod.

PART 3 EXECUTION

3.1 PREPARATION

A. General: Install electrical equipment and material of the size, type and general routing as shown or required.

B. Coordination with Reinforcing: Install raceway, fittings, boxes and cabinets free

from direct contact with reinforcing steel.

C. Alignment: Provide fasteners, anchor bolts, anchorage items and supports as required to insure proper and rigid alignment. Attach equipment with fasteners sized according to size and weight of the equipment and the thickness of the supporting surface.

D. Aluminum Coating: Where aluminum is placed in contact with dissimilar metal or

concrete, separate contact surfaces with gasket, nonabsorptive tape or coating as specified in Section 09900 to prevent corrosion.

E. Grounding: Make metallic raceways electrically and mechanically continuous and

ground as required. Install conduits continuous between outlets, boxes, cabinets and panels.

3.2 INSTALLATION

A. General: Unless otherwise indicated, install conduits exposed, parallel or perpendicular to building floors, ceilings and walls, and to avoid interference with other work. In architecturally finished areas, conceal conduits within finished walls, ceilings and floors. Cut conduits square and deburr the cuts to the same degree as the conduit manufacturer. Fasten conduit securely to outlets, junction, pull and terminal boxes. Provide caps and seals to prevent the entrance of foreign material and moisture during installation and before pulling wire.

AARHIP 16130-11

1. Where conduit size is not shown, provide conduits one size larger than indicated in Table 4, Chapter 9 of the NEC.

2. Support raceways concealed above suspended ceilings from the slab above

suspended ceiling in same manner as exposed raceways. Do not support raceways from suspended ceiling supports.

3. Keep conduit at least six inches away from high temperature piping, ducts,

flues and surfaces. For mounting on concrete and masonry surfaces provide a minimum of 1/4 inch air space between conduit and mounting surface. Support and fasten conduit to building structural members spaced in accordance with electrical codes. Support conduit at least every eight feet or less in accordance with NEC requirements.

4. When two or more exposed conduits are in the same general routing,

provide parallel installation with symmetrical bends and for three or more provide trapeze hangers. Size trapeze hangers with space for 25 percent additional conduits.

5. Make changes in direction with bends or fittings. Use factory-made bends

or elbows wherever possible. Make field bends and offsets with a hand bender or conduit-bending machine. Provide a bending radius not less than 36-inches for conduits containing medium voltage cables.

6. Run conduit in buildings with no more than the equivalent of three 90

degree bends between pull points. Provide no more than 125 feet of conduit runs between pull points. Provide pull boxes where shown, specified or wherever required to install conductors and to meet the above requirement.

7. Install pull and junction boxes in accessible locations with working space in

front of and around the installation. Obtain approval to locate boxes in finished areas.

8. Install an expansion fitting when a conduit crosses a building structural

expansion joint.

9. Unless otherwise approved, install conduits to cross at right angles to building structural expansion joints.

10. Where approved for encased installation, install conduits in slabs as close to

the middle of concrete slabs as practicable without disturbing reinforcement. Do not use conduit with an outside diameter exceeding one-third of the slab thickness. Do not place conduits closer than three diameters on centers, except at cabinet locations where the slab thickness is increased.

11. Pitch conduits to outlet boxes to avoid trapping moisture. Where dips are

unavoidable in exposed conduit runs, install drain fitting at low point.

AARHIP 16130-12

B. Conduit Material Types: Provide conduit as follows:

1. Provide rigid steel conduits in all installations concealed in structures,

concrete encased within structures or under structures.

2. Provide electrical metallic tubing in all installations above suspended ceilings and in partition constructed walls.

3. Provide rigid steel conduits for all instrumentation and electronic equipment

signal wiring in all exposed or concealed noncorrosive installations.

4. Provide rigid steel conduits underground, concrete encased, unless specifically detailed otherwise.

5. Corrosive Locations

a. Corrosive locations are defined in Section 16050 or are as shown:

b. Provide PVC coated rigid steel conduit in all installations in corrosive

locations.

6. Hazardous Locations:

a. Hazardous locations are defined in Section 16050 or as shown.

b. Install all conduits and appurtenances in accordance with the requirements of Chapter 5 in NEC.

c. Provide seal fittings for all conduits that enter or leave a hazardous

location.

C. Connections to Equipment

1. Provide double locknuts and bushing for all boxes, enclosures and cabinets located in dry areas.

2. Provide watertight hub fittings for all boxes, enclosures and cabinets located

below grade or in wet, damp or corrosive areas.

3. Provide rigid conduit connection where equipment is fixed and not subject to adjustment, mechanical movement or vibration. Provide union fittings to permit removal of equipment without cutting or breaking conduit.

4. Provide liquidtight flexible conduit connection where equipment is subject

to adjustment, mechanical movement or vibration.

AARHIP 16130-13

5. Coat all threads in steel conduit runs with zinc dust in oil or other corrosion-preventive compound before making connections.

D. Underground Conduits: Provide underground conduits meeting the requirements

of Section 16132.

E. Penetrations: Make concealed penetrations for single conduits not more than 1/4-inch larger than the diameter of the conduit. Make penetrations through walls, ceilings and floors other than concrete for exposed conduits not more than 1/4-inch larger than the diameter of the conduit. Fill the voids around conduit with caulking compound and finish the surface the same as the wall, ceiling or floor.

1. Where a conduit enters through a concrete roof or membrane waterproofed

wall, floor or ceiling, provide a watertight sealing sleeve that can be tightened from one or both sides. If the sealing sleeve is not placed with the concrete, core drill the proper size hole to provide a mechanically watertight installation.

2. Where a conduit enters through a concrete non-waterproofed wall, floor or

ceiling, provide a galvanized steel sleeve, Schedule 40, and fill the space between the conduit and sleeve with a plastic expandable compound. If the sleeve is not placed with the concrete, drill the hole not less than 1/2-inch nor more than one inch larger than the sleeve, center the sleeve and grout the sleeve for the total depth of penetrated concrete with non-shrink grout, polyurethane or silicone sealant.

F. Spare Conduit: Provide spare conduits for future use as shown or required.

Provide a minimum 200 pound strength nylon pull line in each spare conduit and identify the origin and termination of the conduit at each end. Terminate spare conduits in equipment, boxes or by couplings plugged flush with the inside of building surfaces.

G. Boxes: Provide boxes of the proper dimensions for the size and quantity of

conductors enclosed.

1. For boxes mounted on steel, concrete and masonry surface, provide a minimum 1/4-inch non-metallic spacer to hold the box away from the surface.

2. Provide pressed metal boxes in all partition constructed walls.

3. Provide separate support for boxes and bolt units to buildings with

expansion anchors, toggle bolts or appropriate screws. For lighting fixture outlet boxes, provide supports adequate to support the weight of the fixture to be mounted on the box.

AARHIP 16130-14

4. Remove debris including dust, dirt, wire clippings and insulation from the interior of boxes. Replace boxes with open conduit holes. Repair or replace damaged boxes as directed.

5. Unless otherwise indicated, mount outlet boxes flush with the finished wall

or ceiling, with the long axis vertical. Unless otherwise shown or specified, provide mounting heights measured from the finished floor to centerline of the outlet box as follows:

a. For switches: 3'-2" . Mount the box for lighting switches on the

strike side of the door.

b. For duplex convenience outlets: Finished areas 12 inches and unfinished areas 2 feet.

c. For clock receptacles outlets: 8 feet.

d. For fixtures and equipment: As shown.

e. For desk telephone outlets: 12 inches.

f. For wall telephone outlets: 48 inches.


A. Field Painting: Paint conduits meeting the requirements of Section 09900.

END OF SECTION

AARHIP 16132-1

SECTION 16132

UNDERGROUND ELECTRICAL DISTRIBUTION SYSTEM

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing and installing underground electrical raceway system consisting of concrete encased conduits, direct buried conduits and cables, manholes, handholes, and outdoor electrical equipment pads as shown.

B. Related Work Specified in Other Section Includes, But is Not Limited to, the

Following:

1. Section 02316 - Excavation - Earth and Rock 2. Section 02317 - Backfilling 3. Section 02900 - Landscaping Work 4. Section 03100 - Concrete Formwork 5. Section 03200 - Concrete Reinforcement 6. Section 03150 - Concrete Accessories 7. Section 03310 - Cast-In-Place Concrete 8. Section 16050 - Basic Electrical Materials and Methods 9. Section 16130 - Electrical Raceway Systems 10. Section 16121 - Wire and Cable - 600 Volts and Below 11. Section 16122 – Medium Voltage Cables 12. Section 16060 – Grounding


A. Provide cast-in-place manholes and handholes where indicated on drawings and constructed in accordance with structural requirements.

B. Performance Requirements: Route conduits to allow pulling-in of conductors as

indicated without exceeding the conductor's tension limits. 1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's data for conduits, manholes

and handholes and all accessories.

AARHIP 16132-2

C. Contractors Shop Drawings: Furnish working drawings for underground electrical raceway system showing conduits, concrete encasement, manholes, handholes, electrical equipment pads and reinforcing. Indicate designation, type, size, location, elevations and slope.



1.5 PROJECT CONDITIONS

A. Existing Conditions: Examine record drawings to determine the location of all obstructions along the conduit or cable route and at the sites of manholes, handholes and outdoor electrical equipment pads.

B. Field Measurements: Field survey, and in critical areas, excavate test pits to verify

locations of probable obstacles along the conduit or cable route and at the sites of manholes, handholes and outdoor electrical equipment pads.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Conduit Spacers

a. Carlon Company b. Underground Devices, Inc.

2. Manhole and Handhole Frames and Covers

a. Neenah Foundry Co.

3. Buried warning tape

a. Thomas & Betts b. W. H. Brady Company

4. Manhole Accessories (pulling irons, cable rack and supports, insulators)

a. Cooper Power Systems Division b. A.B. Chance Company

AARHIP 16132-3

2.2 MATERIALS

A. Conduit: Provide conduits meeting the requirements of Section 16130.

B. Cable: Provide cables meeting the requirements of Section 16121 and 16122.

C. Spacers: Provide rigid plastic, conduit spacers to maintain conduit separation as indicated.

D. Reinforcing Steel: Provide reinforcing steel meeting the requirements of Section

03200.

E. Concrete: Provide concrete meeting the requirements of Section 03310. Dye all concrete used for duct bank encasements “red”.

F. Manhole Frames and Covers: Provide waterproof cast iron manhole frame and

solid bolted cover suitable for H-20 truck load. Cast the word "ELECTRIC" in the cover. Provide frame with a clear opening of 36 inches, unless otherwise shown.

G. Grounding: Provide grounding meeting the requirements of Section 16060.

H. Underground Warning Tape: Provide 6-inch wide detectable type plastic tape in

red (electric), yellow (utility) and orange (communications) colors with suitable warning describing the type of buried electrical lines.

2.3 MANHOLE ACCESSORIES

A. Pulling-in Irons: Provide pulling-in irons constructed of hot-forged, hot-dip galvanized steel.

B. Cable Racks and Supports: Provide racks and supports constructed of heavy-duty,

hot-dip galvanized steel.

C. Insulators: Provide insulators made of high grade, dry process porcelain with smooth glazed surfaces.

PART 3 EXECUTION

3.1 CONDUIT INSTALLATION

A. General: Install underground, concrete encased and direct buried conduits as indicated.

B. Conduit Route: Establish and mark exactly conduit or cable routing. Resolve

routing near existing obstacles and coordinate with other sitework. Maintain a 12-inch minimum longitudinal clearance from the conduit bank encasement or direct

AARHIP 16132-4

buried conduit to adjacent utility lines. Maintain a 6-inch minimum vertical clearance from the conduit bank encasement or direct buried conduit to utility lines at crossovers. Adhere to lines, grades, elevations and dimensions as shown.

C. Trench Excavation: Perform excavation work in accordance with the requirements

of Section 02316.

D. Workmat: Install concrete mat on trench bottom to provide an even base for concrete encased conduit bank in accordance with the requirements of Section 03310.

E. Bedding: Provide a sand cover on trench bottoms for a firm and smooth surface

for direct buried conduits.

F. Spacers: Locate spacers at intervals of approximately four feet and stagger locations at each conduit tier to provide not less than 12-inches of longitudinal separation.

G. Conduit: Place conduit in straight lines and with a minimum slope of 0.25 percent

(3 inches per 100 feet). Slope conduit down to manholes, handholes and structures. Install expansion fittings in straight runs exceeding 100-feet. Secure conduits in place to prevent floating and movement.

H. Bends: Install 12-foot minimum radius bends in horizontal turns and vertical

deflections. For bends used at ends of conduit runs install elbows with 4-foot minimum radius for 6-inch and 5-inch conduits, and elbows with 3-foot minimum radius for 4-inch and smaller conduits.

I. Inside Cleaning: Pull a standard flexible mandrel not less than 12-inches long,

having a diameter approximately 1/4-inch less than the inside diameter of the conduit, through each conduit, then pull a brush with stiff bristles through each conduit. Replace conduit runs that do not allow the passage of the mandrel at no increase in Contract Price. Use the pneumatic method to draw into conduit the nylon or polypropylene pull line. Plug and seal all conduits after cleaning.

J. Concrete Reinforcing: Install concrete reinforcing meeting the requirements of

Section 03200. Provide ductbanks with No. 5 reinforcing, spaced 12 inches on centers, top and bottom, with No. 3 ties at 18 inches, unless otherwise shown.

K. Concrete Formwork: Install concrete formwork meeting the requirements of

Section 03100.

L. Outside Cleaning: Remove dirt, sand and debris around conduits and from workmat, prior to concrete placement.

M. Concrete Placement: Place concrete meeting the requirements of Section 03310.

AARHIP 16132-5

N. Connections to Structures: Install as shown.

O. Backfilling: Backfill meeting the requirements of Section 02317. Provide a sand cover that is 6 inches over direct buried conduits or cables.

P. Underground Warning Tape: Install one underground warning tape for each trench

up to 18 inches wide. For trenches wider than 18 inches provide two underground warning tapes, one at each edge of the trench. Place the tape or tapes 12 inches below the finished grade.

Q. Markers: Provide 4-inch round, 6-inch thick, concrete markers identified with the

letter "E" and directional arrows. Place these markers approximately every 200 feet along straight portions of conduit and cable runs, at each change in direction and at the conduit run end. Install markers to protrude 1-inch above adjacent ground. Allow markers to protrude 1/2-inch in finished lawns. Do not place conduit markers at structures and at conduit risers.

R. Surface Finish: Restore existing pavements and curbs with materials and

construction to match existing. Restore landscaped areas meeting the requirements of Section 02900.

3.2 MANHOLES AND HANDHOLES

A. General: Provide cast-in-place reinforced concrete manholes and handholes as shown.

B. Location: Establish and mark manhole and handhole locations exactly. Resolve

locations near existing obstacles and coordinate with other sitework. Adhere to orientation, elevations and dimensions as indicated.

C. Hole Excavation: Install hole excavations meeting the requirements of Section

02316.

D. Cast-In-Place Manhole and Handhole Construction: Install cast-in-place manhole construction meeting the requirements of Sections 03100, 03200 and 03310.

E. Manhole Entrance: Install concrete rings and frame with cover. Adjust position of

frame and cover to protrude 1-inch above adjacent unpaved ground or to be flush with the finished surface of pavement.

F. Backfilling: Backfill meeting the requirements of Section 02317.

G. Accessories: Install pulling-in-irons, cable racks with supports and insulators,

grounding system and other items as indicated.

AARHIP 16132-6

3.3 OUTDOOR ELECTRICAL EQUIPMENT PADS

A. General: Provide reinforced concrete pads for supporting Outdoor Electrical Equipment as shown.

B. Location: Establish and mark pad locations exactly. Resolve locations near

existing obstacles and coordinate with other sitework under this Contract. Adhere to orientation, elevations and dimensions as shown.

C. Site Excavation: Provide site excavation meeting the requirements of Section

02316.

D. Pad Construction: Install pad construction meeting the requirements of Sections 03100, 03200 and 03310.

E. Conduit Entrances: Install conduit risers and laterals under pads prior to

placement of pads. Separate conduits from pads as shown.

F. Grounding: Install grounding conductors through pads meeting the requirements of Section 16060.

END OF SECTION

AARHIP 16140-1

SECTION 16140

WIRING DEVICES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing, wiring devices and appurtenances as indicated, in accordance with the Contract Documents.


1. Section 16050 - Basic Electrical Materials and Methods 2. Section 16130 - Electrical Raceway System 3. Section 16060 - Grounding

1.2 REFERENCES


1. Fed Spec WC 596 - Electrical Power Connector, Plug, Receptacle and Cable Outlet

2. Fed Spec WS 896 - Toggle and Lock, Flush Mounted Switches

3. CSA C22.2-182.1 - Industrial-type, Special-Use Attachment Plugs,

Receptacles and Connectors

4. UL 20 - General - Use Snap Switches

5. UL 508 - Industrial Control Equipment

6. UL 1682 - Plugs, Receptacles, and Cable Connectors of the Pin and Sleeve Type

1.3 SUBMITTALS




AARHIP 16140-2

1.5 SPARE PARTS


1. Ten 20-ampere, 125-volt, 2-pole, 3-wire, grounding type plugs, NEMA 5-20P, nylon housing, Hubbell Cat. No. HBL5366C

2. Ten 20-ampere, 125-volt, 2-pole, 3-wire, grounding type plugs, NEMA 5-

20P, corrosion resistant, yellow nylon housing, Hubbell Cat No. HBL 53CM66C

3. Four 30-ampere, 480-volt, 3-pole, 4-wire plugs with two 15-ampere pilot

contacts, metal alloy housing with baked polyester epoxy coating, Meltric Cat Nos. FH311 and 89-38043-172. Provide cord grips suitable for servicing the cables for submersible mixers and pumps. Install 2 plugs as described in Part 3.

4. Four 200-ampere, 480-volt, 3-pole, 4-wire plugs, fiberglass reinforced

thermoplastic polyester housing, Meltric Cat Nos. 2PHXXX and 37-28043. Provide cord grips suitable for servicing the cables for submersible mixers and pumps. Install 2 plugs as described in Part 3.

5. Four 20-ampere, 600-volt, 6-pole, 7-wire plugs, metal alloy housing with

baked polyester epoxy coating, Meltric Cat Nos. 01-NA013 and 09-P8061. Provide cord grips suitable for servicing the cables for submersible mixers and pumps. Install 2 plugs as described in Part 3.

6. Ten matching plugs for each type and rating of receptacles furnished.

B. Packaging: Package spare parts in containers bearing labels clearly designating

contents. Identify all spare parts with information needed for reordering. Deliver spare parts in original factory packages.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Standard of Quality and General Configuration: Use of manufacturer's name and model or catalog number is for the purpose of establishing the desired.

B. Configuration And Rating: Provide NEMA specification grade wiring devices in

the type, color, configuration and electrical rating for the service indicated.

C. Symbols: See the electrical symbol list shown for identification of all device types.

AARHIP 16140-3

D. Acceptable Manufacturers: Acceptable manufacturers are listed below. Other

manufacturers of equivalent products may be submitted for review.

1. Hubbell Inc. Wiring Device/Kellems Division

2. Bryant

3. Pass and Seymour

4. Cooper Wiring Devices

5. Leviton

6. Appleton Electric Company

7. Crouse-Hinds Company

8. Meltric

9. Tay Mac Corporation

10. Thomas & Betts 2.2 LIGHTING TOGGLE SWITCHES

A. General: Provide toggle switches of specification grade rated 20- amperes, 120-277 volts ac conforming to Fed. Spec. WS 896 and UL Standard 20. Manufacture switches with back and side wired binding screw type terminals, one piece spring contact arm and terminal plate with silver alloy contacts, one piece steel mounting strap with an assured grounding clip, thermoset body color coded for identification by amperage and a brown toggle. Provide ivory toggles in finished areas.

B. Types:

DESCRIPTION HUBBELL CAT. NO.

Single pole HBL1221 Two pole HBL1222 Three way HBL1223 Four way HBL1224 SPDT HBL1385 SPDT center off momentary contact

HBL1557

AARHIP 16140-4

C. Accessories: Provide a flush neon "ON" pilot light in conjunction with switches controlling equipment whose operation is not evident at the switch location. Provide an engraved nameplate to identify equipment controlled.

2.3 AC MANUAL MOTOR STARTING SWITCHES

A. General: Provide ac manual motor starting switches where overload protection is not required or is provided separately. Provide switches similar in construction to the lighting toggle switches except conforming to UL 508 and rated 30-amperes, 120-277 volts ac.

B. Types:

DESCRIPTION HUBBELL CAT. NO.

Single pole HBL-3031 Double pole HBL-3032

C. Accessories: Provide a flush neon "ON" pilot light in conjunction with switches

controlling equipment whose operation is not evident at the switch location. Provide an engraved nameplate to identify the equipment being controlled.

2.4 CONVENIENCE RECEPTACLES

A. General: Provide specification grade convenience receptacles conforming to Fed. Spec. WC 596 UL listed, with nylon impact resistant face, one piece metal wrap around mounting strap with assured grounding clip, back and side wired binding screw type terminals, brass power contacts and a heavy duty heat stabilized thermoset plastic base. Provide brown devices in unfinished areas and ivory devices in finished areas unless otherwise specified.

