SPECIAL NOTICE TO BIDDERS PECIAL NOTICE TO
SPECIAL NOTICE TO BIDDERS
1. DOCUMENTS OF NOTE:
Bidders and contractors shall thoroughly familiarize themselves with the City's GENERAL
INSTRUCTIONS TO OFFERERS (8/1/13), hereinafter referred to as the GENERAL INSTRUCTIONS
and incorporated herein, and the GENERAL TERMS AND CONDITIONS OF THE CITY AND COUNTY
OF HONOLULU (8/1/13), hereinafter referred to as the GENERAL CONDITIONS and incorporated
herein by reference.
The GENERAL CONDITIONS may be obtained from the office of the Division of Purchasing or from
their website at:
http://www2.honolulu.gov/wps/portal/main/agencies/pur/pur_home
The GENERAL INSTRUCTIONS and GENERAL CONDITIONS shall be as amended, modified, and/or
supplemented by these Contract Documents.
A bidder or contractor shall not make any claims against the City for losses that may occur as a
result of his failure to familiarize himself with the instructions, conditions, requirements and
terms of the GENERAL INSTRUCTIONS and GENERAL CONDITIONS. A bidder or contractor shall
not use as an excuse the fact that the GENERAL INSTRUCTIONS and the GENERAL CONDITIONS
include instructions, conditions, requirements and terms which are different from those
contained in contract documents utilized on previous City projects.
2. SPECIAL PROVISION SECTIONS OF NOTE:
Bidder's attention is directed to the complete Special Provisions set attached.
3. TAX CLEARANCES:
Bidders' attention is directed to HRS 103-53, relating to the requirement for tax clearances from
the State Department of Taxation and the Internal Revenue Service, as a prerequisite to entering
into a contract and final payment of a contract.
The apparent successful bidder will be required to submit tax clearances from the State
Department of Taxation and the Internal Revenue Service prior to award of the contract. The tax
clearance certificate may be an original or a copy certified by the State Department of Taxation
or a compliance document from the Hawaii Compliance Express.
4. NOISE PERMIT
The Contractor shall obtain and comply with the provisions of the Community Noise Control for
Oahu regulations.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
-1ADDENDUM NO. 3
SPECIAL NOTICE TO BIDDERS
5. STREET USAGE PERMIT
Contractor shall be responsible for obtaining all street usage permits as required for this Project
at no additional cost to the City. The Contractor shall reference SP 109, “Permits” of these
Special Provisions.
6. CONSTRUCTION DEWATERING PERMIT
The City obtained a State of Hawaii, NPDES General Permit Appendix G, Construction Activity
Dewatering for work at the Kailua Regional Wastewater Treatment Plant (Permit No. HI 0021853
for discharge into Nuupia Pond). The Tunnel Contractor has also obtained Permit No. HI
14GE393 for discharge at Ocean Outfall Serial No. 001 as an alternate. Both permits can be
transferred to this Contract, but if used, both existing permits need to be revised at the
Contractor’s expense. See SP 109, “Permits”. The Contractor shall be solely responsible for
obtaining the final approved Permit(s) at no additional cost to the City.
7. PROJECT PROXIMITY
The Project is located within a residential area. Good public relations with all residents affected
by the Project shall be maintained by the Contractor at all times. Special care shall be taken to
safeguard that all persons, private properties, structures and improvements are protected.
Construction impacts shall be kept strictly within the requirements specified in these contract
documents. If excessive complaints are received by the City due to the Contractor’s exceeding
the requirements, the Officer-in-Charge, at his discretion, shall have the right to stop all work on
the Project until satisfactory corrective action is taken.