B. TYPES:

DESCRIPTION RATING COLOR HUBBELL CAT. NO.

Duplex NEMA 5-20R

20A, 125V, 2P, 3W Brown HBL5362/

Duplex-

corrosion- resistant

NEMA 5-20R 20A, 125V, 2P, 3W

Yellow HBL53CM62

AARHIP 16140-5

2.5 SPECIAL USE RECEPTACLES

A. General: Provide special use receptacles of specification grade in accordance with applicable Fed. Specs., UL, ANSI and CSA Standards.

B. Types:

DESCRIPTION RATING COLOR HUBBELL CAT. NO.

Duplex-ground fault circuit interrupter

NEMA 5-20R 20A, 125V, 2P, 3W

Brown/ Ivory

GFR5352L/ GFR5352IL

Single – twist- lock 3 phase

NEMA L16-30R 30A, 480V, 3P, 4W

Black HBL2730

2.6 TELEPHONE/DATA COMMUNICATIONS OUTLETS

A. General: Provide non-metallic single gang telephone/data communication outlets consisting of a two or three hole straps for mounting modular telephone jacks or Category 6 data jacks.

B. Types:

DESCRIPTION COLOR HUBBELL CAT. NO.

Two hole strap

Ivory FCX244I

Three hole strap

Ivory FCX344I

Telephone Modular Jack (RJ25)

Ivory HBLUEI

Category 6 Modular Jack (T568B Wired)

Ivory HBL6EI

2.7 SUBMERSIBLE MIXER RECEPTACLES

A. Power receptacles rated 100A or less

1. General: Provide submersible mixer and pump receptacles conforming to UL 1682, complete with non-fusible safety switch, receptacle, angle adapter and two or four pilot contacts, threaded cap, silver-nickel pressure contacts

AARHIP 16140-6

capable of breaking full rated loads. Provide the receptacle assembly that are suitable for outdoor installation meeting the requirements for NEMA 4X enclosures constructed from metal alloy with baked polyester epoxy coating.

2. Types

DESCRIPTION RATING MELTRIC

CAT. NO. Single receptacle with two 15 ampere pilot contacts

30A, 480V, 3P, 4W 89-37043-329-NF-172

B. Power receptacles rated above 100A

1. General: Provide submersible mixer and pump receptacles conforming to

UL 1682, complete with receptacle, angle adapter, threaded cap, silver-nickel pressure contacts capable of breaking full rated loads. Provide the receptacle assembly that are suitable for outdoor installation meeting the requirements for NEMA 3R enclosures constructed from fiberglass reinforced thermoplastic polyester material.

2. Types


CAT. NO. Single receptacle 200A, 480V, 3P,

4W 37-24043

C. Control receptacles

1. General: Provide submersible mixer and pump receptacles conforming to

UL 1682, complete with receptacle, angle adapter, threaded cap, silver-nickel pressure contacts capable of breaking full rated loads. Provide the receptacle assembly that are suitable for outdoor installation meeting the requirements for NEMA 4X enclosures constructed from metal alloy with baked polyester epoxy coating.

2. Types


CAT. NO. Control receptacle 20A, 600V, 6P, 7W 09-P4061

2.8 BOXES

A. Outlet Boxes: Provide outlet boxes in accordance with the requirements specified in Section 16130.

AARHIP 16140-7

2.9 PLATES AND COVERS

A. General: Provide covers and plates for the various areas as follows:

1. Architectural Finished Areas: Provide Type 302/304 stainless steel plates and covers for devices.

2. Areas Below Grade, Corrosive and Wet Areas:

a. For switches provide weatherproof, gasketed, covers with external

operating handle.

b. For receptacles provide a weatherproof, gasketed, clear, flame-retardant, jumbo, polycarbonate cover a minimum of 5.4-inches deep, suitable for use with a 10-3 cord that allows the cover to be closed even when the receptacle is in use.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all wiring devices in accordance with manufacturer's recommendations and approved shop drawings as specified in Division 1.

B. Toggle Switches: Install toggle switches applicable for the area environment for

switching lighting or other branch circuit loads.

C. Receptacles: Install receptacles applicable for the area environment.

D. Grounding: Ground all devices in accordance with the requirements specified in Section 16060.

E. Plug Installation: Install plugs on the cables for the following equipment:

1. Submersible Mixer and Pump Plugs:

EQUIPMENT RATINGS QUANTITY WAS Tank Mixer 30A 2 Blend Tank Mixer Power 200A 2 Blend Tank Mixer Control 20A 2

END OF SECTION

AARHIP 16140-8


AARHIP 16220-1

SECTION 16220

ELECTRIC MOTORS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for electric motors as specified.


1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16130 - Electrical Raceway Systems 4. Section 16075 - Electrical Identification 5. Section 16281 – Power Factor Correcting Capacitors 6. Section 16060 - Grounding

1.2 REFERENCES


1. AFBMA 10 - Metal Balls 2. NEMA CP1 - Shunt Capacitors 3. NEMA MG1 - Motors and Generators 4. NEC - National Electrical Code

1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's catalog data for each

motor.

C. Shop Drawings: Furnish shop drawings for each motor detailing arrangement, wiring, conduit boxes, and motor application.

D. Certificate of Compatibility: For each motor controlled by an adjustable frequency

drive, furnish a certificate that the motors are compatible with the adjustable frequency drives and the equipment loads to be driven.

AARHIP 16220-2

E. Quality Control: Furnish test reports for motors as follows:

1. Certified standard commercial test reports for motors 5 hp through 200 hp.

2. Actual shop test reports for motors over 200 hp.

3. Witnessed test reports as specified.

F. Operations and Maintenance Manuals: Furnish operation and maintenance manuals for all motors as specified in Division 1.


A. Codes: Comply with local codes and all other applicable codes.

B. Regulatory Requirements: Comply with requirements of the Regulatory Agencies having jurisdiction over this Project.



PART 2 PRODUCTS

2.1 MANUFACTURERS


1. General Electric Company 2. Ideal Electric 3. Magnetek 4. Reliance Electric 5. Siemens 6. U.S. Electrical Motors 7. TECO/Westinghouse Corp. 8. Baldor

2.2 MATERIALS

A. General: Provide motors and accessories with the equipment as specified under the equipment sections.

AARHIP 16220-3

B. Motor Requirements: Unless otherwise specified, provide motors as follows:

1. Polyphase motors of the high energy efficiency and high power factor type.

2. Motor nameplate horsepower as specified for the driven equipment.

3. Motors that operate continuously over the entire load range of the driven equipment without loading motor in excess of nameplate rating and its specified temperature limit.

4. For motors rated ½ hp to 200 hp operating at 460 volts, 3-phase, 60-hertz,

provide squirrel cage induction type.

5. For motors rated over 200 hp, operating at 460 volts or higher voltages, 3-phase, 60-hertz, provide squirrel cage induction or synchronous type, as specified.

6. For motors less than ½ hp, provide 115-volt, single phase, 60-hertz type.

7. Motors that are suitable for continuous operation with a line voltage

variation within ± 10-percent of rated voltage.

8. Motors that operate continuously in a 40 degrees C ambient.

9. Inverter duty motors when powered from an adjustable frequency drive.

C. Frequent Start Requirements: Provide motors for frequent starting as specified. 2.3 MECHANICAL PROTECTION

A. Indoor Locations:

1. For motors located in dry, clean and well ventilated areas provide open drip-proof type.

2. For motors located below grade, provide totally-enclosed, fan-cooled type

with removable drain plug.

3. For motors located in wet, damp or dusty areas, provide totally-enclosed, fan-cooled type with removable drain plug.

4. In corrosive areas as defined in Section 16050 or as shown, provide totally-

enclosed, fan-cooled type with removable drain plug.

B. Outdoor Locations: For motors located outdoors, provide a totally-enclosed, fan-cooled type with removable drain plug.

AARHIP 16220-4

C. Hazardous Locations: As defined in Section 16050 or as shown or required by the NEC.

1. Class 1, Division 1 Area: Provide totally enclosed fan-cooled explosion-

proof motor.

2. Class I, Division 2 Areas: Provide totally enclosed fan-cooled without brushes, switching mechanisms or other arc-producing devices.

D. Submersible Locations: For operation in an hazardous location, provide a

completely sealed submersible motor. 2.4 BOXES

A. General: Provide oversized conduit boxes on motors to facilitate conductor installation and auxiliary components as required.

1. Provide separate boxes for motor power leads, accessory terminals and RTD

leads. 2. Make conduit box NEMA enclosure ratings compatible with motor

enclosures.

3. Where shown, provide additional space in the power terminal box for the mounting and wiring of the current transformers furnished under the motor protection system.

2.5 NEMA DESIGN AND INSULATION

A. Design Classification: Provide NEMA Design B, unless otherwise specified with NEMA Class F moisture resistant insulation and NEMA Class B, 80 degrees C temperature rise at rated nameplate load.

B. Variable Speed Operation: Provide insulation to protect against adverse affects of

a nonsinusoidal waveform. 2.6 WINDINGS

A. General: Provide copper windings unless otherwise specified. 2.7 BEARINGS

A. Ball and Roller Bearings: Use antifriction ball or roller type bearings at manufacturer's option, unless otherwise specified.

AARHIP 16220-5

B. Regreasable Bearings: Use regreasable bearings with support side thrust loadings, with a AFBMA B-10 bearing life rated at least 100,000 hours, based on a reliability of 90 percent.

2.8 SERVICE FACTOR AND LOADINGS

A. Service Factor: Provide 1.15 service factor for sinusoidal voltage waveforms and 1.0 for nonsinusoidal voltage waveforms unless otherwise specified. Where motors with a 1.0 service factor are furnished, provide motors rated at least 15 percent greater than required brake horsepower.

B. Shaft Loading: Provide steady state shaft loading not to exceed 100 percent of full

load rating under maximum load, excluding the service factor, unless otherwise specified.

2.9 SPEED

A. General: Provide motor speed as specified for the driven equipment.

B. Multispeed: Provide multispeed motors as specified for the driven equipment.

C. Adjustable Speed: Provide motors specifically designed and rated for use with the adjustable speed device furnished.

2.10 TORQUE

A. General: Provide breakdown torque of 200 percent or more of motor full load torque.

B. Locked Rotor: Provide locked rotor torque of 80 percent or more of motor full

load torque.

C. Inertia: Provide necessary WK2 data for special loads to coordinate with motors.

D. Special Motors: Supply special motors where torque requirements exceed standard design.

2.11 SLIDE RAILS AND SOLE PLATES

A. General: Provide slide rails and sole plates as required for proper installation. 2.12 SINGLE PHASE FRACTIONAL HORSEPOWER MOTORS

A. Small Motor Requirements: Provide capacitor or open split phase start, for smaller than 1/2 hp motors unless otherwise specified.

AARHIP 16220-6

2.13 THREE-PHASE MOTORS

A. Induction Motors: Provide horizontal or vertical squirrel cage induction motors for continuous duty with full voltage starting except as otherwise specified.

2.14 EFFICIENCY

A. General: Provide motor meeting the requirements as stated in Table of Full Load Efficiency of Energy Efficient Motors in NEMA MG1-12.

2.15 POWER FACTOR

A. General: Provide motors having the following minimum power factor ratings:

Motor Power Factor - Minimum Percent

Horsepower At 1800 RPMPower Factor

At 1200 RPMPower Factor

1 74.3 69.7

1-1/2 76.5 62.0 2 70.3 70.1 3 79.9 73.7 5 83.8 75.8

7-1/2 82.4 78.2 10 85.0 76.4 15 85.0 81.1 20 84.6 81.9 25 84.5 82.0 30 84.2 82.5 40 84.2 83.3 50 85.0 84.9 60 86.8 85.7 75 86.6 86.0

100 88.3 86.4 125 89.3 85.8 150 88.5 87.5 200 88.5 87.9

B. Power Factor Correction: Provide motors 75-hp and larger with capacitors to

correct the no-load power factor to unity in accordance with Section 16281. Do not provide capacitors for motors controlled by adjustable frequency drives or started by solid-state reduced voltage starters.

Provide capacitors in accordance with the latest NEMA CP-1.

AARHIP 16220-7

2.16 NOISE

A. General: Limit motor machine noise to sound power levels listed in NEMA MG 1-12.

2.17 ACCESSORIES

A. Identification: Provide identification meeting the requirements with Section 16075.

B. Space Heaters: Where specified or shown, provide motor space heaters to prevent

moisture condensation when the motor is not operating. Provide space heaters suitable for 115-volt, single phase, 60-hertz operation.

C. Resistance Temperature Detectors (RTDs): Where specified or shown, provide

motor bearing and winding RTDs of the 100-ohm platinum, three-wire type.

D. Thermal Detectors: Where specified or shown, provide motor winding temperature switches or thermal devices.


A. Shop Tests: Perform actual job motor shop tests for motors over 200 hp. Include standard commercial and additional tests listed below, and special tests listed in other sections.

B. Standard Commercial Tests: Perform the following tests in accordance with

NEMA standards.

1. No load running current and speed

2. Locked rotor current

3. Dielectric routine tests

4. Motor efficiency tests

5. Motor power factor tests

C. Additional Testing: Perform the following additional tests in accordance with NEMA standards.

1. Winding resistance

2. Bearing inspection

3. Power factor at full, 3/4 and 1/2 load

AARHIP 16220-8

4. Efficiency at full, 3/4 and 1/2 load

5. Motor starting torque

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install motors in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1. Make all necessary adjustments to equipment to provide a complete operational system.


A. Inspections and Tests: Perform field preliminary and final inspection and testing for motors as specified in Division 1 and as follows:

1. Preliminary Inspection:

a. Demonstrate that each motor has been properly connected.

b. Check for proper rotation by bumping prior to connecting motor to

driven equipment.

2. Final Test:

a. Measure motor applied voltage and current with equipment operating at full load.

b. Operate equipment as specified.


A. Shop Painting: Paint the motors in accordance with the requirements of Section 09900.

B. Field Painting: Clean and touch up marred surfaces to match the original finish.

END OF SECTION

AARHIP 16266-1

SECTION 16266

ADJUSTABLE FREQUENCY DRIVES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing, installing and testing the 480-volt adjustable frequency drives. Provide drives in individual free standing enclosures, wall mounted enclosures, or incorporated into motor control centers, as shown. Furnish harmonic studies as specified.


Following:

1. Section 01820 - Training 2. Section 09900 - Painting 3. Section 16050 - Basic Electrical Materials and Methods 4. Section 16121 - Wires and Cables - 600 Volts and Below 5. Section 16055 - Electrical Requirements For Shop-Assembled Equipment 6. Section 16075 - Electrical Identification 7. Section 16060 - Grounding 8. Section 16491 - Control Components and Devices 9. Section 16080 - Electrical Testing Requirements 10. Section 11355 - Centrifuge Equipment 11. Section 11395 – Odor Control Equipment, Pug Mill

1.2 REFERENCES


1. NEMA ICS 1 - General Standards for Industrial Control and Systems

2. NEMA ICS 2 - Industrial Control and Systems Controllers, Contactors and Overload Relays Not More than 2000 Volts AC or 750 Volts DC.

3. NEMA ICS 3 - Industrial Control and Systems Factory Built

Assemblies

4. NEMA ICS 7 - Industrial Control and Systems: Adjustable Speed Drives

AARHIP 16266-2

5. NEMA ICS 7.1 - Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems

6. NEMA 250 - Enclosures for Electrical Equipment


8. IEEE 85 - Test Procedure for Airborne Sound Measurements on

Rotating Electric Machinery

9. IEEE 519 - IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

10. UL 845 - Motor Control Centers


A. Design Requirements:

1. Provide adjustable frequency drives to vary the speed of NEMA standard, 3-phase, 460-volt, induction motors and driven equipment by varying the frequency and voltage applied to the motors.

2. Provide adjustable frequency drives that fit in the space shown. Units

exceeding the dimensions shown will not be acceptable.

3. Provide adjustable frequency drives that automatically restart when power is restored after a power outage. Provide control logic so the drive is allowed to restart when power is restored.

B. Rated Output Power: Provide adjustable frequency drives with an output that is at

least 3 percent greater than the driven motor’s full nameplate rating.

C. Torque Output: Provide variable torque or constant torque output drives as required by driven equipment.

D. 6-Pulse Drive Technology: Provide adjustable frequency drives serving motors 75

HP or smaller that utilize 6-pulse drive technology.

E. 18-Pulse Drive Technology: Provide adjustable frequency drives serving motors 100 HP or larger that utilize 18-pulse drive technology.

F. Performance Requirements: Provide adjustable frequency drives to meet the

following requirements of IEEE 519:

AARHIP 16266-3

1. Total harmonic distortion THD (Voltage): Maximum of five percent for general distribution systems as measured at the point of common coupling.

2. Total current harmonic distortion: Not to exceed the values in Table 10.3,

Current Distortion Limits for General Distribution Systems (120 V through 69000 V) of IEEE-519 at the point of common coupling.

3. Capacitor traps for controlling harmonics that require tuning to the power

system are not acceptable.

4. Operate at a minimum efficiency of 93 percent at rated load and base speed.

5. Operate from a 480-volt, 3-phase, 60-hertz supply with a voltage variation of plus 10-percent or minus 20-percent and a frequency variation of plus or minus 2-hertz.

6. Input power factor: Maintain a 95 percent minimum displacement power

factor over a 20 to 100 percent speed range.

7. Operate an induction motor as specified, including a high-efficiency, high-power factor, premium-duty motor, with no detriment to motor life.

8. Operate an induction motor without exceeding a motor sound power level of

96-decibels, A-weighted, when measured in accordance with IEEE 85.

9. Operate under the following ambient conditions:

a. Ambient Temperature: 0 to 40 degrees C b. Humidity: 0 to 95 percent

1.4 SUBMITTALS


B. Product Data and Information: Furnish catalog data including rating and

descriptive literature of all components and systems.

C. Shop Drawings: Furnish the following shop drawings customized for the project:

1. Bill of materials including manufacturers name and catalog number

2. Outline drawings showing dimensions, arrangement, elevations, identification of components and nameplate schedule for all units

3. Interconnection wiring diagrams

AARHIP 16266-4

4. Individual schematic control diagrams for each unit

5. One line diagrams

6. Obtain and enter full performance data for all motors shown

7. Certification that the adjustable frequency drives are compatible with the motors and the equipment loads to be driven

D. System harmonic distortion study: Furnish a system harmonic distortion study as

follows:

1. Obtain data on plant loads and plant operation. Verify electrical service rating including transformer size, short circuit capacity and X/R ratio.

2. Prepare a harmonic distortion study of plant electrical system to determine

voltage and current harmonics at the point of common coupling for worst case speed and load settings.

3. Confirm that the submitted adjustable frequency drives limit the electrical

disturbances below the 5 percent THD (voltage) and below the harmonic current distortion per Table 10.3 as established by IEEE 519.

4. Point of Common Coupling: The point of common coupling is the motor

control center or switchgear directly upstream of the adjustable frequency drive.

5. Include analysis of all data with recommendations.

E. Quality Control: Furnish test reports, certificates of inspection and manufacturer's

instructions.

F. Operations and Maintenance Manuals: Furnish operations and maintenance manuals as specified in Division 1.


A. Standards: Provide all adjustable frequency drives manufactured in accordance with referenced standards.

B. UL Label: Provide a UL Inc. Label or certification of listing for every adjustable

frequency drive for which UL publishes a standard. Where no such standard exists or the manufacturer has alternate labeling like C.S.A. or another recognized testing organization, that may be accepted if they also fit the requirements of the job as determined by the Engineer.

AARHIP 16266-5

C. Codes: Manufacture and install each adjustable frequency drive in accordance with the NEC and local codes.

D. Failure to Meet the Harmonic Requirement: Failure to meet the harmonic

requirement as determined by field measurement: If the installed adjustable frequency drives fail to meet the harmonic limits specified, modify the adjustable frequency drives as follows:

1. Perform work at no additional cost to the OWNER 2. Install additional harmonic reduction equipment until the specified limit is

achieved.

3. In the event that harmonic distortion limits cannot be achieved, replace the adjustable frequency drive equipment with equipment that conforms to this specification.



B. Shipping and Packing: Rigidly brace and protect against weather, damage, and

undue strain, all structures, equipment and materials.

C. Storage and Protection: Furnish clean storage facilities for all equipment delivered but not installed. Provide conditioned air for storage facilities in accordance with the equipment manufacturer's recommendations.

D. Spare Parts: Furnish spare parts at the same time as pertaining equipment. Deliver

the spare parts to the OWNER after completion of the work. 1.7 SPARE PARTS

A. General: Furnish the following spare parts for each type of drive and for each group of similar sized units

1. All parts recommended by the manufacturer in published literature as spare

parts. As a minimum, provide the following:

a. Six of all sizes and types of power and control fuses

b. Six LED displays of each color

c. One speed indicator meter relay

d. Two of each type of push button and selector switch used

AARHIP 16266-6

e. Two keypads of each type used

f. Two printed circuit boards of each type used

g. Four filter capacitors of each size used

h. Four diodes of each type used

i. Four transistors, gate turn off thyristors IGBT’s or SCRs of each type

used

j. Three 12-ounce spray cans of the final finish for touch-up

B. Packaging: Package spare parts in containers bearing labels that identify the job site equipment that they are for and identify all spare parts for reordering. Deliver spare parts in original factory packages.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Acceptable manufacturers are listed below. 1. Allen Bradley

2.2 DESIGN

A. Input Disconnect: Provide an input circuit breaker with an interrupting rating of 65,000 rms symmetrical amperes.

B. Input Reactor: Provide input reactor or isolation transformer, if required, as

determined by system harmonic distortion analysis.

C. Rectifier Section: Provide input section that converts 480-volts, 60-hertz, 3-phase input to a fixed dc voltage using full wave bridge implemented with diodes or SCR’s..

D. Filter Sections: Provide dc link reactor and filter capacitors as required.

E. Inverter Section: Provide adjustable frequency drive inverter section that converts

the fixed dc voltage to an adjustable frequency output utilizing a pulse-width modulation inverter. Maintain a constant volts per hertz ratio on the output with voltage boost for startup as required.

AARHIP 16266-7

F. Control Devices: Provide a digital operator keypad located on the front door to allow setting of all programmable parameters and the following control functions:

1. Start push button 2. Stop push button 3. "Local-Remote" control selection 4. Speed control settings 5. Speed meter with hertz and 0-100 percent scales 6. Output ammeter 7. Elapsed time meter 8. Diagnostics package with fault indication and reset push button

G. Control Features: Provide a control system for each drive that allows the


1. Remote, isolated 4-20 ma speed control input 2. Isolated 4-20 ma speed output 3. Alarm outputs 4. ON/OFF status output 5. Additional features and controls as specified with the driven equipment

H. Internal Control Adjustments: Include the following control adjustments for each

drive:

1. Acceleration time, 4 to 60 seconds 2. Deceleration time, 4 to 60 seconds 3. Minimum speed limit 4. Maximum speed limit 5. Inverter current limit 6. Supply undervoltage trip

I. Protection Features: Provide the following drive protection features:

1. Input line current limiting fuses rated to protect the input circuit breaker

from current in excess of its’ rating during a short circuit condition.

2. Electronic overcurrent protection for instantaneous overload

3. AC input line undervoltage protection, adjustable from 60-100 percent nominal voltage with time delay adjustment and low speed override.

4. Overfrequency protection

5. Phase loss protection

6. DC overvoltage protection

AARHIP 16266-8

7. Logic supply voltage low level protection

8. Line-to-line and line-to-ground output short circuit protection

9. Line-to-line and line-to-ground surge arresters sized for 480-volt 3-phase grounded wye system and any power quality devices required by the drive control microprocessor.

10. Overload capability of 110% of the motor FLA based on the NEC ratings for

60 seconds

11. Control circuit fuses

12. Overtemperature protection

13. Diagnostics module to indicate protection trip conditions

J. Communications: Provide an addressable communication card capable of transmitting the following data over a two-wire network to the Plant SCADA System as specified in Section 16291:

1. Status (ON, OFF, TRIPPED, NO RESPONSE) 2. Input and output current in each phase

3. Output frequency

4. Input and output kW

5. Cause of trip

2.3 COMPONENTS

A. General: Provide circuit breakers, fuses, transformers, push buttons, switches, indicating lights, relays and timers as specified in Section16491.

B. Power Solid State Components: Provide power solid state switching components

with a one minute current rating greater than 110 percent of rated current for variable torque drives or 150 percent of rated current for constant torque drives.

C. Control Power Transformer: Furnish a constant voltage control power transformer

to maintain control power with supply voltage variations from 70-110 percent nominal.

D. Printed Circuit Boards: Apply a clear conformal coating of acrylic to all printed

circuit boards.

AARHIP 16266-9

E. Provide a 15 amp, 120volt – 3 wire grounding type duplex receptacle convenience outlet and lamp for troubleshooting activities in the drive enclosure. Power from the control power transformer.

F. Provide instrumentation and operators as specified to comply with Control

Components and Devices section 16491. 2.4 ENCLOSURES

A. General: Provide adjustable frequency drive drives in NEMA 1 filtered and gasketed enclosures with full rear cover plates.

2.5 IDENTIFICATION

A. General: Provide identification of the adjustable frequency drives and their components as specified in Section 16075.

B. Nameplates: Install nameplates for devices located on doors so they are readable to

a person 5'-8” tall standing 3'-0" in front of the equipment.

C. Location: Locate nameplates so that they are readily associated with items labeled.

D. Additional Nameplate: Where nameplates are installed on removable relay or device doors, install an additional nameplate within the relay or device.

E. Additional Engraving: Where nameplates are located on other compartments than

those served, add additional engraving to identify units served. 2.6 WIRING:

A. General: Provide internal wiring with stranded switchboard wire having 600-volt rated, flame-resistant, type SIS insulation. Use No. 14 AWG wire for control interconnections. Provide power connections as required for the service.

B. Wire Marker: Provide wire markers at each end of all wires.

C. Wiring to Door Mounted Devices: Where wiring connections are made to

equipment mounted on hinged doors, provide connections with extra flexible wires suitably cabled together and cleated.

D. Terminal Blocks: Provide wiring of all control connections to all external

connections through individual, positive-latch, pull-apart type control terminal blocks rated 600-volts. Locate terminal blocks for front access.

E. Terminal for External Connections: Provide sufficient terminals for all devices

external to the adjustable frequency drive.

AARHIP 16266-10


A. Shop Test: Shop test each adjustable frequency drive in accordance with IEEE and NEMA standards, including high potential tests and other standard tests for that particular class of equipment. Notify the OWNER fourteen (14) days prior to start of factory testing so that the OWNER, at his option, may witness the testing.

1. After final assembly, test each adjustable frequency drive at full load with

application of line-to-line and line-to-ground bolted faults and show that the adjustable frequency drive trips electronically without device failure.

2. After all tests have been performed, burn-in each adjustable frequency drive

for 40 hours at 100 percent inductive or motor load.

3. After the burn-in cycle is complete, subject each adjustable frequency drive to a 30 minute cycling motor load test before inspection and shipping.

B. Operational Tests: After the equipment has been completely assembled, perform

operational test to determine operating conditions and circuit continuity. Provide pushbuttons and selector switches to simulate all control input contacts and indicating lights to indicate all control outputs. Provide a 4-20ma signal generator to simulate analog signals.

C. Test Equipment: Provide all equipment, devices, instrumentation, and personnel

required to perform the tests. Upon satisfactory completion of the test, submit two (2) certified copies of the test report to the ENGINEER. Component failure during testing will require repeating any test associated with the failure or modified components to demonstrate proper operation.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all equipment in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Protective Adjustments: Set all adjustable circuit breakers per the approved short

circuit and coordination study.

C. Operational Adjustments: Set all operational devices for proper system operation.

D. Cable Connections: Terminate and label all field wiring per approved drawings.

AARHIP 16266-11


A. Inspections: Inspect, adjust and check the installation for physical alignment, cable terminations and ventilation.

B. Tests: Perform the following field tests:

1. Close and open each circuit breaker to test operation

2. When site conditions permit, energize and de-energize each equipment item

served by each drive, testing the complete control sequence of each item including acceleration and deceleration over complete operating range.

3. Harmonic Measurement: Perform a harmonic system analysis to

demonstrate full compliance with IEEE 519 voltage and current harmonic distortion requirements specified. Accurately measure the amplitude of the harmonic current imposed on the 60 hertz sine wave with a harmonic spectrum analyzer. Where limits are exceeded comply with paragraph 1.5D.

4. Operate each adjustable frequency drive with driven equipment at full load

base and minimum speeds and test for hot spots. 5. Test Reports: Furnish detailed test reports of all tests indicating test

performed, discrepancies found, and corrective action taken.

C. Manufacturer’s Field Services Representative: Provide the services of a factory-trained service engineer, specifically trained on the adjustable frequency equipment to assist in installation, start-up, testing, calibration, placing into operation and provide training, as specified in Section 01820.

1. Provide a service engineer when each drive is placed into operation.

2. Provide a service engineer at the jobsite as often as necessary until all

problems are corrected and the equipment installation and operation are satisfactory.

3. Following completion of installation and field testing provide training for

the designated employees of the OWNER in the proper operation, troubleshooting and maintenance of the equipment as outlined below. All training will be at the OWNER’S facilities at a time agreeable to the OWNER:

a. Operational Training: A minimum of two 4-hour sessions combining

both classroom and hands-on instruction, excluding travel time.

AARHIP 16266-12

b. Maintenance Training: A minimum of two 4-hour sessions combining both classroom and hands-on instruction, excluding travel time.

4. Provide service engineer at the job site as often as necessary to assist in the

programming of the SCADA system in accessing the memory map of each device.

5. Comply with all requirements of Section 01820, Training and those

contained herein. 3.3 CLEANING AND PAINTING

A. Shop Painting: Paint the adjustable frequency drive equipment as specified in Section 09900.

B. Field Painting: Furnish three 12-ounce spray cans of the final finish for touch-up.

Touch-up scratched and marred surfaces to meet the requirements of Section 09900.

END OF SECTION

AARHIP 16275-1

SECTION 16275

SUBSTATION TRANSFORMERS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing substation transformers complete and ready for operation, including (fused primary disconnect switch), (secondary circuit breakers) all accessories and appurtenances necessary for a complete installation and shop and field tests.


1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16060 - Grounding 4. Section 16075 - Electrical Identification 5. Section 16080 - Electrical Testing Requirements 6. Section 16344 - Medium Voltage Fuses 7. Section 16345 - Medium Voltage Interrupter Switches 8. Section 16430 - 480 Volt Switchgear

C. All Inclusive Assembly and Responsibility: The materials specified herein and

otherwise referenced under related work Section 16275, 16344 and 16345, are part of the overall assembly identified as Unit Substation USS-5 on the plans. The components comprising Unit Substation USS-5 with all required interconnecting bussing are to provided by a sole source supplier responsible for the overall assembly meeting the requirements of this and referenced specification sections.

1.2 REFERENCES


1. IEEE C57.12.91 - Test Code for Dry-Type Distribution and Power Transformers


3. UL 486A - Wire Connectors and Soldering Lugs for Use with

Copper Conductors

AARHIP 16275-2


A. General: Provide substation transformers made up of factory-built standardized units, dry type self cooled, completely dead front, totally enclosed and freestanding, with side wall mounted primary and secondary terminations, including accessories, controls and metering with auxiliary compartments and interconnections as shown.

B. Rating: Provide Transformer, with the following ratings:

1. Primary Voltage 4.8/13.2 kV 2. Primary Connection Delta 3. Secondary Voltage 480/277 volts 4. Secondary Connection Wye 4 wire (with insulated ground) 5. kVA as shown 6. BIL 95 kV 7. Impedance (5.75) ± 7-1/2 percent 8. Phase(s) 3 9. Hertz 60

C. Fused Primary Disconnect Switch: Provide a fused primary disconnect switch

meeting the requirements of Section 16345 and Section 16344. 1.4 SUBMITTALS


B. CONTRACTOR's Drawings: Furnish working drawings customized for the

project for the transformer, including the following:

1. Manufacturer's data showing service voltages, number of phases, kVA ratings, voltage taps, temperature rise, BIL, weight, support points and standard accessories.

2. Layout drawings showing accurately scaled basic equipment sections and

openings for cable and conduit. Include plan and front views.

3. Interconnection diagrams, with equipment external to the transformer clearly shown.

4. Wiring diagrams showing voltage taps and high and low voltage

connections.

5. Bills of Material.

6. Catalog data for all accessories and appurtenances.

AARHIP 16275-3

7. Shop test procedures complete with instrument calibration data.

8. Spare parts list.

C. Operation and Maintenance: Furnish transformer operation and maintenance

manuals as specified in Division 1.

D. Source Quality Control: Furnish the following:

1. Manufacturers certificates for insulation rating, temperature rise, impedance and high potential tests of the primary and secondary connections.

2. Certified copies of the factory and shop test results.



B. Packing: Suitable pack all structures and equipment, rigidly braced, and protected

against weather, damage, and undue strain during shipment. 1.6 SPARE PARTS

A. General: Furnish the following spare parts:

1. Parts or material that may be necessary for the proper maintenance and operation of the transformers and cooling system.

2. Three 12-ounce spray cans of the final finish for touch-up

B. Special Tools: Provide a set of special wrenches as required for each transformer.

C. Packaging: Plainly tag and mark spare parts for identification and for reordering,

and properly box and wrap spare parts to prevent deterioration. Completely identify the box on the outside.

PART 2 PRODUCTS

2.1 MANUFACTURERS


AARHIP 16275-4

1. Substation Transformer

a. General Electric Company b. ABB Power T&D Company Inc. c. Square D Company

2.2 SUBSTATION TRANSFORMER

A. General: Provide transformers and accessories and appurtenances designed, assembled and tested in accordance with applicable IEEE, ANSI and NEMA standards. Provide all electrical equipment suitable for operation at their standard nameplate ratings in accordance with applicable IEEE and ANSI standards.

B. Primary Fused Disconnect Switch: Provide close coupled primary fused disconnect

switch as specified in Sections 16345 and 16344.

C. Secondary Equipment: Provide a close-coupled Secondary 480-Volt Switchgear as specified in Section 16430.

Provide suitable structural base members to permit plumb and level installation of the substation transformer on its concrete pad.

2.3 CAST COIL TYPE DRY TRANSFORMER

A. General: Provide the transformer with side-wall mounted primary and secondary terminations.

B. Construction: Provide transformers of a solid-cast, dry-type, mounted in a suitable,

ventilated indoor enclosure.

C. Temperature Rise: Provide average temperature rise of the transformer windings not to exceed 80 degrees C when the transformer is operated at full nameplate rating. Furnish a transformer capable of carrying 100 percent of nameplate kVA rating in a 40 degrees maximum, 30 degrees C average ambient as defined by IEEE C57.12.00.

D. Taps: Provide two 2-1/2 percent full-capacity above normal and two 2-1/2 percent

full-capacity below normal primary taps.

E. Windings: Provide copper conductors for both the high voltage (HV) and low voltage (LV) windings. Separately cast each HV and LV windings as one rigid tubular coil, and arranged coaxially. Fully reinforce each coil with glass cloth, and cast under vacuum to provide complete, void-free resin impregnation throughout the entire insulation system. Reinforcement with suspended particulate matter (filled-resin) is not acceptable. Support coils by cast epoxy bottom supports and space blocks and spring loaded top blocks in order to absorb thermal expansion

AARHIP 16275-5

and contraction of the coils. Rigid mechanical connection between HV and LV coils will not be accepted.

F. Windings Absorption and Storage: Provide windings to not absorb moisture, and

suitable for both storage and operation in adverse environments, including prolonged storage in 100 percent humidity at temperature from -40 degrees C to +40 degrees C. Provide the transformer that are capable of immediately being switched on after such storage periods without requiring predrying.

G. Ventilation: Provide all ventilating openings in accordance with NEMA and NEC

standards for ventilated enclosures.

H. Enclosure Base: Provide transformer base that permits rolling or skidding in any direction, and equip with jacking pads designed to be flush with the transformer enclosure.

I. Forced Air Cooling: Provide fan cooling system automatically controlled by

sensors placed in the LV air ducts to increase the transformer capacity by 33 percent. Provide cooling system that consists of fans, control wiring, controller with test switch, current limiting fuses, indication lights, alarm silencing relay, and necessary push buttons to properly control the system. Derive the power for the fan cooling system from a 240 volt, single phase control power transformer located in the primary disconnect switch compartment.

J. Testing: Conduct the following tests in accordance with IEEE C57.12.91:

1. Ratio 2. Polarity 3. No-Load Loss 4. Excitation Current 5. Impedance 6. Full Load Loss 7. Applied Potential 8. Induced Potential

2.4 WIRING

A. General: Provide completely assembled transformers, wired, and tested at the factory, including buses, connections, insulators, cleats, terminals, and terminal blocks. Insulate all current carrying parts. Run all low voltage wiring in high voltage compartments in conduit or in metal wiring troughs. Provide terminal blocks with approved covers and mounted so that the wires to them can be grouped and laced together in a neat and workmanlike manner. Provide cup washers for wires No. 12 and smaller and solderless lugs for larger sizes. Provide a sufficient number of terminal connections, including 15 percent of spare terminals, for all control and instrument wiring. Provide No. 14 AWG stranded copper or larger, insulated with NEC Type SIS for 600 volts for all low voltage wiring.

AARHIP 16275-6

2.5 TEMPERATURE RISE

A. General: Do not exceed the temperature rise of switching devices within the enclosure as permitted by the standards for such devices and measured over the average ambient. Provide temperature rise of buses and connections not exceeding 35 degrees C over the average air temperature inside the enclosure.

2.6 IDENTIFICATION

A. General: Provide the substation transformer with a nameplate identifying the circuit or unit controlled. Identify all switches, meters, instruments, and other features as specified in Section 16075.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Arrange the transformer equipment as shown, and suitable for installation in the spaces as shown without appreciable revision to other equipment, foundation arrangements and structures.

B. Conformance: Install transformer assembly as indicated, in accordance with

manufacturer's written instructions and with recognized industry practices; comply with NEMA Standards, NEC, applicable ANSI Publications and local codes.

C. Coordination: Coordinate with other work including cabling/wiring work to

interface installation of transformer assembly.

D. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with equipment manufacturer's published torque tightening requirements for equipment connectors. Where manufacturers' torquing requirements are not included, tighten connectors and terminals in accordance with UL Standard 486A.

E. Grounding Connections: Make equipment grounding connections for the

transformers and appurtenances. Tighten connections in accordance with UL Standard 486A for permanent and effective grounding.

F. Adjustments: Make all necessary adjustments to the equipment to provide

complete and satisfactory operation upon completion of the Contract.

G. Neutral Connections: Make suitable provisions for connections to the neutral cables from the transformer secondary and to the ground cables from the grounding system.

AARHIP 16275-7


A. Manufacturer’s Representative: Provide a factory-trained, authorized representative of the manufacturer as specified in Division 1. Provide all instruments necessary to conduct required tests and adjustments. Have the manufacturer's representative utilize prepared comprehensive check sheets covering inspections, checks and tests required for the assembly of the product. Submit copies of these documents executed and signed by the manufacturer's representative. Have the representative present when the equipment is placed in operation. Provide representative service as often as necessary until all problems are corrected and the equipment is installed and operating satisfactorily.

B. Certified Report: Furnish a written report certifying that the equipment (1) has

been properly installed, (2) is in accurate alignment, (3) is free from any undue stress imposed by connecting piping or anchor bolts, and (4) has been operated under full load conditions and that it operated satisfactorily.

C. Testing: Furnish an ac or dc 5-minute high potential test applied after the

installation is complete for all substation equipment. Provide test voltages in accordance with the IEEE and NEMA Standards for the voltage class of equipment and components to be tested. Provide tests for all bus, cable, wire, switches, breakers, transformer, and control devices.


A. Shop Painting: Paint the substation transformers as specified in Section 09900.

B. Field Painting: Furnish three 12-ounce spray cans of the final finish for touch-up. Touch-up scratched and marred surfaces to meet the requirements of Section 09900.

END OF SECTION

AARHIP 16275-8


AARHIP 16344-1

SECTION 16344

MEDIUM VOLTAGE FUSES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing medium voltage fuses for medium voltage interrupter switches.


Following:

1. Section 16050 - Basic Electrical Materials and Methods 2. Section 16275 - Substation Transformers 3. Section 16345 - Medium Voltage Interrupter Switches


A. Provide medium voltage fuses for use with medium voltage interrupter switches. 1.3 SUBMITTALS


B. Shop Drawings: Furnish catalog data and time-current curves for the medium

voltage fuses. 1.4 DELIVERY, STORAGE AND HANDLING


PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Boric Acid Type

a. ABB Power T&D Company Inc.

AARHIP 16344-2

b. S&C Electric Company c. Cooper Power Systems

B. Boric Acid Type Fuse

1. Provide boric acid expulsion type fuses having an interrupting capacity of

29,000 rms symmetrical amperes. Equip each fuse with a discharge filter. Provide fuses with the voltage class corresponding to the intended service.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all fuses in accordance with manufacturer's recommendations and approved shop drawings and as specified in Division 1.

END OF SECTION

ARRHIP 16345-1

SECTION 16345

MEDIUM VOLTAGE INTERRUPTER SWITCHES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing medium voltage interrupter switches, complete and ready for operation, including fuses, all accessories and appurtenances necessary for a complete installation and shop and field tests.


Following:

1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16075 - Electrical Identification 4. Section 16275 - Substation Transformers 5. Section 16344 - Medium Voltage Fuses 6. Section 16060 - Grounding 7. Section 16080 - Electrical Testing Requirements 8. Section 16210 - Utility Coordination and Requirements 9. Section 16291 - Electrical Monitoring System 10. Section 16430 - 480 Volt Switchgear


otherwise referenced under related work Section 16275, 16344 and 16345, are part of the overall assembly identified as Unit Substation USS-5 on the plans. The components comprising Unit Substation USS-5 with all required interconnecting bussing are to provided by a sole source supplier responsible for the overall assembly meeting the requirements of this and referenced specification sections.

1.2 REFERENCES


1. IEEE C37.20.3 - Standard for Metal-Enclosed Interrupter Switchgear

2. IEEE DRAFT C37.20.4 - Standard for Indoor AC Medium-Voltage

Switches used in Metal-Enclosed Switchgear.