8. COORDINATION OF WORK AND STAGING AREAS AT KAILUA RWWTP
Bidders and contractors shall be aware that other projects may be in construction concurrently at
the Kailua RWWTP, and other contractors may be onsite at the same time. The work areas and
authorized staging areas for other known projects are noted on the construction drawings, but
may be subject to change. It is the responsibility of the bidders and contractors to coordinate the
work and schedule with Operations and/or any other contractor. Bidders and contractors shall
not make any claims against the City for losses that may occur as a result of his failure to
recognize that other contractors may be onsite and available staging areas (in addition to what
has been authorized for this project) may be limited.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
-2ADDENDUM NO. 3
SPECIAL NOTICE TO BIDDERS
9. PROPOSAL SCHEDULE PROVIDED IN EXCEL FILE FORMAT
Bidders may choose to complete their Proposal Schedule using a Microsoft Excel spreadsheet
file to be provided by the City, upon request by contacting the City (BFS Purchasing, telephone
808-768-5535). This separate Excel file is available solely for the bidder’s convenience and will
automatically compute the TOTAL SUM BID amount and values under the “UNIT TOTAL” column,
upon entering Unit Price or Lump Sum values in the color coded fields. The computed TOTAL
SUM BID amount will also include all predetermined fixed dollar amounts for specified Allowance
and Force Account items. If the Bidder elects to use the Excel file to complete the Proposal
Schedule, he shall confirm that the UNIT TOTAL and TOTAL SUM BID prices computed by the
Excel program are correct prior to the submittal of his bid and shall make no claim against the
City for an error in the program.
A bidder may elect not to use the Excel file in completing the Proposal Schedule and instead use
the more traditional approach by printing the Proposal Schedule found in the contract
documents and fill out and compute his bid values by hand.
Bidders using the Excel file shall ensure their printed Proposal Schedule has the same page
format and total number of pages as the original file. Bidders should be aware that their printed
output may differ from the original file due to the printer being used. The bidder may have to
purchase necessary software such as Adobe Acrobat (Version 5.0 or later) to achieve the desired
results.
The City reserves the right to reject a bid containing an improperly formatted Proposal Schedule
or for tampering and modifying the original Excel file.
10. OFFICIAL COMMENCEMENT DATE AND SITE ACCESS
Bidders shall be aware that this Project is a subsequent and connecting project to the
Kaneohe/Kailua Sewer Tunnel Project, City Project No. W11-12 (Tunnel Project). Bidders shall
be aware that access to the project sites on the official commencement date will be limited
and/or unavailable until certain project components of the Tunnel Project are completed. See
Section 01014 for site access dates. A Preconstructiion Planning Phase as defined in Section
01110 has been established from the Notice to Proceed date.
11. SOLICITATION TIME SCHEDULE
Milestone
Date
Solicitation Date
Pre-Bid Conference
Request for Hawaii Product Preference due date
Questions/requests for substitution due date
Last day for addenda to be issued
Opening date
December 8, 2014
January 7, 2015
February 20,
20, 2015
February 20,
20, 2015
March 6,
6, 2015
2015
March 12,
12, 2015,
2015 2:00 pm, HST
END SPECIAL NOTICE TO BIDDERS
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
-3ADDENDUM NO. 3
SPECIAL NOTICE TO BIDDERS
SP 103 – EXAMINATION OF SITE
103.01 DESCRIPTION
A.
This special provision replaces the provisions of Section 2.4 of the GENERAL
INSTRUCTIONS.
103.02 SITE CONDITIONS
A.
Each bidder is responsible for making an independent evaluation and judgment of
the site conditions, market conditions, existing facilities, local conditions, site access,
uncertainty of weather, soil conditions, applicable federal, state, and local laws and
regulations, and all other contingencies, and of the difficulties of the execution of the
work called for by the Contract Documents. Information relating to site, locale,
market or other conditions derived from the Contract Documents or from other
reports or investigations made available by the City, or from the Officer-in-Charge, is
not warranted or guaranteed, either expressly or implied, by the City. In submitting a
bid, a bidder shall rely on the bidder’s own interpretation of the data disclosed by
soils and other geologic tests, borings or reports.
B.
Reports relating to site and subsurface conditions are available for review at the
City’s office:
C.
1.
Final Environmental Impact Statement, Kaneohe/Kailua Wastewater
Conveyance and Treatment Facilities, May 2011, prepared by Wilson
Okamoto Corporation;
2.
Geotechnical Baseline Report, Kaneohe/Kailua Sewer Tunnel Project,
February 2013, prepared by Jacobs Associates;
3.
Final Geotechnical Data Report, Kaneohe/Kailua Sewer Tunnel Project,
February 2013, prepared by Yogi Kwong Engineers, LLC;
4.
Preliminary Geotechnical Exploration Report, Kaneohe to Kailua Wastewater
Facilities Plan, July 2011, prepared by Geolabs, Inc.