3. IEEE C37.90 - IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus

ARRHIP 16345-2

4. UL 486A - Wire Connectors and Soldering Lugs for Use

with Copper Conductors 1.3 SYSTEM DESCRIPTION

A. General: Provide medium voltage interrupter switches made up of factory-built standardized units, totally enclosed, and freestanding, including accessories, controls and metering with auxiliary compartments and interconnections as shown meeting the requirements of IEEE C37.20.3 and IEEE DRAFT C37.20.4.

1.4 SUBMITTALS


B. CONTRACTOR's Drawings: Furnish working drawings customized for the

project for the medium voltage interrupter switch including the following:

1. Manufacturer's data showing service voltages, number of phases, temperature rise, BIL, weight and standard accessories.

2. Layout drawings showing accurately scaled basic equipment sections and

openings for cable and conduit. Include plan and front views.

3. Interconnection diagrams, with equipment external to the transformer.

4. Catalog data for all accessories and appurtenances.

C. Operation and Maintenance: Furnish operation and maintenance manuals for the switches as specified in Division 1.

D. Quality Control: Furnish the following as specified in Division 1.

1. Manufacturers certificates for insulation rating, temperature rise, impedance

and high potential tests of the medium voltage interrupter switches.

2. Certified copies of the factory and shop test results. 1.5 DELIVERY, STORAGE AND HANDLING


1. Provide all structures and equipment suitably packed, rigidly braced, and

protected against weather, damage, and undue strain during shipment.

ARRHIP 16345-3

B. Storage and Protection: Store all equipment and materials in a dry, covered, heated and ventilated location. Provide any additional measures in accordance with manufacturer's instructions.

1.6 SPARE PARTS


1. Two complete sets of replacement power fuses for each medium voltage interrupter switch.

2. Complete set of replacement fuses for all potential transformers.

3. Complete set of replacement fuses for all low voltage circuits.

4. One current transformer of each type and rating provided.

5. Test jumpers as required.

6. Two hook sticks.

7. One neon tube test stick with neon tubes and ground cable and clamp.

8. Two insulated handle adjustable fuse pullers.

9. Three 12-ounce spray cans of the final finish for touch-up.

10. Provide two complete sets of replacement power fuses for the 13.2 KV

implementation of the USS-5 transformer assembly.

Any other parts or material that may be necessary for the proper maintenance and operation of the switches.

B. Special Tools: Provide a set of special wrenches as required for each switch.

C. Packaging: Plainly tag and mark spare parts for identification and for reordering,

and properly box and wrap spare parts to prevent deterioration. Completely identify the box on the outside.

PART 2 PRODUCTS

2.1 MANUFACTURERS


ARRHIP 16345-4

1. Medium Voltage Switches

a. Cutler Hammer b. General Electric Company c. S&C Electric Company d. Square D Company

2. Microprocessor Based Protective Relays and Metering Systems

a. Cutler Hammer IQ-4000 b. General Electric Company Multilin c. Square D Company Powerlogic

2.2 MEDIUM VOLTAGE INTERRUPTER SWITCH

A. General: Provide fused medium voltage interrupting switches of the load break type with separate main, make and break contacts and quick make-quick break operation independent of the handle speed.

Provide the switch with two positions, open and closed, with an intermediate position impossible. Provide the operating mechanism with sufficient power to overcome the magnetic blow-out forces when closing the switch into a fault. Provide the switch with separate main, make and break contacts, providing maximum endurance when closing during a fault or load interruption. Provide spring loaded arcing contacts on the making and breaking to provide the first in and last out features.

Provide arc interruption within arc chutes that produce a high dielectric gas to assist in extinguishing the arc.

B. Ratings: Rate each switch as follows:

1. Nominal voltage 4.16/15 kV 2. Basic impulse level 95 kV 3. Continuous current 600 amperes 4. Interrupting current 600 amperes 5. Fault closing 61,000 amperes 6. 2 Second fault current 38,000 amperes 7. Momentary current 61,000 amperes

C. Power Fuses: Provide power fuses meeting the requirements of Section 16344.

2.3 STRUCTURE

A. General: Provide the switch structure built of welded structural steel members, with formed or fitted sections of smooth steel sheet not less than 11-gauge front

ARRHIP 16345-5

and 13-gauge top, rear and sides. Provide adequate means of ventilation as well as heating elements to prevent condensation.

1. Provide a formed hinged front door and rear panel with concealed hinges,

stops, and handles of cast bronze, and a shape such as to accept and protect a padlock under the top of the handle. Provide a rectangular high impact viewing window in the door. Provide padlocks suitable for outdoor use, each with four keys, and master-keyed as directed.

2. Provide removable plates permitting access to all compartments

individually. Provide a rigid and self-supporting structure. Provide the fused medium voltage interrupting switch, buses, instrument transformers, and incoming and outgoing cables of the primary unit isolated within separate compartments formed by sheet metal barriers. Completely seal all openings in barriers between compartments against passage of gas or flame.

Provide suitable structural base members to permit plumb and level installation of the switch on its concrete pad.

3. Provide copper primary buses rated 1200 amperes rms extending the full

width of the completed assembly, including transition bay.

4. Provide silver plated and bolted connections to the primary buses.

5. Brace the primary buses to mechanically and thermally withstand the full effect of short circuit currents equivalent to the interrupting ratings of the interrupter switches furnished with the switchgear.

6. Provide a 1/4-inch by 2-inch, bare-copper ground bus extending the full

width of the complete assembly. 2.4 WIRING

A. General: Provide the medium voltage interrupter switch completely assembled, wired, and tested at the factory, including buses, connections, insulators, cleats, terminals, and terminal blocks. Insulate all current carrying parts. Run all low voltage wiring in high voltage compartments in conduit or in separate wiring troughs. Provide terminal blocks and mounted so that the wires to them can be grouped and laced together in a neat and workmanlike manner. Furnish cup washers for wires No. 12 and smaller and solderless lugs for larger sizes. Provide a sufficient number of terminal connections, including 15 percent of spare terminals, for all control and instrument wiring. Provide No. 14 AWG stranded copper or larger, with NEC Type SIS insulation for all voltage wiring.

ARRHIP 16345-6

2.5 TEMPERATURE RISE

A. General: Do not exceed the temperature rise of switching devices within the enclosure permitted by standards of such devices measured over the average ambient. Provide the switchgear so that the average temperature inside the enclosure will not exceed the temperature permitted by ANSI Standard on an average ambient temperature of 30 degrees C and a maximum ambient 40 degrees C outside the enclosure.

2.6 OPERATION SEQUENCE

A. Refer to Specification Section 16430 for key interlock requirements with the Unit Substation USS-5 secondary switchgear main breakers.

2.7 IDENTIFICATION

A. General: Provide identification of the medium voltage interrupter switch and its components as specified in Section 16075.

B. Nameplates: Install nameplates for devices located on doors so they are readable to

a person 5'-8” tall standing 3'-0" in front of the equipment.

C. Location: Locate nameplates so that they are readily associated with items labeled.

D. Additional Nameplates: Where nameplates are installed on removable relay or device doors, install a nameplate within the relay or device.

E. Additional Engraving: Where nameplates are located on other compartments than

those served, add additional engraving to identify units served.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install medium voltage interrupter switches in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

B. Conformance: Install switch assembly as indicated, in accordance with

manufacturer's written instructions and with recognized industry practices; comply with NEMA Standards, NEC, Project-applicable portion of NECA's Standard of Installation and applicable ANSI Publications and local codes.

C. Coordination: Coordinate with other cabling/wiring work to interface installation

of switch assembly.

ARRHIP 16345-7

D. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with equipment manufacturer's published torque tightening values for equipment connectors. Where manufacturers' torquing requirements are not included, tighten connectors and terminals in accordance with UL Standard 486A.

E. Ground Connections: Make equipment grounding connections for the switch and

appurtenances. Tighten connections in accordance with UL Standard 486A for permanent and effective grounding.

F. Adjustments: Make all necessary adjustments to the equipment to provide

complete and satisfactory operation. 3.2 PAINTING AND LABELING

A. Painting: Paint switch enclosures in accordance with the requirements of Section 09900.

B. Touch-Up: Touch-up scratched and marred surfaces to match with original

finishes. 3.3 FIELD QUALITY CONTROL

A. Manufacturer’s Representative: Furnish the services of a qualified representative of the manufacturer to be present when the equipment is placed in operation. Provide the service as often as necessary until all problems are corrected and the equipment is installed and operating satisfactorily.

B. Certified Report: Furnish a written report certifying that the equipment (1) has

been properly installed, (2) is in accurate alignment, (3) is free from any undue stress imposed by connecting piping or anchor bolts, and (4) has been operated under full load conditions and that it operated satisfactorily.

C. Testing: Furnish an ac or dc 5-minute high potential test applied after the

installation is complete for all substation equipment. Provide test voltages in accord with the IEEE and NEMA Standards for the voltage class of equipment and components to be tested. Provide tests for all bus, cable, wire, switches, breakers, transformer, and control devices.

END OF SECTION

ARRHIP 16345-8


AARHIP 16411-1

SECTION 16411

DISCONNECT SWITCHES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing and installing enclosed (fused) (nonfused) safety switches for use as feeder and branch circuit switching and disconnect devices for motors and equipment.


Following:

1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16075 - Electrical Identification 4. Section 16060 - Grounding

1.2 REFERENCES



2. NEMA KS1 - Enclosed Switches

3. UL 198E - Class R Fuses

4. UL 486A - Wire Connectors and Soldering Lugs for Use With Copper Conductors

1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's data indicating disconnect

switch ratings and dimensions. Furnish manufacturer's data on fuses including time-current curves.

AARHIP 16411-2


A. Codes: Provide disconnect switches meeting the requirements of NFPA, the National Electrical Code and local codes.

B. Regulatory Requirements: Provide all disconnect switches designed,

manufactured and tested in accordance with latest ANSI, IEEE and NEMA Standards, and UL listed.



1.6 SPARE PARTS


1. Twelve of each size and type fuse installed.

B. Packaging: Plainly tag and mark spare parts for identification and for reordering and properly box and wrap spare parts to prevent deterioration. Completely identify the box on the outside.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable Manufacturers: Acceptable manufacturers are as listed below. Other manufacturers of equivalent products may be submitted for review.

1. Disconnect Switches

a. Square D Company b. Cutler Hammer c. Killark

2. Fuses

a. Bussmann b. Littelfuse

2.2 DISCONNECT SWITCHES

A. General: Provide disconnect switches of the NEMA KS-1, heavy-duty, load–interrupter, enclosed-knife switch type with externally operating handle

AARHIP 16411-3

interlocked to prevent opening of the front cover with the switch in the ON position. Provide an interlock that is be defeatable and operable from the front of the switch. Provide handle lockable in the OFF position.

B. Disconnect Switch Ratings: Provide disconnect switches rated for 600-volts as

applicable and horsepower rated when used in motor circuits. Current ratings are as indicated.

C. Service Entrance: Where shown, provide disconnect switches suitable for service

entrance.

D. Fusible Switches: Furnish switches with rejection feature to allow only Class R fuses to be installed.

E. Disconnect Switch Housings: Provide disconnect switches housed in NEMA rated

enclosures as follows:

AREA ENCLOSURE All areas listed Class 1, Division 1 and 2, Group D as defined in Section 16050 or as shown.


Outdoor and process indoors

NEMA 4 – Watertight

Corrosive areas as defined in Section 16050 or as shown

NEMA 4X- Corrosion-resistant fiberglass reinforced thermal setting polyester formulation with stainless steel external hardware. Provide external operators of the same material as that of the enclosures

Indoor dry areas NEMA 12 – Industrial

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install disconnect switches as shown or required. Comply with requirements of NEC and local electrical codes.

B. Coordination: Coordinate with other work including cabling and wiring work.

C. Torque Requirements: Tighten electrical connectors and terminal including screws

and bolts, in accordance with equipment manufacturers', published torque

AARHIP 16411-4

tightening recommendations. Where manufacturers' torquing requirement are not available, tighten connectors and terminals in accordance with UL Standard 486A.


A. Painting: Paint the disconnect switches as specified in Section 09900.

END OF SECTION

AARHIP 16415-1

SECTION 16415

AUTOMATIC TRANSFER SWITCHES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing automatic transfer (bypass-isolation) switches including control modules to provide completely automatic operation.


Following:

1. Section 01820 - Training 2. Section 09900 - Painting 3. Section 16050 - Basic Electrical Materials and Methods 4. Section 16060 - Grounding 5. Section 16075 - Electrical Identification 6. Section 16121 - Wires and Cables - 600 Volts and Below 7. Section 16230 - Packaged Engine Generator Systems

1.2 REFERENCES


1. NFPA 70 - National Electrical Code (NEC)

2. NEMA ICS 10 - AC Automatic Transfer Switches

3. UL 486A - Wire Connectors and Soldering Lugs For Use With Copper Conductors

4. UL 1008 - Standard for Automatic Transfer Switches


A. Design Requirements: Provide equipment capable of operating in an ambient temperature range of 0 to 40 degrees C and humidity of up to 90 percent noncondensing.

1. Arrange the equipment for convenient and ready accessibility from the front,

for inspection and maintenance of all devices, terminals and wiring.

AARHIP 16415-2

1.4 SUBMITTALS


B. Product Data and Information: Furnish manufacturer’s data for all associated

equipment and devices indicating dimensions, size, voltage ratings, current ratings, withstand and interrupting ratings.

C. Shop Drawings: Furnish shop drawings for automatic transfer switches to include

the following:

1. Outline drawings showing arrangement, elevations and identification of components.

2. Bill of materials including manufacturers' name and catalog number.

3. Interconnecting wiring diagrams, where required.

4. Individual schematic and wiring diagrams.

D. Quality Control: Furnish the following test reports and certificates as specified in

Division 1:

1. Certified Shop Test Reports for the automatic transfer switch and related components.

E. Operation and Maintenance Manuals: Furnish operation and maintenance manuals

as specified in Division 1.


A. Codes: Manufacture all automatic transfer switches in accordance with NEMA ICS10, and UL 1008.

1. Manufacture and install each automatic transfer switch in accordance with

the NFPA 70 and local codes.

B. UL Label: Provide a UL Label on each automatic transfer switch.



B. Shipping and Packing: Provide all structures, equipment and materials rigidly

braced and protected against weather, damage, and undue strain during shipment.

AARHIP 16415-3

C. Storage and Protection: Store all equipment and materials in a dry, covered,

heated and ventilated location. Provide any additional measures in accordance with manufacturer's instructions.

1.7 SPARE PARTS


1. Two complete replacements of all indicating lamps and fuses used in the installation.

2. Two of each special tool required for maintenance. 3. Three 12-ounce spray cans of the final finish.

B. Packaging: Pack spare parts in containers bearing labels clearly designating contents and related pieces of equipment. Deliver spare parts in original factory packages. Identify all spare parts with information needed for reordering.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Automatic Transfer Switch

a. ASCO Controls 7000 b. General Electric Zenith ZTS c. Russelectric RMT

2. Automatic Transfer Bypass-Isolation Switch

a. ASCO Controls 7000 b. General Electric Zenith ZBTS c. Russelectric RTB

2.2 AUTOMATIC TRANSFER SWITCHES

A. Description: Provide enclosed, double-throw automatic transfer (bypass-isolation) switches with single operating mechanism.

B. Configuration: Electrically-operated, mechanically held with required relays,

controls, and contacts.

AARHIP 16415-4

2.3 RATINGS

A. Voltage: 480V B. Switched Poles: 3

C. Amperage: 260A, 400A, 600A

D. Loads: Combination tungsten, ballast, resistance, and inductive loads.

Switch Rating

Withstand and Closing Ratings Amperes

260 A to 400 A 42,000 600 A & 800 A 65,000

E. Withstand and Closing Ratings: 42,000 and 65,000 minimum rms symmetrical

amperes at 480V, when used with molded-case circuit breaker. F. Thermal capacity: 20 times continuous ampere rating at 60 cycles.

2.4 COMPONENTS

A. Phase Sequence: A-B-C, left to right, front to back, top to bottom.

B. Contacts: Provide silver surfaced main contacts protected by a separate renewable arcing contact. Mechanically lock normal and emergency contacts by the operating linkage when in the open or closed position. Provide an operating linkage that will not permit a neutral position when a failure of any coil or disarrangement of any part occurs.

C. Bypass-Isolation Switch: Provide a manual bypass-isolation switch to connect the

load to either source and permit isolation of the automatic transfer switch from all source and load power conductors, Design the bypass-isolation switch to have the following features:

1. Switch and all components to be front accessible for all switch ratings.

2. Provide separate bypass and isolation handles for clear distinction between

the functions.

3. Provide a bypass handle that operates without opening the enclosure door.

4. Accomplish the bypass to the load-carrying source without interruption of power to the load (make before break contacts).

AARHIP 16415-5

5. Provide a bypass handle with three operating modes: "Bypass to Preferred," "Automatic," and "Bypass to Standby." The operating speed of the bypass contacts is to be independent of the speed at which the manual handle is operated. Provide the bypass contacts that are out of the power circuit when in the “Automatic” mode.

6. Provide an isolation handle with three operating modes: "Closed," "Test,"

and "Open." In the "Test" mode, the entire emergency power system, including the automatic transfer switches can be tested with no interruption of power to the load. In the "Open" mode, the automatic transfer switch will be completely isolated from all source and load power conductors allowing the automatic transfer switch to be completely withdrawn for inspection or maintenance without removal of power conductors. Provide an automatic transfer switch that will operate manually when the isolation switch is in either the "Test" or "Open" position.

D. Operating Mechanism: Isolate the mechanical driving system and mechanical

interlocks to be electrically dead. Do not use molded plastic parts for the operating linkage between the electrical operator and the main operating shaft of the switch.

E. Main Bearings: Radial, ball-bearing type.

F. Sensing and Control Relays: Continuous-duty, industrial type with wiping contacts

rated 10 amperes minimum.

G. Control Logic: Solid-state, microprocessor-based with generator exercise accessories.

H. Arc Barriers: Provide arc barriers and arc suppression for each pole.

2.5 ACCESSORIES

A. Indicating Lights: Provide 30.5 mm, LED type indicating lights mounted in the cover of the enclosure to indicate the following:

1. Preferred source available 2. Standby source available 3. Load connection to preferred source 4. Load connection to standby source.

B. Test Switch: Mount in the cover of the enclosure to simulate failure of preferred

source.

C. Preferred Source Selector Switch: Mount in the cover of the enclosure to select the preferred power source.

AARHIP 16415-6

D. Transfer Switch Auxiliary Contacts: Provide the following auxiliary contacts rated for 10 amperes at 120 volts.

1. Normal power position: 2 set N.O., 2 set N.C. 2. Standby power position: 2 set N.O., 2 set N.C. 3. Normal power failure monitor: 2 sets N.O., 2 sets N.C.

E. Preferred Source Monitor: Monitor voltage and frequency on each phase of the

preferred source.

F. Standby Source Monitor: Monitor voltage and frequency on each phase of the standby source.

G. In-Phase Monitor: Monitor phase timing of the normal and standby sources.

H. Adjustable Time Delay Transfer Logic: Provide adjustable, solid-state, time delays

for the following functions:

1. Preferred to standby: 0-5 minutes 2. Standby to preferred: 0-30 minutes

2.6 ENCLOSURE

A. Enclosure: NEMA Type 12 - Industrial

B. Accessibility: Provide an enclosure with all current carrying contacts and parts readily accessible from the front for maintenance and inspection without removal of the switch panel, disconnecting of the operating linkage, or disconnecting of power conductors.

2.7 AUTOMATIC SEQUENCE OF OPERATION

A. Controller: Provide a programmable, microprocessor-based controller to provide an automatic sequence of operation as follows:

1. Initiate transfer load to standby source: Signals from preferred source

monitor, standby source monitor, and in-phase monitor.

a. Preferred Source Monitor: Initiate when preferred source voltage drops below 70 percent from rated nominal value or frequency varies more than 10 percent from rated nominal value.

b. Standby Source Monitor: Initiate when standby source voltage is at

least 90 percent of rated nominal value and frequency is within 5 percent of rated nominal value.

AARHIP 16415-7

c. In-Phase Monitor: If normal and emergency sources are energized, initiate when sources are synchronized to within 15 electrical degrees.

d. Time Delay to Transfer Load to Standby Source: Adjustable from 0

to 5 minutes, initially set at 2 seconds.

2. Initiate retransfer load to preferred source: Signals from preferred source monitor and in-phase monitor.

a. Preferred Source Monitor: Initiate when normal source voltage is at

least 90 percent of rated nominal value and frequency is within 5 percent or rated nominal value.

b. In-Phase Monitor: Initiate when sources are synchronized to within

15 electrical degrees.

c. Time Delay To Transfer Load to Preferred Source: Adjustable from 0 to 30 minutes, set at 10 minutes. Bypass time delay in event of standby source failure.

PART 3 EXECUTION

3.1 INSTALLATION


B. Cable Connections: Terminate and label all field wiring per the approved

diagrams.

C. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with equipment manufacturers' published torque tightening recommendations. Where manufacturers' torquing requirements are not available, tighten connectors and terminals in accordance with UL Standard 486 A.



B. Adjustments: Make all necessary adjustments to the equipment to provide

complete and satisfactory operation upon completion of the Contract.

AARHIP 16415-8

C. Tests: Perform field tests as follows:

1. Inspect and test the installation with respect to the safety requirements of NFPA 70 pertaining to grounding and insulation resistance.

2. Demonstrate proper operation of the automatic transfer switch by simulating

conditions.

3. Repair or replace defective materials at no cost to the OWNER. 3.3 OPERATION DEMONSTRATION

A. Manufacturer's Representative: Provide the services of the automatic transfer switch manufacturer's representative to assist in installation, start-up, field testing, calibration, placing into operation and providing training, as specified in Section 01820. The representative is required to carry out a thorough inspection of the installation and certify that the installation is correct and complete in accordance with the manufacturer's instruction and to confirm that the automatic transfer switch is ready for the final acceptance. Also to instruct operating personnel in the operation and maintenance of the automatic transfer switch.

B. Training: Following completion of installation and field testing provide training

for 6 employees of the OWNER in the proper operation, troubleshooting and maintenance of the equipment as outlined below. All training will be at the OWNER’S facilities at a time agreeable to the OWNER:

1. Operational Training: A minimum of two 4-hour sessions combining both

classroom and hands-on instruction, excluding travel time.

2. Maintenance Training: A minimum of two 4-hour sessions combining both classroom and hands-on instruction, excluding travel time.


A. Shop Painting: Paint automatic transfer switches in accordance with Section

09900.

B. Field Painting: Clean and touch up any scratched or marred surface to match original finish.

END OF SECTION

AARHIP 16421-1

SECTION 16421

CONTACTORS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing, installing and testing enclosed contactors for controlling feeders and branch circuits for lighting, heating and general purpose loads.


Following:

1. Section 00990 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16075 - Electrical Identification 4. Section 16060 - Grounding 5. Section 16121 - Wires and Cables - 600 Volts and Below 6. Section 16491 - Control Components and Devices 7. Section 16500 - Lighting

1.2 REFERENCES




3. UL 486A - Wire Connectors and Soldering Lugs For Use With

Copper Conductors 1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's data indicating contactor

dimensions size, voltage ratings, current ratings and withstand ratings.

C. Shop Drawings: Furnish shop drawings for the contactors.

AARHIP 16421-2

D. Operations and Maintenance Manuals: Furnish six copies of the manufacturer's

operations and maintenance manuals. Furnish instructions for replacing and maintaining contacts and coils.


A. Codes: Provide contactors meeting the requirements of NFPA and the National Electrical Code.

B. Regulatory Requirements: Provide all contactors designed, manufactured and

tested in accordance with latest ANSI, IEEE and NEMA Standards, and UL listed. 1.5 SPARE PARTS


1. One set of contacts for each type of contactor furnished

2. One coil for each type of contactor furnished

B. Packaging: Package and identify the spare parts properly for use and reordering. Provide spare parts in original factory cartons.



PART 2 PRODUCTS

2.1 MANUFACTURERS


1. ASCO Controls 2. Square D Company 3. Cutler Hammer

2.2 MATERIALS

A. General Purpose Contactors: Provide general purpose contactors in accordance with NEMA ICS 2 meeting the following:

1. Coil Voltage: 120-volts, 60-hertz as shown

AARHIP 16421-3

2. Poles: Provide three-pole contactors, unless otherwise indicated.

3. Size: NEMA rated contactors Size 1 or larger designed to handle the

connected load.

B. Lighting Contactors: Provide lighting contactors meeting the following:

1. Configuration: Electrically operated, mechanically held for 2 or 3 wire control as indicated.

2. Coil Voltage: 120-volts, 60-hertz as shown.

3. Poles: Provide six-pole contactor, unless otherwise indicated.

4. Contact Rating: 20 amperes for tungsten or ballast loads and 30 amperes for

all other loads at 600 volts.

C. Contactor Housings: Provide contactors housed in NEMA rated enclosures as follows:

AREA ENCLOSURE

Above grade indoor NEMA 12 – Industrial

2.3 ACCESSORIES

A. Push Buttons, Selector Switches and Indicating Lights: Provide push buttons, selector switches and indicating lights as specified in Section16491.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all contactors in accordance with the manufacturer's recommendations and approved shop drawings and recognized industry practices and as specified in Division 1. Comply with requirements of NEMA, NEC, and local electrical codes.

B. Coordination: Coordinate contactor installation with other work including cabling

and wiring work.

C. Torque Requirements: Tighten electrical connectors and terminals including screws and bolts, in accordance with equipment manufacturers' published torque tightening recommendations. Where manufacturers' torquing requirement are not available, tighten connectors and terminals in accordance with UL 486 A.

AARHIP 16421-4


A. General: Clean and paint contactor enclosures as specified in Section 09900.

END OF SECTION

ARRHIP 16430-1

SECTION 16430

480 VOLT SWITCHGEAR

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing, installing and testing 480-volt switchgear including the following major components:

1. Stationary structure including bus bars 2. Main and tie power air circuit breakers 3. Distribution power air circuit breakers 4. Control, protection, monitoring and metering equipment


Following:

1. Section 01820 - Training 2. Section 09900 - Painting 3. Section 16050 - Basic Electrical Materials and Methods 4. Section 16060 - Grounding 5. Section 16075 - Electrical Identification 6. Section 16080 - Electrical Testing Requirements 7. Section 16085 - Short Circuit and Coordination Study 8. Section 16121 - Wires and Cables - 600 Volts and Below 9. Section 16291 - Electrical Monitoring System 10. Section 16275 - Substation Transformers 11. Section 16344 - Medium Voltage Fuses 12. Section 16345 - Medium Voltage Interrupter Switches


otherwise referenced under related work Section 16275, 16344 and 16345, are part of the overall assembly identified as Unit Substation USS-5 on the plans. The components comprising Unit Substation USS-5 with all required interconnecting bussing are to be provided by a sole source supplier responsible for the overall assembly meeting the requirements of this and referenced specification sections.

1.2 REFERENCES


1. NEC - National Electrical Code (NEC).

ARRHIP 16430-2

2. IEEE C37.13 - Low-Voltage AC Power Circuit Breakers Used in Enclosures

3. IEEE C37.20.1 - Metal-Enclosed Low Voltage Power Circuit Breaker

4. ANSI C37.51 - Conformance Testing of Metal-Enclosed Low-Voltage

AC Power Circuit Breaker Switchgear Assemblies.

5. IEEE C37.90 - IEEE Standard for Relays and Relay-Systems Associated with Electric Power Apparatus

6. NEMA SG3 - Low-Voltage Power Circuit Breakers.

7. IEEE C62.41 - IEEE Recommended Practice on Surge Voltages in Low

Voltage AC Power Circuits

8. IEEE C62.45 - IEEE Guide on Surge Testing for Equipment Connected to Low Voltage AC Power Circuits

9. MIL-STD-220A - Method of Insertion-loss Measurement 12/1/59; with N1

and N2 (Fed/mil H-q)

10. NEMA SG5 - Power Switchgear Assemblies.

11. UL 486A - Wire Connectors and Soldering Lugs for Use with Copper Conductors

12. UL 1283 - Electromagnetic Interference Filters

13. UL 1449 - Transient voltage surge suppressors

14. UL 1558 - Metal-Enclosed Low Voltage Power Circuit Breaker

Switchgear

B. Material Workmanship Requirements: Provide all materials and workmanship meeting the requirements of NFPA Standards and Codes.

C. Design and Testing Requirements: Provide all switchgear components designed,

manufactured and tested in accordance with the latest NEMA, IEEE and ANSI Standards; and UL listed.

D. Installation Requirements: Install the switchgear assemblies meeting the

requirements of NEC and local Electrical Codes.

ARRHIP 16430-3

1.3 SUBMITTALS


B. Product Data and Information: Furnish the following.

1. Manufacturers catalog data on switchgear assemblies and on each

component detailing materials, ratings, type, model and reference number.

2. Layout drawings customized for the project including physical details, dimensions, clearances, mounting, elevations, sections, and nameplates.

3. Electrical control schematics, wiring diagrams, internal interconnection

diagrams and interconnection diagrams, including equipment external to the switchgear.

4. Terminal lists for all connections.

5. Furnish instruction booklets and time-current curves for each circuit breaker

supplied.

6. Furnish microprocessor-based metering system and overload protection systems address, memory map and instruction booklets.

7. Furnish the following information on transient voltage surge suppressors

(TVSS):

a. Verification that TVSS devices comply with UL 1449 and UL 1283 SVR.

b. Actual let through voltage test data in the form of oscillograph results

for both the ANSI/IEEE C62.41 Category C3 (combination wave) and B3 (ringwave) tests in accordance with ANSI/IEEE C62.45.

c. Spectrum analysis of each unit based on MIL-STD-220A test

procedures between 50 kHz and 200 kHz verifying that the device's noise attenuation exceeds 50 dB at 100 kHz.

d. Test reports from a recognized independent testing laboratory

verifying the suppressor components can survive published surge current ratings on both a per mode and per phase basis using the IEEE C62.41, 8 x 20 microsecond current wave. Note: Test data on individual modules are not acceptable.

ARRHIP 16430-4

C. Contractors Drawings: Furnish switchgear installation details including concrete pad details, mounting details, conduit and cable termination details and shipping section split field connection details.

1.4 QUALITY CONTROL

A. Test Reports: Furnish the manufacturer's certified shop test report and field test report for each 480-volt switchgear.

1.5 OPERATIONS AND MAINTENANCE MANUALS

A. Furnish operation and maintenance manuals, including spare parts lists, as specified in Division 1.



B. Storage and Protection: Store all equipment in a dry, covered, heated and

ventilated location. Provide any additional measures in accordance with manufacturer's instructions.

1.7 SPARE PARTS


1. One transfer truck with fixed and swivel wheels and rubber tires suitable for moving the largest circuit breakers.

2. One portable circuit breaker test kit.

3. Two auxiliary power modules to power breaker trip units when breaker is

not in the "connected" position.

4. One complete solid-state sensor unit for each size furnished.

5. Six replacement indicating light color lens for each color furnished.

6. Three current transformers of each type and rating.

7. Two potential transformers of each type and rating.

8. Twelve potential transformer primary fuses.

9. Twelve potential transformer secondary fuses.

ARRHIP 16430-5

10. Two sets of control jumpers.

11. One hand crank per switchgear for circuit breaker withdrawal and insertion.



PART 2 PRODUCTS

2.1 MANUFACTURERS


1. 480-Volt Switchgear

a. Cutler-Hammer Magnum DS Low Voltage Metal Enclosed

Switchgear with (Magnum DS) (DSII) drawout power circuit breakers with Digitrip RMS solid state tripping units.

b. General Electric Company AKD-10 Low Voltage Switchgear with

Wave-Pro drawout power circuit breakers with MicroVersa Trip Plus solid state tripping units.

c. Square D Company Power-Zone 4 Low Voltage Metal Enclosed

Switchgear with Masterpact drawout power circuit breakers with Powerlogic RMS solid state tripping units.

2. Microprocessor Based Protective Relays and Metering Systems

a. Cutler-Hammer IQ-4000 b. General Electric Company Multilin c. Square D Company Micrologic

3. Transient Voltage Surge Suppression (TVSS):

a. Cutler-Hammer b. Advanced Protection Technology

4. Power Transducers

a. Scientific Columbus Type Exceltronic b. Rochester Instrument Systems

ARRHIP 16430-6

2.2 SERVICE CONDITIONS

A. Power Supply: The switchgear is part of the overall Unit Substation USS-5 assembly. The power supply to the switchgear will be from the secondaries of the two substation transformers which are fed on the primary from the plant’s 13.2 kV Main Switchgear located elsewhere on site. Coordinate the circuit breaker trip units with the upsteam feeder protection.

B. Switchgear:

1. Provide switchgear with the following features:

a. Individually mounted, drawout power air circuit breakers

b. Full insulated and isolated bus

c. Insulated run back bus

d. Circuit breakers rated for 100 percent continuous ampere when

installed in the switchgear enclosure

e. Interrupting rating of 100,000 rms symmetrical amperes at rated voltage

2. Label the switchgear suitable for use as service entrance equipment where

appropriate.

3. Provide all components required for complete functioning units as specified and as shown using factory built standardized units, completely dead front, totally enclosed and freestanding. Each unit comprises a stationary structure and a drawout circuit breaker.

4. Design, manufacture and test all equipment in accordance with the NFPA

70, NEMA SG3, and SG5; IEEE C37.13, C37.20.1 and C37.51 and UL 1558 Standards.

5. Provide the required number of units based on the necessary controls and

metering as shown and specified.

C. Distribution System: Connect the switchgear to 480-volt, 3-phase, 60-hertz, 4-wire, solidly grounded neutral power system.

ARRHIP 16430-7

2.3 COMPONENTS

A. Stationary Structure: Construct the stationary structure of the switchgear as follows:

1. Build each unit out of bolted structural steel members, together with formed

or fitted sections of smooth sheet steel approximately 90 inches high.

2. Form completely enclosed compartments for various combinations of circuit breakers and auxiliary equipment.

3. Provide sufficient structural strength to support all the equipment mounted

within, withstand the handling and shipment of the units, maintaining the proper alignment, and be rigid and freestanding.

4. Provide a formed front door panel for each compartment consisting of

concealed type hinges.

5. Reinforce panels as required to retain alignment and to support instruments, relays, and control equipment mounted thereon.

6. Provide removable plates to permit access to all compartments individually.

7. Isolate circuit breaker, buses, and incoming or outgoing cables with separate

compartments formed by sheet steel barriers.

8. Provide a circuit breaker cubicle that allows the front face of the circuit breaker to extend to the front of the switchgear enclosure or be enclosed behind the circuit breaker compartment door.

9. Provide suitable ventilation for the individual compartments to keep the

temperature of devices and buses within the permissible temperature limits as specified by the Standards.

10. Include insulated buses, fixed portion of primary disconnect devices,

insulated connections, instrument transformers, control devices and fuses in the stationary structure. Provide removable boots to give access to bus joint for inspection and maintenance.

11. Provide a positioning mechanism for moving the removable circuit breaker

to or from the connected position.

12. Provide guides for proper alignment of all engaging parts during movement of circuit breakers between the connected or disconnected position.

13. Provide stationary structure and circuit breakers that are interchangeable

with every other circuit breaker of the same rating.

ARRHIP 16430-8

14. Extend the potential buses across all units of the switchgear.

15. Fully isolate the main bus compartment from the circuit breaker

compartment and cable terminations.

16. Provide main buses rated not less than shown, consisting of rigidly supported insulated copper bars of suitable design and cross-sectional area to satisfactorily carry the rated current without exceeding the temperature rise as specified in the IEEE and NEMA standards.

17. Connect the bus with bolts having Belleville type lock washers.

18. Silver plate the copper bars at current-carrying connections.

19. Insulate all standard bus joints with preformed insulating boots secured by

nylon hardware. Insulate nonstandard joints with tape and insulating compound.

20. Equip each switchgear unit with a 1/4-inch by 2-inch bare copper ground

bus with a momentary rating at least equal to the highest momentary rating of the unit’s circuit breakers. Extend the ground bus the entire length of the structure and comply with all applicable codes and regulations.

21. Ground each stationary unit directly to the ground bus.

22. Provide suitable lug terminals on the ground bus for connections to the

station grounding system.

23. Construct and arrange the stationary structure so that circuit breakers are completely isolated from each other within the same section and that sections are isolated from adjoining sections.

24. Provide steel floor channels suitable for embedding into the concrete floor

for leveling and anchoring the switchgear. Drill and tap the floor channels as required. Provide bolts, nuts, and washers for anchoring the switchgear to the channel.

B. Switchgear Enclosure:

1. Provide switchgear suitable for installation indoors.

C. Drawout Circuit Breakers and Tripping Units:

1. Provide 480 volt, 3-pole, 600-volt class, drawout-type, power air circuit

breakers with solid-state trip units rated as shown, having 100,000 rms amperes interrupting rating without current limiting fuses. Provide breakers

ARRHIP 16430-9

having a 100 percent ampere rating when installed in the switchgear enclosure.

2. Provide circuit breakers with tripfree, manual-operating handles, stored-

energy type trip mechanism and push-to-trip button; rated for 40 degrees C ambient operation. Provide main and tie circuit breakers with key interlocks as shown.

3. Equip the circuit breaker with mechanical interlocks to prevent moving the

circuit breaker to and from the connected position without the circuit breaker open.

4. Provide circuit breakers that cannot be closed at any point between the

operating and test positions or when the key interlock is engaged.

5. Provide means to padlock the circuit breaker in the disconnect position.

6. Provide manually-operated distribution, main and tie circuit breakers.

7. Provide control connections between the stationary structure and removable circuit breaker that have floating terminals mounted in the stationary structure and engaging mating contacts on the breaker that are engaged when the breaker is in either the connected or test position.

8. Provide all circuit breakers with true rms sensing and microprocessor-based

logic circuitry having the following protection features for tripping the circuit breaker.

a. Trip Indicators b. Long time setting and time delay c. Short time setting, time delay and I2t response. d. Instantaneous setting (distribution circuit breakers only). e. Ground fault setting, time delay and I2t response. f. Short time and ground fault zone interlocking.

D. Switchgear Connections and Terminals:

1. Construct all current-carrying connections of copper having suitable

capacity, bracing, insulation, temperature rating as the main bus.

2. Connect current transformers in such a way that the transformers may be removed and changed without damaging the connection.

ARRHIP 16430-10

E. Instrument Transformers:

1. Current Transformers

a. Provide dry type current transformers, suitable for indoor service and rated as shown.

b. Provide sufficient thermal and mechanical capacity to withstand the

maximum momentary current rating of the circuit breaker.

c. Provide solderless, clamp type shorting terminal blocks for secondary connections.

d. Properly identify the polarity of all current transformers with standard

marking symbols.

e. Provide current transformers having an accuracy suitable for the instruments and meters specified using the normal burdens of the various devices, and not less than ANSI Standard requirements.

2. Potential Transformers

a. Provide dry type potential transformers, suitable for indoor service.

single-phase, 60 hertz, 120 volts.

b. Provide potential transformers that fit into and coordinate with the complete switchgear units, and with the instruments, relays, meters, and devices specified.

c. Rate the potential transformers not less than 100-volt-amperes at 55

degrees C ambient or 150-volt-amperes at 30 degrees C ambient thermal rating.

d. Provide potential transformers that can withstand a secondary short

circuit for at least one second.

e. Provide the transformers meeting the requirements of the ANSI Standard accuracy classifications.

f. Provide current-limiting type primary fuses.

g. Provide secondary fuses sized for the protection of potential

transformers.

ARRHIP 16430-11

3. Grounding

a. Ground current and potential transformer secondaries with copper conductors not smaller than No. 10 AWG and connecting to the ground bus.

b. Ground potential transformer neutrals, where shown or required with

a 600-volt green insulated copper conductor not smaller than No. 10 AWG.

c. Provide connections to the bus that can be easily disconnected and

isolated for field testing individually.

d. Install each ground wire as a continuous run without intervening splices or terminal blocks.

e. Ground secondary circuits of metering and relaying transformers at

one point only.

f. Effectively ground meter, relay and instrument transformer cases.

F. Lightning Arresters and Surge Capacitors:

1. Provide lightning arresters and surge capacitors for each incoming service.

G. Control Devices:

1. Provide control switches of the standard rotary, multistage type suitable for the use specified.

2. Provide auxiliary relays, switches and mechanisms required for the

particular manufacture of the breaker. 3. Provide a manually-operated trip bar or lever for each circuit breaker.

4. Provide provisions for manual closing of each circuit breaker.

H. Microprocessor-Based Metering and Protection System: Provide a

microprocessor-based metering and protection system having the following features:

1. UL recognized component meeting IEEE C37.90.

2. Housed in an enclosure suitable for door mounting.

3. Derive control power from metered line.

ARRHIP 16430-12

4. Auto ranging metering of the following values:

a. AC amperes in each phase, 0.5 percent accuracy b. AC voltage, phase-to-phase, phase-to-neutral, 0.5 percent accuracy c. Watts, 1 percent accuracy d. Vars, 1 percent accuracy e. Power factor, 2 percent accuracy f. Frequency, 0.5 percent accuracy g. Watt demand, 1 percent accuracy with programmable 5-, 10-, 15-, 30-

minute intervals h. Watt-hours, 1 percent accuracy i. Percent total harmonic distortion through the 31st harmonic

5. Protection system with the following functions:

a. Voltage phase loss, less than 50% nominal line voltage

b. Current phase loss, less than 1/16 of the largest phase

c. Voltage phase unbalance, 5 to 40% in 5% increments

d. Phase voltage reversal

e. Overvoltage, 105 to 140% in 5% increments

f. Undervoltage, 95 to 60% in 5% increments

g. Time delay for overvoltage, undervoltage, and phase unbalance, zero

to twenty seconds in one second intervals.

6. Separate Form C (NO/NC) trip and alarm outputs contacts rated 10 amperes at 115-volt ac or 30-volt dc resistive.

7. Addressable communications card capable of transmitting all data over a

modbus two-wire RS485 link to the Plant SCADA system.

a. The following breakers are provided with a Microprocessor Metering System to be monitored in Plant SCADA System:

(1) Unit Substation USS-5 Main Breaker Nos. 1 and 2

b. The following data from each of these breakers are to be monitored in

the Plant SCADA System:

(1) Voltage (V) (2) Current (A) (3) Real Power (KW)

ARRHIP 16430-13

(4) Reactive Power (KVAR) (5) Total Power (KVA)

I. Transient Voltage Surge Suppression (TVSS):

1. Provide transient voltage surge suppression (TVSS) equipment that complies with UL 1449 and UL 1283.

2. Provide units with a maximum continuous operating voltage that exceeds

115 percent of the nominal system operating voltage.