The conditions indicated by such investigations apply only at the specific location of
each boring or excavation at the time the borings or excavations were made, and it is
not a warranty or guarantee, either expressed or implied, that the conditions will be
the same in that or other locations during actual construction. When a log of tests,
borings, or excavations showing a record of the data obtained by the investigation of
subsurface conditions is provided to bidders it represents only the data recorder’s
determination of the type or character of the materials encountered at that specific
location. Nothing in any of these documents shall be construed as a representation
or warranty by the City of any subsurface condition and nothing in any document
shall relieve any bidder of the bidder’s obligation to make an independent
determination of site and other conditions affecting the construction of the proposed
Work.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
SP103-1
ADDENDUM NO. 3
EXAMINATION OF SITE
D.
The Geotechnical Data report (GDR),
(GDR), Kailua RWWTP – Tunnel Influent Pump Station
and Headworks Facility,
Facility, dated January 2015,
2015, prepared by Yogi Kwong Engineers, LLC
has been provided to bidders as a reference document.
103.03 SITE INVESTIGATIONS AND REPRESENTATION
A.
The Contractor acknowledges that it has satisfied itself as to the nature and location
of the work; the general and local conditions—particularly those bearing upon
availability of transportation; access to the site; disposal, handling, and storage of
materials; availability of labor, water, electric power, roads; and uncertainties of
weather ocean tides—or similar physical conditions at the site; the conformation and
condition of the ground; the character of equipment and facilities needed before and
during prosecution of the work; and all other matters that can in any way affect the
work or the cost thereof under this Contract.
B.
The Contractor further acknowledges that it has satisfied itself as to the character,
quality, and quantity of surface and subsurface materials to be encountered from its
inspection of the site and from reviewing any available records of exploratory work
furnished by the City. Failure by the Contractor to acquaint itself with the physical
conditions of the site and all available information will not relieve it of responsibility
for properly estimating the difficulty or cost of successfully performing the work.
C.
The Contractor warrants that as a result of its examination and investigation of all the
aforesaid data that it can perform the work in a good and workmanlike manner and
to the satisfaction of the City. The City assumes no responsibility for any
representations made by any of its officers or agents during or prior to the execution
of this contract, unless (1) such representations are expressly stated in the Contract,
and (2) the Contract expressly provides that the responsibility therefore is assumed
by the City.
-- END OF SP --
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
SP103-2
ADDENDUM NO. 3
EXAMINATION OF SITE
SECTION 02270
EROSION, SEDIMENTATION, AND DUST CONTROL
PART 1--GENERAL
1.01
1.02
SUMMARY
A.
SCOPE: This Section specifies the requirements for planning, installation,
maintenance and repair of temporary and permanent water pollution, erosion,
sediment, and dust control Best Management Practices (BMPs) at the project site,
including work areas, material stockpiling areas, and haul roads. Compliance with
applicable City and County, State, and Federal Permits is also covered in this
Section.
B.
OFF-SITE OPERATIONS: The requirements of this Section also apply to borrow pit
operations, haul roads, and/or Contractor’s storage sites located outside the
contract limits.
C.
AUTHORIZED REPRESENTATIVE: Designate an officer of the Contractor as an
Authorized Representative who will be responsible for certification and submission of
any required permits required by SP 109 to the applicable regulatory agency. The
Authorized Representative will be responsible for implementation of these permits
and adherence to their requirements and the requirements of this Section for the
duration of the project.
D.
FINES: All fines imposed for improper erosion, sediment, and dust control shall be
paid by the Contractor.
E.
SEPARATE AGREEMENTS: Requirements under this Section shall apply to all work
directly related to the performance of work under this Contract. In the event that the
Contractor elects to utilize excavated material as backfill material on private
properties in areas outside of the project work limits or elects to perform additional
grading and/or excavation work on properties outside of the work limits; such
agreements shall be considered as private agreements between the Contractor and
the private property owner. In such cases, the Contractor shall be responsible for the
costs of all required water pollution and erosion control measures for that work.
QUALITY ASSURANCE
A.
REFERENCES:
1.
This Section contains references to the following documents. They are a part
of this Section as specified and modified. Where a referenced document
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-1
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
contains references to other standards, those documents are included as
references under this Section as if referenced directly. In the event of conflict
between the requirements of this Section and those of the listed documents,
the requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect at the time of Advertisement for Bids. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or otherwise
identified by that organization or, if there are no replacement documents, the
last version of the document before it was discontinued. Where document
dates are given in the following listing, references to those documents shall
mean the specific document version associated with that date, regardless of
whether the document has been superseded by a version with a later date,
discontinued or replaced.