3. Provide TVSS equipment suitable for wye-configured systems.

4. Provide TVSS equipment having directly connected suppression elements between line-neutral (L-N), line-ground (L-G), and neutral-ground (N-G).

5. Provide TVSS equipment that distributes the surge current to all MOV

components to ensure equal stressing and maximum performance and provides equal impedance paths to each matched MOV.

6. Provide high-performance EMI/RFI noise rejection filters that attenuate the

electric line noise at least 55 dB at 100 kHz using the MIL-STD-220A insertion loss test method.

7. Wire internal components with connections utilizing low impedance

conductors and compression fittings.

8. Provide a monitoring panel for each system that incorporates the following features:

a. Green/red solid state indicator light to indicate which phase(s) have

been damaged. b. A flashing trouble light to indicate fault detection c. Transient event counter d. Audible alarm e. Form C dry contacts for remote indication of the unit status.

9. Provide each TVSS for service entrance or branch location application with

a minimum total surge current capable of withstanding 250kA or 160kA per phase respectively or as shown.

J. Wiring:

1. Completely assemble, wire and test each switchgear section at the factory,

including buses, phase, neutral and ground connections, insulators, cleats, terminals, and terminal blocks.

ARRHIP 16430-14

2. Insulate all current-carrying parts.

3. Route all secondary wiring in the front of secondary compartments in wiring troughs and terminate at approved, molded-type terminal blocks with numbered marking strips, conveniently located with respect to the control conduits.

4. Provide terminal blocks with covers mounted so that the wires can be

grouped and laced together. 5. Mark and identify all wiring in accordance with the manufacturer's wiring

diagrams.

6. Label control wiring with an identification tag that indicates the terminal number of the opposite end connection.

7. Include wire labels and terminal numbers on schematic control and wiring

diagrams.

8. Provide spade connectors for wires No. 12 and smaller and solderless lugs for larger sizes.

9. Provide terminals for all connections and an additional 15 percent spare

terminals for all control and instrument wiring.

10. Provide No. 10 AWG stranded copper or larger with NEC Type SIS insulation for all current transformer secondary wiring.

11. Provide No. 14 AWG stranded copper or larger with NEC Type SIS

insulation for all other control wiring.

12. Provide a fused switch or circuit breaker for the control power supply in each breaker compartment.

K. Identification:

1. Provide identification of the switchgear and its components as specified in

Section 16075. 2. Install nameplates for devices located on doors so they are readable to a

person 5'-8" tall standing 3'-0" in front of the equipment.

3. Locate nameplates so that they are readily associated with the items labeled.

4. Where nameplates are installed on removable relays or removable device doors, install a nameplate within the relay or device.

ARRHIP 16430-15

5. Where nameplates are located on other compartments than those served, add additional engraving to identify units served.

2.4 ACCESSORIES

A. Circuit Breaker Lifting Device: Provide a traveling type circuit breaker lifting device rail mounted on the top of each switchgear assembly. Provide all accessories required for lifting and lowering circuit breakers.

2.5 OPERATION SEQUENCE

A. Provide Unit Substation USS-5 with multiple key interlocks. Design the main and tie circuit breakers and the unit substation primary medium voltage interrupter switches with key interlock systems having the following operating schemes:

1. Provide an interlock system between each main breaker and the associated

medium voltage interrupter switch which prevents the medium voltage interrupter switch from being opened when the main breaker is closed.

2. Provide an interlock system between the main breakers and bus tie breaker

which prevents the three breakers from being closed at the same time. 2.6 SOURCE QUALITY CONTROL

A. Tests:

1. Conduct shop tests after the switchgear has been assembled to determine general operating condition and circuit continuity, high voltage withstand and other safety standards.

2. Witness Tests: Carry out inspection and witness test of the completed

switchgear assembly to assess its state of workmanship and standard of performance.

3. Notify the ENGINEER of the proposed date of testing a minimum of ten

working days prior to the test.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install the switchgears in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1.

ARRHIP 16430-16

B. Conformance: Install the switchgears as shown, in conformance with manufacturers written instruction and recognized industry practices. Comply with requirements of NEMA standards, and applicable ANSI publications.

C. Coordination: Coordinate with other work including cabling and wiring work as

necessary to interface installation of switchgears with other work.

D. Torque Requirements: Tighten electrical connectors and terminals including screws and bolts, in accordance with equipment manufacturer's published torque tightening values of equipment connectors. Where manufacturer's torquing requirements are not indicated, tighten connectors and terminals in accordance with UL Standard 486A.

E. Fuses: Provide fuses in switchgear assemblies as required.

F. Circuit Breaker Parameters: Set the circuit breaker protection parameters in

accordance with the protective coordination study specified in Section 16085.

G. Grounding Connections: Make equipment grounding connections for the switchgear as shown. Tighten connections in accordance with UL standard 486A for permanent and effective grounding.

H. Adjustments: Make all necessary adjustments to the equipment to provide

complete and satisfactory operation of the system. 3.2 FIELD QUALITY CONTROL

A. Manufacturer’s Representative: Provide a factory-trained experienced, competent, and authorized representative of the switchgear manufacturer to visit the site of the Work and inspect, check, adjust if necessary, approve the equipment installation and provide training as specified in Section 01820. Provide all instruments and equipment necessary to conduct required tests, adjustments and training. Have the manufacturer's representative utilize prepared comprehensive check sheets covering inspections, checks and tests required for the assembly of the switchgear. Submit copies of these documents executed and signed by the manufacturer's representative. Have the representative present when each equipment item is placed in operation. Provide representative service as often as necessary until all problems are corrected and each equipment item is installed and operating satisfactorily.

B. Certified Report: Furnish a written report certifying that the equipment:

1. Has been properly installed

2. Is in accurate alignment

3. Is free from any undue stress imposed by connections or anchor bolts, and

ARRHIP 16430-17

4. Has been operated under full load conditions and that it operated

satisfactorily

C. SCADA Programming: Provide manufacturers representative at the job site as often as necessary to assist in the programming of the SCADA system for accessing the memory map of each device.

D. Tests and Inspections: Perform the following tests and inspections. Record all

tests and submit a written report for approval. Retest as necessary.

1. Check all breakers, relays, meters, power and control fuses and auxiliaries for proper size, rating, and location. Clean control panels and cubicles. Remove all shipping materials.

2. Inspect equipment and each breaker and report installation or shipping

damage, loose materials, shipping blocks or contamination.

3. Torque test bus connections where field joints are made.

4. Test key interlock systems to demonstrate proper function.

5. Check that all control and panel circuits are numbered and tagged and panel door legends are engraved and installed as per drawings.

6. Check equipment to determine that it is level, secured to foundations and

that doors operate properly.

7. Test insulation of all control and relay circuits to ground with a suitable megohmmeter. Take suitable precautions where electronic devices, instruments and instrument transformers are involved.

8. After installation, but before any external connections are made to the

switchgear, subject the switchgear to a 10-minute high potential test applied on the stationary structure and breakers. Use a test voltage of 75 percent of the standard factory production tests.

9. Test all bus, cable, wire and other equipment operating at the service voltage

that is energized by closing the incoming main line breakers. This test may be witnessed by the ENGINEER.

10. Test protective relays to verify settings and determine proper operation.

E. Training: Following completion of installation and field testing provide training

for 8 employees of the OWNER in the proper operation, troubleshooting and maintenance of the equipment as outlined below. All training will be at the OWNER’S facilities at a time agreeable to the OWNER:

ARRHIP 16430-18

1. Operational Training: A minimum of two 4-hour sessions combining both

classroom and hands-on instruction, excluding travel time.

2. Maintenance Training: A minimum of two 4-hour sessions combining both classroom and hands-on instruction, excluding travel time.

3.3 GROUNDING

A. System Inspections: Inspect ground system for compliance with the latest approved drawings.

B. Connection Inspections: Inspect all ground connections for evidence of looseness

and/or corrosion. 3.4 CLEANING AND PAINTING

A. Shop Painting: Paint the switchgear as specified in Section 09900.

B. Field Painting: Touch up scratched and marred surfaces to match with original finishes.

3.5 IDENTIFICATION

A. General: Provide identification meeting the requirements of Section 16075.

B. Component Identification: Identify all system components, cables and wires by labels indicating unit numbers, circuit numbers and date of installation.

END OF SECTION

AARHIP 16443-1

SECTION 16443

PANELBOARDS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing lighting and distribution panelboards including circuit breakers and cabinets.


Following:

1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16075 - Electrical Identification 4. Section 16060 - Grounding

1.2 REFERENCES


1. NEMA PB 1 - Panelboards

2. UL 67 - Panelboards

3. Fed. Spec. W-P-115 - Power Distribution Panel

4. UL 486A - Wire Connectors and Soldering Lugs for Use With Copper

Conductors

5. NEC - National Electrical Code 1.3 SUBMITTALS


B. Product Data and Information: Furnish the manufacturer's catalog data for

panelboards, circuit breakers and accessories.

C. Operations and Maintenance Manuals: Furnish operation and maintenance manuals for the panelboards as specified in Division 1.

AARHIP 16443-2


A. Codes: Provide all materials and workmanship meeting the requirements of the NFPA, the National Electrical Code and local codes.

1. Design, fabricate and test the panelboards in accordance with applicable

ANSI, IEEE and NEMA standards.

2. Provide panelboards suitable for operation at their standard nameplate ratings in accordance with ANSI standards.



PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Panelboards

a. General Electric Company b. Square D Company c. Cutler Hammer

2.2 MATERIALS

A. General: Provide factory-assembled fully rated dead-front type, panelboards, suitable for surface or flush mounting with branch circuit breakers and a main circuit breaker or main lugs as indicated.

1. Provide panelboards with a full capacity separate ground bus and connected

to a three-phase four-wire or a single-phase three-wire service with insulated neutral buses as indicated.

2. Provide panelboards with the voltage, frequency and current ratings as

indicated conforming to NEMA Standard PB 1, Fed. Spec. W-P-115, UL 67 and the NEC.

3. Provide panelboards with copper main, neutral and ground buses.

AARHIP 16443-3

4. Where required, label panelboards suitable for use as service entrance equipment

B. Bracing: Provide main bus bracing exceeding the lowest interrupting rating of any

circuit breaker installed.

C. Fabrication: Fabricate panelboards using galvanized steel, continuously welded. Provide cabinet fronts with doors over the circuit breakers. Provide doors fastened with concealed hinges and equipped with flush type catches.

1. Provide panelboards at least 20 inches wide, 5-3/4 inches deep, with wiring

gutters on both sides.

2. Provide all panelboard trims exceeding five square feet in area with an inside permanently secured angle to support the trim during fastening.

2.3 COMPONENTS

A. Circuit Breakers: Provide bolt-on type branch and main circuit breakers.

1. Furnish the frame sizes, trip settings and number of poles as indicated. Mark ampere trip rating on the circuit breakers clear and visible.

a. For lighting panelboards, provide 20-ampere, single-pole, 120 or 277

volt circuit breakers unless otherwise shown or scheduled.

b. For distribution panelboards, provide 20-ampere, three-pole, 600-volt circuit breaker, unless otherwise shown or scheduled.

2. Provide all breakers with quick-make, quick-break, toggle mechanisms with

automatic thermal-magnetic, inverse time-limit overload and instantaneous short circuit protection on all poles, unless otherwise indicated. Indicate automatic tripping by the breaker handle assuming a clearly distinctive position from the manual ON and OFF position. Design the breaker handle to be trip-free on overloads.

3. Interrupting Rating: 10,000 rms symmetrical amperes for circuit breakers

on 240 volt systems or less, and 65,000 rms symmetrical amperes for circuit breakers on 277 or 480 volt systems.

4. Provide multipole breakers that utilize a common tripping bar.

5. Provide ground fault interrupter circuit breakers for all circuits serving

receptacles located below grade and outdoors and as scheduled.

6. Provide full module size single-pole breakers. Do not install two-pole breakers in a single-pole module.

AARHIP 16443-4

2.4 ACCESSORIES

A. Directories: Provide directories in accordance with Section 16075. B. Circuit Breaker Handle Lock: Where shown provide circuit breakers with handle

clamp that holds the circuit breaker handle in the ON position.

C. Keying: Key all panelboards alike.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all panelboards in accordance with manufacturer's recommendations and approved shop drawings and as specified in Division 1 and in compliance with the requirements of NEMA standards, NEC, and applicable ANSI Publications.

B. Mounting Height: Mount all panelboards either surface or flush mounted as

shown such that the height of the top operating handle does not exceed 6 feet 6 inches from the floor.

C. Coordination: Coordinate with other Work including cabling and wiring work to

interface the installation of the panelboards.

D. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with the equipment manufacturer's published torque tightening values for the equipment connectors. Where manufacturer's torque requirements are not indicated, tighten connectors and terminals in accordance with UL 486A.

E. Circuit Breaker Handle Lock: Install circuit breaker handle clamp on each circuit

breaker as shown.

F. Directory: Provide a laminated typewritten directory with the following information:

1. Circuit number 2. Area served 3. Utilizing equipment

AARHIP 16443-5


A. Shop Painting: Paint the panelboards as specified in Section 09900.

B. Field Painting: Touch up scratched and marred surfaces to match the original finish.

END OF SECTION

AARHIP 16443-6


AARHIP 16445-1

SECTION 16445

MOTOR CONTROL CENTERS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing new motor control centers, (and modifying existing motor control centers).


1. Section 01820 - Training 2. Section 09900 - Painting 3. Section 16050 - Basic Electrical Materials and Methods 4. Section 16060 - Grounding 5. Section 16075 - Electrical Identification 6. Section 16080 - Electrical Testing Requirements 7. Section 16121 - Wires and Cables - 600 Volts and Below 8. Section 16266 - Adjustable Frequency Drives 9. Section 16491 - Control Components and Devices 10. Section 16291 - Electrical Monitoring System

1.2 REFERENCES


1. IEEE C37.90 - IEEE Standard for Relay and Relay Systems Associated With Electrical Power Apparatus

2. IEEE C62.41 - IEEE Recommended Practice on Surge Voltages in Low

Voltage AC Power Circuits

3. IEEE C62.45 - IEEE Guide on Surge Testing for Equipment Connected to Low Voltage AC Power Circuits

4. MIL-STD-220A - Method of Insertion-loss Measurement 12/1/59; with N1

and N2 (Fed/mil H-q)


AARHIP 16445-2

6. NEMA ICS 3 - Industrial Control and Systems Factory Built Assemblies

7. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts

Maximum)

8. UL 486A - Wire Connectors and Soldering Lugs for Use With Copper Conductors

9. UL 845 - Motor Control Centers

10. UL 1283 - Electromagnetic Interference Filters

11. UL 1449 - Transient Voltage Surge Suppressors



1. Provide motor control centers designed for 480-volt, three-phase, three-wire,

60-hertz operation.

2. Provide all control devices in the center suitable for operation at 120-volts, 60-hertz, unless specifically noted otherwise.

3. Provide all control equipment and devices that meet the requirements of the

600-volt insulation class.

4. Provide motor control centers to include the indicated number of 20 or 21-inch deep sections and the components arranged as shown.

5. Arrange the equipment for convenient and ready accessibility from the front

for inspection and maintenance of devices, terminals and wiring.

6. Where shown or required, label the motor control center suitable for use as service entrance equipment.

1.4 SUBMITTALS


B. Product Data and Information: Provide catalog data for all associated equipment

and devices.

AARHIP 16445-3

C. Shop Drawings: Furnish shop drawings customized to the project for motor control centers to include the following:

1. Outline drawings showing dimensions, weights, arrangement, elevations,

identification of components and a nameplate schedule for all units.


3. Interconnecting wiring diagrams, where required.

4. Individual schematic and wiring diagrams for each compartment.

5. Furnish details showing electrical connections between main and tie circuit breakers and corresponding main buses.

6. Furnish instruction booklets and time-current curves for each circuit breaker

supplied.

7. Furnish microprocessor-based metering system and overload protection systems address, memory map and instruction booklets.

8. Furnish the following information on transient voltage surge suppressors

(TVSS):

a. Verification that TVSS devices comply with UL 1449 and UL 1283 SVR.

b. Actual let through voltage test data in the form of oscillograph results

for both the ANSI/IEEE C62.41 Category C3 (combination wave) and B3 (ringwave) tests in accordance with ANSI/IEEE C62.45.

c. Spectrum analysis of each unit based on MIL-STD-220A test

procedures between 50 kHz and 200 kHz verifying that the device's noise attenuation exceeds 50 dB at 100 kHz.

d. Test reports from a recognized independent testing laboratory

verifying the suppressor components can survive published surge current ratings on both a per mode and per phase basis using the IEEE C62.41, 8 x 20 microsecond current wave. Test data on individual modules are not acceptable.

Obtain and enter full performance details on all motors and other equipment being served on the above drawings.

AARHIP 16445-4

D. Quality Control: Furnish the following test reports and certificates as specified in Division 1:

1. Certified Shop Test Reports for motor control centers and related

components. Provide a minimum of 15 days written notice prior to shop tests.

2. Detailed field test reports of all tests indicating test performed as specified,

discrepancies found, and corrective action taken.

E. Operation and Maintenance Manuals: Furnish operation and maintenance manuals as specified in Division 1.


A. Standards: Provide motor control centers in accordance with NEMAICS 2, ICS 3, and UL Standard No. 845.

B. Codes: Provide motor control centers in accordance with the NEC and local

codes.

C. UL Label: Provide a UL Label on each vertical section of each motor control center.



B. Shipping and Packing: Provide all structures, equipment and materials rigidly

braced and protected against weather, damage, and undue strain during shipment.

C. Storage and Protection: Store all equipment and materials in a dry, covered, heated and ventilated location. Provide any additional measures in accordance with manufacturer's instructions.

1.7 SPARE PARTS


1. One current transformer of each type and each rating.

2. One set of contact tips, control power transformers and operating coils for each six or less of each size of motor starter.

3. One auxiliary contact unit or one set of auxiliary contact tips for each six or

less motor control units.

AARHIP 16445-5

4. Ten percent but not less than two complete control, latching and timing

relays of each type used in motor control centers.

5. One complete reset and repeat cycle timer of each type and rating used in motor control centers.

6. Two complete replacements of overload heater units for each catalog

number installed in motor control centers and motor starters.

7. Two central monitoring units.

8. Two complete replacements of all LED indicating lamps and fuses used in the installation.

9. One complete magnetic starter with motor circuit protector for each size

required.

10. Two sets of replacement indicating light color lenses of each color furnished.

11. One circuit breaker test unit.


B. Packaging: Pack spare parts in containers bearing labels clearly designating

contents and related pieces of equipment. Deliver spare parts in original factory packages. Identify all spare parts with information needed for reordering.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Motor Control Centers:

a. Cutler-Hammer 2100 Series b. General Electric Company Evolution Series E9000

2. Microprocessor Based Metering and Protection Systems:

a. Cutler-Hammer IQ-4000 b. General Electric Company Multilin

AARHIP 16445-6

3. Transient Voltage Surge Suppression (TVSS): a. Cutler-Hammer b. Advanced Protection Technology

4. Power Transducers:

a. Scientific Columbus Type Exceltronic b. Rochester Instrument Systems

2.2 MOTOR CONTROL CENTER

A. Basic Structural Components: Provide totally enclosed, dead-front, rigid, NEMA 12, gasketed, self-supporting and freestanding structures.

1. Construct the various sections from channels not less than 12 gauge, formed

into proper shape, suitably reinforced and welded. Grind all internal welds smooth and round off all corners to give a neat and pleasing appearance. Construct doors and covers from a minimum of 14-gauge steel sheets.

2. Provide steel bottom plates in each compartment section.

3. Cover the rear of each structure with easily removable steel panels for rear

access.

4. Provide both ends of a completely assembled center so that extensions can be easily added in the future.

5. Provide hinges, screws, bolts, circuit breaker operating mechanisms,

nameplate mounting screws and other metallic appurtenances with a noncorrodible metal covering.

6. Install full height steel barriers on each side of the tie breaker structure to

prevent the passage of flames and ionized gases.

7. Provide each motor control center with a three-phase bus compartment at the top and a conduit and cable compartment at the top and bottom.

8. Provide the cable compartments that run the full length of the motor control

center.

9. Provide access to cable compartments by means of removable hinged doors.

10. Provide each structure with a vertical wiring space between the starter cells and side sheet for unit wiring.

AARHIP 16445-7

11. Equip the vertical wiring space with cable supports to hold the cables and wiring in place.

B. Motor Control Center Enclosure:

1. Provide motor control centers suitable for installation indoors.

C. Bus Requirements: Provide main buses of silver plated copper bars across each

structure, sized in accordance with UL temperature rise of 50 degrees C based on a 40-degree C ambient temperature.

1. Provide a 600-ampere minimum, main horizontal bus, unless otherwise

shown.

2. Support all bus bars in each structure by means of bus supports fabricated from an insulating material.

3. Connect the horizontal bus to the incoming line circuit breakers and from

both sides of the tie breaker with copper bars, securely fastened in place.

4. Provide tin-plated vertical three-phase copper bus of sufficient size to carry loads served.

5. Insulate main and vertical buses over their entire length. Provide insulated

covers over all bolted connections.

6. Separate the bus bar compartments from breaker and controller cubicles by insulated barriers or steel plates.

7. Provide a 300-ampere uninsulated copper grounding bus with lugs for

connections to the plant grounding system in the bottom of each motor control center.

8. Brace all bus work suitably to withstand a minimum of 65,000 rms amperes

symmetrical short circuit current. Substantiate construction by a certified laboratory test covering units of similar construction.

D. Individual Units: Provide motor control or circuit breaker units in combinations of

not less than 12-inch modular heights.

1. Provide units of the plug-in or nonremovable type in accordance with the manufacturer's standard for type and size of controller.

2. Provide plug-in units within-plated, pressure-type line disconnecting stabs of

high strength copper alloy. Hold each plug-in unit in place and arrange the units such that they can be removed or remounted readily without access to the rear of the structure.

AARHIP 16445-8

3. Provide units that are totally enclosed and effectively baffled to isolate

ionized gases that may occur within each unit. In addition, ventilate each unit so that it can be located anywhere within the structure using the same overload heaters for the same load.

4. Provide automatic shutter mechanism to cover the vertical bus stub area

when a unit is removed.

5. Provide spaces for future equipment in unit structures with blank hinged doors and removable metal barriers for isolation of the vertical buses.

6. Construct doors to be drip-proof and dust-tight. Provide all doors with

hinges and screw fasteners for holding the doors closed. Fabricate each door as a part of the structure and not part of the unit.

7. Equip the doors for motor control compartments with a motor circuit

protector operating mechanism, thermal overload relay reset mechanism, controls and indicating lights and other required devices as shown.

8. Equip the doors for branch feeder equipment with a circuit breaker operating

mechanism.

9. Provide mechanical interlocks between the compartment door and circuit breaker operating mechanism to prevent opening of the door unless the breaker is in the OFF position, and to prevent closing the breaker unless the door is fully closed.

10. Provide circuit breaker operating mechanisms or handles that are

padlockable in the OFF position with room for a minimum of three padlocks.

11. Provide units having devices that are serviceable from the front, without

provisions for rear access.

12. Provide control power transformers, relays, timers, alternators and accessories for each unit as shown or specified.

E. Wiring:

1. Provide NEMA Class II Type B wiring for the motor control centers,

including internal interlock and internal wiring between controller units and devices.

2. Provide internal wiring runs for interconnecting units with stranded

switchboard wire having 600-volt rated, flame-resistant, type SIS insulation.

AARHIP 16445-9

Provide No. 14 AWG wire for control interconnections. Provide power connections as required for the service.

3. Provide No. 10 AWG or larger stranded copper wire with NEC Type SIS

insulation for all current transformer secondary wiring.

4. Provide wire markers at each end of all wires.

5. Where wiring connections are made to equipment mounted on hinged doors, provide connections with extra flexible wires suitably cabled together and cleated.

6. Provide the wiring of all control connections to individual terminal blocks at

each motor starter. Locate terminal blocks for front access.

7. Provide interlocking wiring between units of a motor control center or between units of grouped centers as internal wiring with terminals provided for external connections.

8. Provide sufficient pull apart terminal blocks for all devices external to the

motor control center.

9. Provide communication cables from the microprocessor-based metering system and microprocessor-based overload protection systems to a single terminal block located in the incoming line structure.

F. Magnetic Starters: Provide 480-volt, 3-phase, 60-hertz across-the-line

combination motor circuit protector and magnetic starters having individual control power transformers.

1. Provide full-voltage nonreversing; full voltage reversing; full voltage

two-speed nonreversing two-winding; and full voltage two-speed nonreversing one-winding starters as required.

2. Provide starter contacts of the replaceable, spring-loaded, wedge type with

silver-cadmium oxide-plated contact surfaces. Provide replaceable coils of the epoxy sealed type.

3. Thermal Overload Elements: Provide each magnetic starter unit with a

Class 20 thermal overload element and all required accessories. Provide size five and larger starters with current transformer operated overload relays.

a. Provide overload relays of the bimetallic type with an adjustment

knob that allow plus or minus 15 percent adjustment of the nominal heater rating.

AARHIP 16445-10

b. Provide and adjust overload relays to match the associated motor nameplate running current rating. Size the overload relays after approval of the corresponding motor.

c. Provide a set of isolated normally-open and normally-closed contacts

for each overload relay.

4. Replaceability: Provide starters having component parts that are easily replaceable.

5. Equip each starter with all required auxiliary contacts.

G. Motor Circuit Protectors: Provide a motor circuit protector for each combination

starter using molded-case, air-break type designed for 600-volt, 60-hertz service with an interrupting capacity of 65,000 rms symmetrical amperes at 480 volts. Provide three-pole motor circuit protectors with magnetic, adjustable-trip units actuating a common tripping bar to open all poles when an overload or short circuit occurs. Provide motor circuit protectors with no thermal elements. Provide magnetic trip units capable of being adjusted from 700 to 1,300 percent of the motor full load amperes.

H. Contactors: Provide NEMA sized, 30 ampere minimum, contactors for electric

heating and other nonmotor loads equal to the motor starters except without overload relays or heaters.

I. Solid State Reduced Voltage Combination Starter:

1. Provide solid-state reduced voltage starters that achieve reduced voltage

starting and once a motor reaches full speed, automatically close a run contactor in parallel with the solid state devices to handle the motor’s continuous duty operation. Provide solid-state starters that transfer the motor from the run contactor back to the solid-state devices to provide a smooth stepless stop.

2. Provide solid-state reduced-voltage starters that consist of a SCR based

power section, logic board and paralleling run contactor.

3. Rate the solid-state reduced-voltage starter for severe duty providing a ramp current of 450 percent of motor full load current for 30 seconds and capable of starting the motor four times per hour.

4. Provide solid-state, reduced-voltage starters having the following features:

a. Motor running overload protection

b. Six SCR control

AARHIP 16445-11

c. Phase loss and phase reversal protection

d. Kick-start: Adjustable 0 to 85 percent of locked rotor current for 0 to 2 seconds to provide additional torque to start motor.

e. Ramp Start: Adjustable 0 to 180 seconds to provide constant increase

in torque of the motor

f. Current limit Start: Adjustable 0 to 85 percent of locked rotor current to limit the maximum current drawn by the motor during the startup 0 to 180 seconds ramp time.

g. Soft Stop: Adjustable 0 to 60 seconds for controlled stopping of

motor.

h. Overtemperature protection

i. Selectable overload trip class (5, 10, 20 and 30 seconds)

j. A normally open (NO) contact to indicate when the run contactor is closed and a normally open (NO) contact to annunciate fault conditions, and display on the logic board the type of fault (current trip, phase loss, phase rotation).

5. Provide motor circuit protector for shot-circuit protection.

J. Feeder Circuit Breakers: Provide molded-case type, two- or three-pole feeder

circuit breakers as shown, with a minimum voltage rating of 600-volt ac.

1. Interrupting Ratings: Provide an interrupting capacity of 65,000 rms symmetrical amperes at 480 volts. Base interrupting rating on the IEEE and NEMA Standard duty cycle for this class of equipment.

2. Provide circuit breakers trip units as follows:

a. Provide individual, thermal-magnetic trip units for all frame sizes

smaller than 400 amperes.

b. Provide solid-state trip units for all frame sizes 400 amperes and larger.

c. Provide trip units that actuate a common tripping bar to open all poles

when an overload or short circuit occurs on any one.

AARHIP 16445-12

d. Provide trip elements with inverse time tripping and instantaneous tripping at about ten times the normal trip device rating.

e. Provide circuit breakers with trip-free handles.

K. Main and Tie Circuit Interrupters: Provide all main and tie circuit interrupters

rated as shown, of equal construction to the feeder breakers, and with the following additional features:

1. Adjustable ground fault pickup and delay setting for breakers with trip

ratings of 1,000 amperes or larger.

2. Auxiliary normally open and normally closed contacts and tripped alarm contacts.

3. Key interlocks as shown.

L. Instrument Transformers: Provide transformers in an accuracy class to meet the

requirements of ANSI Standards, and for the secondary burdens connected to the transformers.

1. Provide dry-wound type, current transformers with fully coordinated

insulation for 600-volt insulation class.

2. Provide window-type, current transformers for ground sensing where shown.

3. Provide potential transformers rated at 480 to 120 volts.

M. Microprocessor-Based Metering and Protection System: Provide a

microprocessor-based metering and protection system having the following features:

1. UL recognized component meeting IEEE C37.90.

2. Housed in a enclosure suitable for door mounting.

3. Derive control power from metered line.

4. Auto ranging metering of the following values:

a. AC amperes in each phase, 0.5 percent accuracy b. AC voltage, phase-to-phase, phase-to-neutral, 0.5 percent accuracy c. Watts, 1 percent accuracy

AARHIP 16445-13

d. Vars, 1 percent accuracy e. Power factor, 2 percent accuracy f. Frequency, 0.5 percent accuracy g. Watt demand, 1 percent accuracy with programmable 5-, 10-, 15-, 30-

minute intervals h. Watt-hours, 1 percent accuracy i. Percent total harmonic distortion through the 31st harmonic

5. Protection system with the following functions:

a. Voltage phase loss, less than 50% nominal line voltage

b. Current phase loss, less than 1/16 of the largest phase

c. Voltage phase unbalance, 5 to 40% in 5% increments

d. Phase voltage reversal

e. Overvoltage, 105 to 140% in 5% increments

f. Undervoltage, 95 to 60% in 5% increments

g. Time delay for overvoltage, undervoltage, and phase unbalance, zero

to twenty seconds in one second intervals.

6. Separate Form C (NO/NC) trip and alarm outputs contacts rated 10 amperes at 115-volt ac or 30-volt dc resistive.

7. Addressable communications card capable of transmitting all data over a

modbus two-wire RS485 link to the Plant SCADA System.

a. The following breakers are provided with a Microprocessor Metering System to be monitored in Plant SCADA System:

(1) Motor Control Center MCC-51 Main Breaker Nos. 1 and 2 (2) Motor Control Center MCC-52 Main Breaker Nos. 1 and 2 (3) Motor Control Center MCC-53 Main Breaker Nos. 1 and 2 (4) Motor Control Center MCC-54 Main Breaker Nos. 1 and 2 (5) Motor Control Center MCC-55 Main Breaker Nos. 1 and 2 (6) Motor Control Center MCC-56 Main Breaker Nos. 1 and 2

AARHIP 16445-14

b. The following data from each of these breakers are to be monitored in the Plant SCADA System:

(1) Voltage (V) (2) Current (A) (3) Real Power (KW) (4) Reactive Power (KVAR) (5) Total Power (KVA)

N. Transient Voltage Surge Suppression (TVSS):

1. Provide transient voltage surge suppression (TVSS) equipment that complies with UL 1449 and UL 1283.

2. Provide units with a maximum, continuous-operating voltage that exceeds

115 percent of the nominal system operating voltage.

3. Provide TVSS equipment suitable for wye configured systems.

4. Provide TVSS equipment having directly connected suppression elements between line-neutral (L-N), line-ground (L-G), and neutral-ground (N-G).

5. Provide TVSS equipment that distributes the surge current to all MOV

components to ensure equal stressing and maximum performance and provides equal impedance paths to each matched MOV.

6. Provide high-performance EMI/RFI noise rejection filters that attenuate the

electric line noise at least 55 dB at 100 kHz using the MIL-STD-220A insertion loss test method.

7. Wire internal components with connections utilizing low impedance

conductors and compression fittings.

8. Provide a monitoring panel for each system that incorporates the following features:

a. Green/red solid state indicator light to indicate which phase(s) have

been damaged. b. A flashing trouble light to indicate fault detection c. Transient event counter d. Audible alarm e. Form C dry contacts for remote indication of the unit status.

AARHIP 16445-15

9. Provide TVSS’s suitable for service entrance or branch location application with a minimum total surge current capable of withstanding 250kA or 160kA per phase respectively or as shown.

O. Control Power Transformers: Provide individual control power transformers for

each starter to derive the 120 volts for the unit's control circuit meeting the requirements of Section 16491. Ground the unfused leg of the secondary to the enclosure.

P. Push Buttons, Selector Switches and Indicating Lights: Provide push buttons,

selector switches and indicating lights including legend plates having the same type, appearance, shape and catalog number throughout each motor control center meeting the requirements of Section 16491.

Q. Control Components: Provide control components including elapsed time meters,

control relays, latching relays, time delay relays, reset timers, repeat cycle timers, alternators, phase failure and undervoltage relay and ground fault protection relays meeting the requirements of Section 16491.

R. Feeder Cable Terminals: Provide closed-end, compression-type, solderless

connectors and terminals, suitable for copper conductors for terminating cables in accordance with Section 16121.

S. Wiring Schematic: Provide a schematic wiring diagram of each unit and affix it to

the inside of the door of that unit.

T. Identification: Provide nameplates having the same type, appearance and shape throughout each motor control center in accordance with the requirements of Section 16075.


A. Tests: Shop test each motor control center in accordance with IEEE and NEMA standards.

1. Operational Tests: After the equipment has been completely assembled,

perform operational tests to determine the general operating conditions and circuit continuity. Also, perform high potential tests and other standard tests for that particular class of equipment.

PART 3 EXECUTION

3.1 INSTALLATION


AARHIP 16445-16

B. Adjustments: Set all motor circuit protectors and circuit breakers for the approved

short circuit and coordination study.

C. Overloads: Adjust the thermal overloads on each phase of the starter units to the actual motor installed.

D. Cable Connections: Terminate and label all field wiring per the approved

diagrams.

E. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with equipment manufacturers' published torque tightening recommendations. Where manufacturers' torquing requirements are not available, tighten connectors and terminals in accordance with UL Standard 486 A.



B. Tests: Perform the following field tests:

1. Close and open each circuit breaker and motor circuit protector to test

operation.

2. Energize the motor control center and test for hot spots.

3. When site conditions permit, energize and de-energize each equipment item served by each motor control center, testing the complete control sequence of each item.


A. Manufacturer’s Representative: Furnish the services of a qualified, factory-trained service engineer to assist in installation, start-up, field testing, calibration, placing into operation and provide training of each motor control center, as specified in Section 01820.

1. Furnish the services of a service engineer when the equipment is placed into

operation.

2. Furnish the services of a service engineer at job site as often as necessary until all problems are corrected and the equipment installation and operation are satisfactory.

3. Training: Following completion of installation and field testing provide

training for 6 employees of the OWNER in the proper operation,

AARHIP 16445-17

troubleshooting and maintenance of the equipment as outlined below. All training will be at the OWNER’S facilities at a time agreeable to the OWNER:

a. Operational Training: A minimum of two 4-hour sessions combining

both classroom and hands-on instruction, excluding travel time.

b. Maintenance Training: A minimum of two 4-hour sessions combining both classroom and hands-on instruction, excluding travel time.

B. SCADA Programming: Provide service engineer at the job site as often as

necessary to assist in the programming of the SCADA system in accessing the memory map of each device.

C. Operation and Maintenance: Furnish operation and maintenance instructions as

specified in Division 1. 3.4 CLEANING AND PAINTING

A. Shop Painting: Paint motor control centers in accordance with Section 09900.

B. Field Painting: Clean and touch up any scratched or marred surface to match original finish.

END OF SECTION

AARHIP 16445-18


AARHIP 16460-1

SECTION 16460

GENERAL PURPOSE DRY TYPE TRANSFORMERS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing ventilated, dry-type transformers.


Following:

1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16130 - Electrical Raceway Systems 4. Section 16060 - Grounding

1.2 REFERENCES


1. ASTM D 635 - Test Method for Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position


3. NEMA ST 20 - Dry Type Transformers for General Applications

1.3 SUBMITTALS


B. Product Data and Information: Furnish manufacturer's data including:

1. KVA ratings 2. Service voltages 3. Impedance and X/R ratio 4. Number of phases 5. Taps 6. Insulation class 7. Sound level

AARHIP 16460-2

8. Dimensions 9. Weights 10. Mounting details

C. Quality Control: Furnish the following as specified in Division 1.

1. Test Reports:

a. Certified production reports for sound-level and temperature in

accordance with NEMA ST 20

2. Manufacturer's Installation Instructions

D. Operations and Maintenance Manuals: Furnish 6 copies of manufacturer's operations and maintenance manuals.


A. UL Label: Provide UL listing label or mark. 1.5 DELIVERY, STORAGE AND HANDLING

A. General: Deliver, store and handle all products and materials as specified in Division 1 (and as follows:)

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. General Electric Company 2. Cutler Hammer 3. Square D Company

2.2 MATERIALS

A. General: Provide dry-type transformers suitable for indoor use.

B. Insulation: Provide transformers above 15 kVA with 220-degree C temperature insulation materials. Provide transformers 15 kVA and below with a minimum of 185-degree C insulation materials.

C. Flame Retardant Materials: Provide transformers with flame retardant materials

that will not support combustion as defined in ASTM D 635.

AARHIP 16460-3

2.3 FABRICATION

A. Transformer Taps: Provide transformers rated over 15 kVA with at least two 2-1/2 percent full capacity taps above and below nominal in the primary winding. Provide transformers rated 15 kVA and below with two five percent taps or with four 2-1/2 percent taps below rated voltage on the primary winding.

B. Windings: Provide primary and secondary windings fabricated from copper

conductors.

C. Voltage and KVA Ratings: Provide three-phase or single-phase transformers with primary and secondary voltages and kVA ratings as specified.

D. Connections:

1. Three phase: Primary - 3-wire Delta; Secondary - 4-wire, solidly-grounded

wye.

2. Single Phase: Primary - 2-wire; Secondary - 3-wire with mid-point solidly-grounded.

E. Continuous Operations: Provide transformers suitable for continuous operation at

the rated kVA with a normal life expectancy as defined in NEMA ST 20 and the performance obtained without exceeding 115 degrees C average temperature rise by resistance or 145 degrees C hot spot temperature rise in 40-degree C maximum ambient and 30-degree C average ambient. Do not provide transformers that exceed 185-degree C maximum coil hot spot temperature.

F. K-Factor: Provide three-phase transformers with a K-Factor not less than 13.

G. Electrostatic Shields: Provide electrostatic shields between windings.

H. Construction: Provide transformers with core mounting frames and enclosures of

welded and bolted construction with sufficient mechanical rigidity and strength to withstand shipping, erection and short circuit stresses.

I. Sound Levels: Do not provide transformers that exceed the following sound

levels:

Transformer kVA Average Sound Level in dB

NEMA ST 20 0 – 09 40 10 - 50 45

51 – 150 50

AARHIP 16460-4

J. Lifting Lugs and Jacking Plates: Provide lifting lugs and jacking plates as required on the transformer.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all transformers and provide guards as specified by the latest NEC and ANSI standards, and in accordance with manufacturer's instructions.

B. Clearances: Provide clearance around the transformer meeting the manufacturer's

recommendation.

C. Supports: Provide suitable supports for all transformers. Mount transformers on one inch of Korfund, or equal sound-absorbent material.

D. Primary Disconnect: Provide primary disconnect circuit breaker or disconnect

switch as shown or required. 3.2 CLEANING AND PAINTING

A. Shop Painting: Paint transformers meeting the requirements of Section 09900.

B. Field Painting: Clean and touch up scratched and marred surfaces to match the original finish.

END OF SECTION

AARHIP 16491-1

SECTION 16491

CONTROL COMPONENTS AND DEVICES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing manual starters, motor controllers and remote control stations. In addition, the requirements for control components and devices for use in equipment provided under various other sections.


Following:

1. Section 09900 - Painting 2. Section 16050 - Basic Electrical Materials and Methods 3. Section 16121 - Wires and Cables - 600 Volts and Below 4. Section 16055 - Requirements for Shop-Assembled Equipment 5. Section 16266 - Adjustable Frequency Drives 6. Section 16268 - Medium Voltage Adjustable Frequency Drives 7. Section 16075 - Electrical Identification 8. Section 16060 - Grounding 9. Section 16445 - Motor Control Centers 10. Section 16421 - Contractors 11. Section 16500 - Lighting

1.2 REFERENCES


1. NEMA ICS 2 - Industrial Control Devices, Controllers and Assemblies

2. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

3. UL 486A - Wire Connectors and Soldering Lugs for Use With

Copper Conductors 1.3 SYSTEM DESCRIPTION


AARHIP 16491-2

B. Motor Controllers: Provide motor controllers suitable for 480-volt, three-phase, three-wire, 60-hertz operation.

C. Control Devices: Provide control devices suitable for operation at 120-volts, 60-

hertz, unless specifically noted otherwise.

D. Insulation Class: Provide control equipment and devices that meet the requirements of the 600-volt insulation class.

1.4 SUBMITTALS


B. Product Data and Information: Furnish catalog data for all associated equipment

and devices.

C. Shop Drawings: Furnish shop drawings customized to the project for manual starters, motor controllers and remote control stations that include the following:

1. Outline drawings showing dimensions, identification of components and a

nameplate schedule for all units.


3. Individual schematic and wiring diagrams for each motor controller

D. Equipment Ratings: Obtain and enter full performance details on all motors and other equipment being served on the above drawings.