Reference
Title
Hawaii Administrative Title 11, Chapter 55, (11-55) Water Pollution Control
Rules
Title 4, Subtitle 6, Chapter 67, Seed Rules
Revised Ordinances of Revised Ordinances of Honolulu (ROH) Chapter 14, Public
Honolulu
Works Infrastructure Requirements Including Fees and
Services, Articles 13 through 16.
City BMP Manual
Best Management Practices Manual for Construction Sites
in Honolulu, 1999
City Rules
Rules for Soil Erosion Standards and Guidelines, 1999
ASTM C33
Standard Specification for Concrete Aggregates
ASTM D4751
Standard Test Method for Determining Apparent Opening
Size of a Geotextile
ASTM D4632
Standard Test Method for Grab Breaking Load and
Elongation of Geotextiles
ASTM D4355
Standard Test Method for Deterioration of Geotextiles by
Exposure to Light, Moisture and Heat in a Xenon Arc Type
Apparatus
ASTM D4491
Standard Test Methods for Water Permeability of
Geotextiles by Permittivity
City Standard
Specifications
Standard Specifications for Public Works Construction,
September 1986
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-2
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
1.03
EROSION, DUST AND SEDIMENTATION CONTROL PERMITS
A.
Obtain permits covering erosion, dust, and sedimentation control per the
requirements of SP 109 and this Section. Where this Section, permits, or regulations
have conflicting provisions, the more restrictive provision shall apply.
B.
CITY OBTAINED PRELIMINARY PERMITS: The City has obtained or is in the process of
obtaining the following permits for the project:
C.
D.
1.04
1.
The City is obtaining the preliminary State of Hawaii, NPDES Individual Permit
Form C for Storm Water Associated with Construction Activities from the
Department of Health (DOH).
2.
The City is obtaining the preliminary State of Hawaii, NPDES General Permit,
Appendix G for Construction Activity Dewatering at the Kaneohe Wastewater
Pretreatment Facility and the Kailua Regional Wastewater Treatment Plant.
CONTRACTOR OBTAINED PERMITS:
1.
Obtain the final approved Permits as required by SP 109 and conform to the
requirements of the NPDES Notice of Individual and/or General Permit
Coverage issued by the DOH. Adhere to the requirements stipulated under
Hawaii Administrative Rules 11-55, Water Pollution Control, and follow the
guidelines set forth in the “Best Management Practices Manual for
Construction Sites in Honolulu,” dated May 1999 and the City and County of
Honolulu “Rules for Soil Erosion Standards and Guidelines” when preparing
the final permits for approval.
2.
Obtain stockpiling, grading, and grubbing permits from the City per SP 109
and comply with the stipulations set forth in the Revised Ordinances of
Honolulu, Chapter 14, Articles 13 through 16.
ADDITIONAL CONTRACTOR OBTAINED PERMITS: If the Contractor elects to discharge
hydro-testing effluents into Waters of the State or existing drainage systems, obtain
an NPDES permit covering hydro-testing waters from the State of Hawaii, DOH Clean
Water Branch.
EROSION, DUST AND SEDIMENT CONTROL BMPs
A.
GENERAL: Establish, construct, and maintain erosion and sediment control Best
Management Practices (BMPs). All erosion and sediment control BMPs shall be
installed before construction begins.
B.
TEMPORARY BMPs: Install temporary erosion and sediment controls which will
ensure that the storm water and other drainage from job site areas which will be
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-3
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
stripped or modified of its naturally existing or artificially established stabilization or
protection against erosion shall pass through a filter system before being
discharged. The installation of the silt fence and compost filter socks shall be in
accordance with manufacturer’s installation guidelines. The installation of these
erosion and sediment control measures shall be in accordance with the approximate
locations shown on the Drawings.
1.05
C.
TEMPORARY BMP MAINTENANCE: All erosion and sediment control measures shall
be kept in good repair and maintained throughout construction. The temporary
erosion and sediment control structures shall be maintained until temporary or
permanent ground cover is established to stop all sediment, dust, and erosion from
leaving the construction site.
D.
PERMANENT BMPs: Install permanent BMPs as specified and maintain temporary
BMPs until permanent BMPs are established and can prevent sediment, dust, and
other pollutants from leaving the construction site. Modification of the specified
permanent BMPs or extent of their installation may be necessary to address
conditions during construction.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
NPDES PERMIT APPLICATIONS: Review the Preliminary NPDES Permits
obtained by the City and prepare Final NPDES permit application materials
per the requirements of the State of Hawaii Department of Health. A draft
copy of each permit application shall be submitted to the Officer-in-Charge
for general review prior to Contractor submission. Information included in a
complete NPDES permit application includes but is not limited to the
following:
a.
An identification and source of potential pollutants;
b.
A list of all materials and heavy equipment to be used during
construction;
c.
Descriptions of methods and devices used to minimize the discharge
of pollutants into Waters of the State and drainage systems;
d.
Details for the installation and maintenance of any erosion or silt
control BMPs;
e.
Methods for removal and disposal of hazardous waste encountered
during construction;
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-4
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
f.
Methods for storing and handling of oil, paint, and other products
used for the project;
g.
A plan outlining the procedures for fueling and maintenance of
vehicles;
h.
Site plan drawings for material storage and handling areas, and other
staging areas;
i.
Concrete truck washouts detail drawings and sizing estimates;
j.
BMPs and methods for reducing tracking of sediment off-site from
entries and exits to the project site;
k.
A litter management plan;
l.
A dust control plan including methods, frequency of control and any
chemicals or additives to be used;
m.
A hazardous waste spill prevention and control plan including a
description of spill control BMPs standing-by, their location and
quantity;
n.
Erosion and Sedimentation Control Plans clearly indicating the
location of water pollution and erosion and sediment control BMPs;
plans and details of BMPs, areas of soil disturbance, storage and
staging areas and the intended drainage patterns;
o.
A description of fill material to be used on the project;
p.
A construction schedule;
q.
The name(s) of the individuals designated to be Authorized
Representatives responsible for the water pollution and erosion
controls on the project site along with home, business, and cellular
telephone numbers. Individuals shall be available during off-hours,
weekends and holidays.
2.
PLAN REVISIONS: Modify and resubmit the above items to correct unforeseen
conditions that develop during pre-construction and construction phases.
3.
CITY PERMIT APPLICATIONS: Prepare final permit applications that cover
erosion, dust and sediment control as required by SP 109. These may
include clearing, grading, and stockpiling permits. A draft copy of each permit
application shall be submitted to the Officer-in-Charge for general review
prior to Contractor submission of the permit application and submit final
permits once approved.
4.
PERMANENT BMPs: Submit product data, manufacturers recommended
installation procedures and site specific installation plans for all permanent
BMPs.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-5
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
PART 2--PRODUCTS
2.01
SILT FENCE
A.
FABRIC: Silt fence fabric shall be slit film polypropylene or woven fabric inert to
chemicals commonly found in soil, and resistant to mildew, rot, insects, and rodent
attack that meets the following specifications:
Property
Silt Fence Fabric Specifications
Test Method
Apparent opening size (AOS)
ASTM D4751
U.S. standard sieve
100 minimum
30 maximum
Grab tensile strength
ASTM D4632
120 lb minimum
UV Resistance
ASTM D4355
70% strength at 500 hours
Permittivity
ASTM D4491
0.1 sec-1 maximum
Flow rate
ASTM D4491
10 gal/min/ft2 maximum
Useable life
Weight
2.02
Criteria
6 months minimum
ASTM D5261
3.0 ounces/yard minimum
B.
PRODUCTS: Silt fence fabric shall be TenCate Mirafi® 100X, Hanes Geo Components
SF-D, or approved substitute.
C.
POSTS: Posts shall be #4 size rebar furnished with OSHA approved rebar safety caps.
CRUSHED ROCK FOR CONSTRUCTION ENTRANCES/EGRESS AND STAGING AREAS
A.
CRUSHED ROCK: Crushed rock shall be 1” to 3” coarse aggregate with a gradation
similar to ASTM C33 No. 2 coarse aggregate.
B.
2.03
FILTER FABRIC MATERIAL: As specified in Section 02310.
COMPOST FILTER SOCK
A.
FILTER SOCK MATERIAL: The sock shall utilize an outer layer of filtration mesh, an
inner layer of containment netting and be 10-inches-in-diameter.