A. Codes: Provide manual starters, motor controllers and remote control stations that are in accordance with NEMA ICS 2.

1. Provide manual starters, motor controllers and remote control stations that

are in accordance with the NEC and local codes.

B. UL Listing: Provide UL-listed manual starters, motor controllers and remote control stations.



AARHIP 16491-3

B. Storage and Protection: Store all equipment and materials in a dry, covered, heated and ventilated location. Provide any additional measures in accordance with manufacturer's instructions.

1.7 SPARE PARTS


1. Two control stations of each type provided.

2. Three of each type of manual starter.

3. One of each type of motor controllers.


PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Manuel Starters, Motor Controllers and Remote Control Stations:

a. Cutler-Hammer b. General Electric Company c. Square D Company d. Appleton Electric Company e. Crouse-Hinds Company

2. Control Relays:

a. Cutler-Hammer b. Square D Company

3. Timing Relays:

a. Agastat 7000 Series b. Eagle Signal

AARHIP 16491-4

4. Reset and Repeat Cycle Timers:

a. Eagle Signal b. Automatic Timing and Controls

5. Alternators

a. Time Mark Corp. Model 261 b. ABB SSAC Inc. Series ABP

6. LED Stack Lights

a. Edwards Signaling and Security Systems

7. Traffic Lights and Traffic Signal Bulbs

a. Lights to Go

2.2 MANUAL MOTOR STARTERS

A. Manual Motor Starters: Provide toggle-type, thermal-switch, manual, motor

starters with pilot lights for all 120-volt, single-phase motors rated less than ½ hp.

1. Where shown or required, provide starters complete with a HAND/OFF/AUTO selector switch.

2. Provide starter enclosures as specified under the section Remote Control

Stations. 2.3 MOTOR CONTROLLERS

A. General: Provide 480-volt, 3-phase, 60-hertz, across-the-line, combination motor

circuit protector magnetic starters with individual control power transformers.

B. Magnetic Starters: Provide magnetic starters as follows:

1. Full voltage nonreversing or full voltage reversing, as required.

2. Starter contacts of the replaceable, spring-loaded, wedge type with silver-cadmium oxide plated contact surfaces.

3. Provide replaceable coils of the epoxy sealed type.

AARHIP 16491-5

4. Thermal Overload Elements: Class 20 thermal overload element and all required accessories. Provide size five and larger starters with current transformer operated overload relays.

a. Bimetallic type with an adjustment knob which allow plus or minus

15-percent adjustment of the heater’s nominal rating.

b. Size the overload relays after approval of the corresponding motor.

c. Provide and adjust overload relays that match the associated motor nameplate running-current rating.

d. Provide a set of isolated, normally-open and normally-closed contacts

for each overload relay.

C. Motor Circuit Protectors: Provide a motor circuit protector for each combination starter as follows:

1. Molded-case, air-break type designed for 600-volt, 60-hertz service with an

interrupting capacity of 65,000 rms symmetrical amperes at 480 volts.

2. Three-pole motor circuit protectors with magnetic, adjustable-trip units actuating a common tripping bar to open all poles when an overload or short circuit occurs.

3. No thermal elements.

4. Magnetic trip units capable of being set from 700 to 1,300 percent of the

motor full-load amperes.

D. Control Components: Provide push buttons, switches, indicating lights, transformers, relays and timers as specified under the section Control Components.

E. Enclosures: Provide motor controllers installed in NEMA 250 rated enclosures as

follows:



AARHIP 16491-6

AREA ENCLOSURE Corrosive areas as defined in Section 16050 or as shown



2.4 REMOTE CONTROL STATIONS

A. General: Provide heavy-duty, oiltight remote control stations, consisting of push buttons, indicating lights, and selector switches with double-break silver contacts meeting the requirements specified under the section Control Components.

B. Enclosures: Provide motor controllers installed in NEMA 250 rated enclosures as

follows:



Corrosive areas as defined in Section 16050 or as shown



C. Lockout Attachments: Where shown, provide lockout attachments as follows:

1. Push buttons with padlockable attachment that holds the button depressed.

2. Selector switch with a padlockable attachment that covers the selector switch operators and allows the switch to be set in any position. Selector switch operators that use a removable key are not acceptable.

AARHIP 16491-7

2.5 CONTROL COMPONENTS

A. Push Buttons, Selector Switches and Indicating Lights:

1. Provide heavy-duty, oiltight, 30.5 mm, push-button or selector-switch control stations arranged for flush-panel mounting.

2. Provide the additional switches, relays, and other electrical accessories

necessary to control and safeguard the operation of the associated equipment.

3. Provide 30.5 mm, low-voltage, push-to-test, LED type indicating lights

suitable for operation at 120-volt, 60-hertz ac control circuit voltages.

4. Color code indicating lights as follows:

Red - Motor running or valve open Green - Motor off or valve closed Amber - Capable of operation from this point Blue - Alarm or trouble condition

B. Control Power Transformer: Provide an individual, control power transformer for

each starter to derive the 120 volts for the unit's control circuit. Provide transformers with sufficient capacity to meet the energy demands for all related control components including relays, solenoids and other indicated items. Provide dual fuses on the primary and one fuse on the secondary. Ground the unfused leg of the secondary to the enclosure.

C. Elapsed Time Meters: Provide nonreset-type elapsed time meters to register up to

9999.9 hours, having square cases suitable for panel mounting and having coils for 120-volt, 60-hertz operation.

D. Control and Latching Relays: Provide control and latching relays of 600-volt

class, machine-tool quality with convertible contacts. Provide relay-operating contacts rated at a minimum of 10 amperes, 120 volts, 60 hertz.

E. Timing Relays: Provide four-pole, double-throw, timing relays with timing ranges

and ON/DELAY or OFF/DELAY operation as required. Provide contacts rated a minimum of 10 amperes at 120 volts, 60 hertz.

F. Reset and Repeat Cycle Timers: Provide electromechanical or solid-state type

reset and repeat cycle timers, with timing ranges and functions as indicated. Provide contacts rated at a minimum of 10 amperes, 120 volts, 60 hertz. Solid-state output contacts are not acceptable.

AARHIP 16491-8

G. Alternators: Provide alternators suitable for 120-volt, 60-hertz operation.

1. Provide alternator-operating double pole, double throw cross wired contacts rated at minimum of 7 amperes at 120 volts, 60 hertz.

2. Provide alternators suitable for circuit design requiring alternating "lead-lag"

operations.

3. Provide alternators with integral three position switch “Load 1 – Alternate – Load 2” switch and LED status indicators.

4. Provide 8-pin plug-in alternator with an 8-pin socket.

H. Phase Failure and Undervoltage Relay: Provide a 3-phase, power monitor to

detect phase failure, phase reversal, phase unbalance and undervoltage, suitable for operation at 480 volts. Provide an adjustable, drop-out voltage range of 380 to 500 volts and an adjustable time delay from 0.2 to 20 seconds. Provide a normally-open and normally-closed alarm contact rated 10 amperes at 120 volts with automatic reset.

I. Ground Fault Protection Relay: Provide a manually-reset, ground-sensing relay

suitable for use with a window-type current transformer. Provide an adjustable time delay and pickup settings. Provide single-pole, double-throw, alarm contacts rated 10 amperes at 120 volts.

2.6 LED STACK LIGHTS (FOR TRUCK BAY ENTRANCE CONTROL)

A. The stack lights shall have molded-in gasketed lens modules.

B. The stack lights shall be suitable for outdoor installations.

C. Provide two stack light assemblies for the entrance to each truck bay (total of four light assemblies). At each truck entrance, one stack light is for liquid loading and one is for solids loading control indication.

D. Provide each stack light with two light modules, one red and one green. The green

module shall be on the bottom.

E. Provide steady-on LED light modules for the stack lights.

F. The stack lights shall be suitable for operation at 120 VAC, 60 Hertz, wired for independent control of each light color from an external control contact (separate inputs for red and green plus a common).

G. Provide Edwards Signaling and Security Systems 102 Series stack lights or equal.

AARHIP 16491-9

2.7 TRAFFIC LIGHTS (TRUCK LOADING CONTROL LIGHT BOXES)

A. The traffic lights shall be made of a lightweight-polycarbonate resin.

B. The traffic lights shall be suitable for indoor/outdoor installations.

C. Each traffic light shall be a two-light assembly with a red light and a green light. The traffic light shall have cap style visors.

D. The traffic lights shall be suitable for operation at 120 VAC, 60 Hertz and are to be

wired for independent control of each light color from an external control contact (separate inputs for red and green plus a common).

E. Provide Lights-To-Go Model PSRG traffic light as available on trafficlights.com

or equal.

F. Provide one light assembly for each truck bay (total of two) to be located as shown.

G. Traffic Signal Bulbs

1. Provide a 40W traffic signal bulb rated for a 17,000 hour life.

2. The traffic signal bulb shall be suitable for operation at 120 VAC, 60 Hertz.

3. Provide Lights To Go Model L40W traffic signal bulbs as available on

trafficlights.com or equal.

4. Provide a total of four spare bulbs.

PART 3 EXECUTION

3.1 INSTALLATION


B. Mounting: Mount manual starters, motor controllers and remote control stations 4

feet 6 inches from the finished floor up to their centerlines, unless otherwise shown. Mount all devices at least ½ inch away from concrete wall surfaces.

C. Adjustments: Set all motor circuit protectors and circuit breakers based on the

approved short circuit and coordination study.

D. Overloads: Adjust the thermal overloads on each phase of each starter unit for the actual motor installed.

AARHIP 16491-10

E. Cable Connections: Terminate and label all field wiring per the approved

diagrams.

F. Torque Requirements: Tighten electrical connectors and terminals, including screws and bolts, in accordance with equipment manufacturers' published torque tightening recommendations. Where manufacturers' torquing requirements are not available, tighten connectors and terminals in accordance with UL Standard 486 A.



B. Operation and Maintenance: Furnish operation and maintenance instructions as

specified in Division 1.

END OF SECTION

AARHIP 16500-1

SECTION 16500

LIGHTING

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing complete lighting systems as specified and as shown.


1. Section 09260 - Gypsum Wallboard System 2. Section 09511 - Suspended Acoustical Ceilings 3. Section 09900 - Painting 4. Section 16050 - Basic Electrical Materials and Methods 5. Section 16075 - Electrical Identification 6. Section 16130 - Electrical Raceway Systems 7. Section 16140 - Wiring Devices 8. Section 16421 - Contactors 9. Section 16491 - Control Components and Devices

1.2 REFERENCES


1. NEC - National Electrical Code 2. UL 924 - Emergency Lighting and Power Equipment


A. System Components: Provide all interior and exterior lighting fixtures including all supports, plaster frames, trim rings, outlet boxes, light standards, concrete bases, ground rods, and all accessories and appurtenances required for complete functioning lighting systems, as shown and as specified.

B. Performance Requirements: Provide lighting systems that adhere to code and are

in accordance with manufacturers recommendations. 1.4 SUBMITTALS


AARHIP 16500-2

B. Manufacturer's Data and Information:

1. Furnish catalog data for all equipment provided under this section.

2. Furnish complete photometric data reports from an independent testing laboratory with shop drawings for each luminaire. Luminaires submitted without photometric data will not be reviewed.

C. Shop Drawings: Furnish layout drawings showing arrangement, circuiting,

erection requirements of equipment and details of construction and assembly.

D. Quality Control: Furnish the following:

1. Manufacturers certificates for equipment performance.

2. Manufacturers test reports.

3. Manufacturers installation instructions.

E. Operation and Maintenance Manuals: Furnish two copies of the operation and maintenance manuals for lighting equipment as specified in Division 1.


A. Codes: Provide materials and workmanship that meet the requirements of the NFPA Standards and the National Electrical Code.

B. Regulatory Requirements: Provide UL and FMS listed and labeled lighting

equipment. 1.6 DELIVERY, STORAGE AND HANDLING


B. Storage and Protection: Store and protect equipment, components and accessories

in accordance with the manufacturer's instructions and in accordance with the requirements of Division 1.

1.7 SPARE PARTS


1. Fixtures: Provide one lighting fixture of each type for every 40, but not less than one, for each type provided.

AARHIP 16500-3

2. Ballasts: Provide 10 percent, but not less than two, of each type of:

a. Fluorescent ballast provided.

b. Metal halide ballast and capacitor provided.

c. High pressure sodium ballast, capacitor and starting aid provided.

d. Compact fluorescent ballast provided.

3. Fluorescent Lamps: Provide 20 percent, but not less than 12, of each type of fluorescent lamp provided.

4. Metal halide Lamps: Provide 20 percent, but not less than 12, of each type

of metal halide lamp provided.

5. High pressure sodium Lamps: Provide 20 percent, but not less than 12, of each type of high pressure sodium lamp provided.

6. Compact fluorescent Lamps: Provide 20 percent, but not less than 12, of

each type of compact fluorescent lamp provided.

7. Lens and Globes: Provide 10 percent, but not less than 6, of each type of lens or globes provided.

8. Provide one contactor of each type provided.

9. Provide two of each type photo cell provided.

10. Provide five sets of special tools that may be required for maintenance of

lighting fixtures.

B. Packaging: Deliver all spare parts neatly wrapped or boxed, indexed and tagged with complete information for use and reordering.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. General: The lighting fixture descriptions and catalog numbers listed in the Lighting Fixture Schedule are used to indicate the acceptable quality, design and distribution characteristics of approved lighting fixtures.

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B. Acceptable Manufacturers: Acceptable manufacturers are listed below. Other manufacturers of equivalent products may be submitted for review.

1. Lamps:

a. General Electric Company Lamp Division b. Philips Lighting Company c. Osram Sylvania d. Venture Lighting

2. Ballasts:

a. Advance Transformer Company b. Universal Manufacturing Corporation c. Osram Sylvania

3. Photocells:

a. Tork b. Intermatic

2.2 MATERIALS

A. General: Provide lighting fixtures complete with all required lamps, ballasts, fittings, receptacles, gaskets, globes and diffusers, as shown and scheduled.

B. Wiring Channel Construction: Construct the wiring channels to permit access to

the auxiliaries and sockets for repair or replacement of components without removal of the fixture.

C. Fluorescent Fixture Diffusers: Secure diffusers for fluorescent fixtures securely in

place in a manner which enables them to be removed when required.

D. Suspended Ceilings: Provide fixtures suitable for the type of suspended ceilings in which they are installed. Provide trim moldings to conceal exposed parts of a concealed ceiling suspension system.

E. Globes: Provide gasketed, heat and impact-resistant, glass globes for incandescent,

metal halide and sodium vapor fixtures.

F. Lamp Holders: Rigidly support screw-type, lamp holders, secure them against turning, and install them in a manner that allows for easy replacement. In general, fixtures designed to accept lamps of different wattages shall have adjustable sockets to allow for variations in lamp light centers. Provide brass, shell-type lamp holders. Aluminum shells will not be accepted.

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G. Insulation: Provide a wire insulation systems and components that are capable of withstanding the temperatures to which they will be subjected in the fixture, while maintaining normal expected ballast life.

2.3 COMPONENTS

A. Ballasts:

1. Provide Class P ballasts for fluorescent fixtures bearing CBM and UL labels having a high power factor. Provide non-PCB capacitors. Provide ballasts with the quietest sound rating available for its type. In general, use A-sound rated, 34-watt, rapid-start, energy saving ballasts. Provide two-lamp ballasts whenever possible, unless specifically noted otherwise.

2. Provide ballasts for metal halide and sodium vapor fixtures that are

integrally mounted and suitable for operating the high intensity discharge lamp of the type and wattage rating scheduled. Provide non-PCB capacitors. Provide ballasts with sufficient open circuit voltage to strike and operate the lamp at temperatures down to 0 degrees F indoors and minus 20 degrees F outdoors. Provide a ballast system that will not fail when a burned-out lamp is left in place for 120 days or less.

a. Provide metal halide ballasts of the constant wattage, autotransformer

type pulse start system.

b. Provide sodium vapor ballasts of the high power factor, lag-type with a minimum power factor of 90 percent. Provide ballasts that have a rated life and lamp lumen output in accordance with the trapezoidal limits described by ANSI. Encapsulate the starting aid in epoxy.

2.4 OUTDOOR LIGHTING

A. General: Provide outdoor lighting luminaires and standards as listed in the Lighting Fixture Schedule.

B. Mounting: Mount outdoor lighting on concrete bases or structures as shown.

2.5 EMERGENCY BATTERY LIGHTING

A. General: Provide emergency battery lighting equipment as listed in the Lighting Fixture Schedule capable of providing emergency lighting instantaneously upon the failure or interruption of the normal electric power supply.

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B. Nonhazardous Locations:

1. Batteries: Provide 12-volt, sealed, maintenance-free, lead-calcium batteries capable of operating 36 watts of light for 1-1/2 hours to 87-1/2 percent of the battery capacity.

2. Charging Systems: Provide solid-state, 2-rate, charging systems consisting

of a high-charge rate and a trickle-charge rate. Provide chargers suitable for operation on 120 or 277 volts.

3. Lamps: Provide 8-watt, sealed-beam tungsten halogen type lamps.

4. Housings: Provide NEMA 4X sealed and gasketed, fiberglass or

thermoplastic enclosures.

5. Controls: Provide a test push buttons and ac ON indicating lights. 2.6 LIGHTING CONTROL PANELS

A. General: Provide lighting control panels consisting of a NEMA Type 12 enclosure with soundproofing, contactors, time switches, relays and controls as shown.

B. Enclosures: Provide enclosures designed for surface mounting, as specified in

Section 16130.

C. Contactors: Provide contactors, as specified in Section 16421. Provide contactors with vibration mounts.

D. Relays and Control Devices: Provide relays, switches, indicating lights as

specified in Section 16491. 2.7 PHOTOCELLS

A. General: Provide SPST photocells suitable for 120-volt operation and capable of switching 1800 VA. Provide photocells that turn on at light levels of 1.5 to 5.5 footcandles and turn off at approximately three times the turn-on value. Incorporate a built-in, approximately 2 minute time delay to avoid false switching due to lights from vehicles or lightning. Provide photocells with a 1/2-inch conduit fitting and a die-cast zinc housing suitable of operating from -40 degrees F to 140 degrees F.

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PART 3 EXECUTION

3.1 PREPARATION

A. Packing: Suitably pack and rigidly brace all equipment and protect it against weather, damage and undue strain during shipment.

3.2 INSTALLATION

A. General: Install lighting fixtures and lamps in accordance with the manufacturer's recommendations and approved shop drawings and as specified in Division 1. Locate fixtures to suit the architectural details of the area involved. Coordinate placement with the details indicated on the architectural reflected ceiling drawings or architectural elevations. Install lamps of proper type, wattage and voltage rating in fixtures prior to completion of project. Install all fixtures to comply with applicable provisions of NEC.

B. Recessed Fixtures: Install recessed fluorescent fixtures in suspended ceiling

openings in conformance with manufacturer's recommendations. Install fixtures with adjustable fittings to permit alignment with ceiling panels. Support recess fixtures using the ceiling suspension system. Provide additional steel work as required to support fixtures. Install recessed fixtures to permit removal from below.

C. Obstructions: In areas, such as equipment and mechanical rooms, which have

obstructions at the ceiling or walls such as ducts, large pipes, groups of pipes, and like items, install fixtures so that maximum utilization of the light is achieved.

D. Accessories: Provide straps, mounting plates, nipples, plaster rings, brackets and

all accessories necessary for proper installation.

E. Suspended Fixture Support: Support suspended fixtures by approved means, consisting of rods, stems attached to studs, hickeys and suitable outlet box cover aligners of the shock-absorbing, vaportight or swivel type having flexible joints permitting fixtures to hang plumb. Install stems using 3/4-inch galvanized steel conduits, unless otherwise specified. Where indicated or required, support fixtures by means of a suspended channel. Provide channels that meet the requirements for the type of conduit provided, as specified in Section 16130. Where the channel is used as the wiring raceway, provide closure strips, end caps and fittings as required for an approved raceway.

F. Connect emergency light fixtures to the branch circuits serving the general lighting

in the area.

G. Exit Fixtures: In general, mount exit signs so that the bottom of the fixture will be three inches above the top of the door frame.

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H. Photocells: Install photocells 6-inches above roof peak with the lens facing north.

I. Nameplates: Install nameplates as specified in Section 16075. 3.3 FIELD QUALITY CONTROL

A. Testing: Test the entire lighting system for continuity and balance after installation and prior to acceptance.

3.4 ADJUSTING

A. Fixtures: Aim and adjust fixtures as shown.

B. Exit Sign Arrows: Adjust exit sign directional arrow as shown.

C. Relamping: Relamp fixtures that have failed lamps at substantial completion. 3.5 OPERATION DEMONSTRATION

A. Manufacturer’s Representative: Furnish the services of an authorized and qualified representative of the manufacturer of the emergency system battery packages for high intensity discharge luminaires as specified in Division 1 and sign and date the manufacturer's warranty book/card on behalf of the manufacturer for the equipment and system components installed.


A. Shop Painting: Shop paint equipment as specified in Section 09900.

B. Steel Surfaces: Prior to final completion of the Work, thoroughly clean all steel surfaces and retouch all scratches and abrasions. Use the same paint as used for shop finishing coats.

C. Photometric Control Surfaces: Clean photometric control surfaces as

recommended by the manufacturer.

END OF SECTION