B.
COMPOST FILTRATION MEDIA: Use only mature compost that has no offensive odor
and meets the following specifications:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-6
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
Property
2.04
2.05
2.06
2.07
Compost Specifications
Acceptable Range
pH
5.0 – 8.5
Moisture content
30 - 60%
Organic matter
25 - 65%, dry weight
Particle size
99% passing 2-inch sieve
30 to 50% passing 3/8-inch sieve
Maximum length is 6-inches
Physical Contaminants
Less than 1% dry weight
C.
PRODUCTS: Compost filter sock shall be Filtrexx Sediment Control, Envirotech
Biosolutions Biosock or approved substitute.
D.
ANCHOR STAKES: Anchor stakes shall be manufactured from wood and shall be a
minimum of 1 x 1-inch with a minimum length of 16 inches.
ROCK CHECK DAM
A.
CRUSHED ROCK: Washed 2 inch to 6 inch crushed coarse aggregate similar to TypeH riprap specified in Section 02200.
B.
FILTER FABRIC MATERIAL: As specified in Section 02310.
DRAIN INLET PROTECTION
A.
CRUSHED ROCK: Type E drain rock, per Section 02200.
B.
FILTER FABRIC MATERIAL: As specified in Section 02310.
CURB INLET CATCH BASIN PROTECTION
A.
GENERAL: Curb inlet catch basin protectors shall be specifically manufactured for
curb inlet style catch basins without the gutter grate and designed to limit sediment
from entering the catch basin.
B.
PRODUCTS: UltraTech Gutter Guard®, Dandy Products Dandy Curb®, or approved
substitute.
RAIN GAUGE
A.
PRODUCTS: Rain Gauge shall be AcuRite Weather Environment System 1050C/1055
with AcuLink Internet Bridge remote monitoring function or approved substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-7
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
2.08
2.09
ROLLED EROSION CONTROL PRODUCT
A.
GENERAL: Rolled erosion control product (RECP) shall be biodegradable,
manufactured of jute fibers, curled wood fibers, coconut fiber, or a combination of
these materials and designed to decompose after 2 years.
B.
JOINING MATERIALS AND NETTING: Netting, sewing or adhesive system that holds
the biodegradable mulch fibers together should also be biodegradable or
photodegradable.
C.
STAPLES: Staples shall be per the manufacturer’s recommendations but should be
made of minimum 11 gauge steel wire and should be U-shaped with 8 inch legs and
2 inch crown.
D.
PRODUCTS: RECP shall be Hanes Geo Components Coconut Blanket, Propex Landlok
CS2, or approved substitute.
TURBIDITY/SILT CURTAIN
A.
GENERAL: Turbidity/silt curtain shall
shall be Type I,
I, DOT.
DOT.
B.
FABRIC:
FABRIC: Constructed of impermeable nylon reinforced vinyl. The color shall be a
bright yellow or international orange. The fabric shall meet the following
specifications:
Turbidity/Silt Curtain
Curtain Fabric Specification
Criteria
Property
Weight
18 oz.
Grab Tensile Strength
300 lbs minimum
UV Resistant
Yes
C.
FLOATION DEVICE: A minimum 6” diameter expanded polystyrene float shall be
used.
D.
BALLAST CHAIN: A ¼” thick noncorrosive, galvanized
galvanized chain shall be used.
E.
CURTAIN CONNECTORS
CONNECTORS: Brass or stainless steel grommets connected with ¼”
minimum diameter nylon or polyester rope shall be used.
F.
ANCHORS: Anchors shall be supplied in accordance with the manufacturer’s
recommendations
recommendations.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-8
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
2.09
GRASS SEED AND HYDROMULCH
A.
GENERAL: Grass seed,
seed, hydromulch,
hydromulch, and fertilizer shall conform to the products
specified in Section 51 of the Standard Specifications for Public Works
Construction.
PART 3--EXECUTION
3.01
3.02
PRE-CONSTRUCTION REQUIREMENTS
A.
SUBMITTALS: Work shall not begin on the project until the submittals detailed in
paragraph 1.04 above are completed, reviewed by the Officer-in-Charge, and
submitted/accepted by the appropriate regulatory agency.
B.
PERMITS: Obtain final permits as specified in paragraph 1.03 and conform to the
requirements of the permits. Keep a copy of all final approved permits and any
revisions onsite for the duration of the project.
C.
RAIN GAUGE: Install and maintain a rain gauge at location determined by the Officerin-Charge. The rain gauge shall be maintained in working condition and removed at
project completion.
D.
TRAINING: Provide training for all on-site employees of the Contractor and any
subcontractors. At a minimum, training should cover proper practices, operating
procedures and BMPs that have been accepted, approved and implemented on the
project.
TEMPORARY BMPS
A.
GENERAL: Install BMPs as specified on the Drawings, or in the final NPDES permit
documents, or as accepted by the Officer-in-Charge before commencement of work
activities that result in the disturbance of earth material. Coordinate and maintain
BMP’s throughout the construction and post-construction period.
B.
MINIMUM BMP IMPLEMENTATION TIME: Apply accepted erosion control measures to
all exposed surfaces subject to erosion. If after 7 days, the erosion control measures
have not been applied, the Contractor shall stop work and apply an accepted erosion
control measure at no cost to the City.
C.
RESPONSE TO CONCERNS: Address any water pollution, erosion and sediment
control concerns of the Officer-in-Charge or permit violations within 24 hours of
notification.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-9
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
D.
GOOD HOUSEKEEPING: Maintain good housekeeping so that mud, dirt and debris is
not tracked onto roadways or offsite.
E.
CONSTRUCTION ENTRANCE/EGRESS: Install an 8-inch-thick crushed rock
construction entrance and egress at all locations where equipment or vehicles enter
or exit the project area to minimize tracking of dirt, and mud onto the roadways.
F.
SILT FENCE: Construct silt fences on a level contour. Where multiple Sections of the
silt fence are required to form a continuous run, the Sections shall have a minimum
overlap of 6 inches. The silt fence shall be anchored using posts spaced at a
maximum of 6-feet apart. Posts shall be installed to a minimum depth of 24-inches
below existing grade and be installed upslope of the fence fabric. The finished height
of the posts shall not exceed 1 inch above the finished height of the silt fence
installation.
G.
COMPOST FILTER SOCK: Install compost filter socks along a level contour in a 3-inchdeep trench. Where multiple Sections of compost filter socks are required to form a
continuous run, the Sections shall have a minimum overlap of 6 inches. Anchor
stakes shall be installed to a minimum depth of 8 inches below the bottom of the
trench. The finished height of anchor stake installation shall not exceed 1 inch above
the finished height of the compost filter sock installation. Anchor stakes shall be a
maximum of 4 feet apart and 1 foot from the ends.
H.
ROCK CHECK DAM: Install rock check dams along a level contour perpendicular to
flow. Construct with a minimum height of 2-feet and wrap the crushed rock with filter
fabric. Anchor the filter fabric with crushed rock as specified on the Drawings.
I.
DRAIN INLET PROTECTION: Install drain inlet protection as specified on the Drawings
or at any drain inlet potentially impacted by construction stormwater runoff.
Construct drain inlets as specified on the Drawings.
J.
CURB INLET PROTECTION: Install curb and gutter inlet protection as specified on the
Drawings or at any curb inlet potentially impacted by construction stormwater runoff.
K.
DUST CONTROL: Exercise precautionary measures to minimize dust emissions and
wind erosion from staging areas, stockpiles, and all other construction activities.
Dust control shall include, but shall not be limited to, periodic sprinkling or wetting of
the site, covering stockpiles, or hydromulching of exposed dust producing areas. The
Contractor has the option of using a dust palliative. Palliatives shall be as
recommended in the City BMP Manual.
L.
TURBIDITY/SILT CURTAIN: Install turbidity/silt curtain as specified on the Drawings.
Drawings.
Connect and anchor per manufacturer’s recommendations. Maintain a minimum
3” freeboard above the water surface level under all flow conditions.
conditions.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-10
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
3.03
MAINTENANCE, MONITORING AND REPORTING REQUIREMENTS:
A.
GENERAL: Monitor and maintain temporary BMPs at locations identified in
Contractor’s site-specific BMPs submitted for the NPDES permit(s). Particular care
shall be taken to prevent the discharge of unsuitable drainage to the ocean, a water
supply, or surface water body. The Contractor shall take sufficient precautions during
construction to eliminate run-off of polluting substances such as silt, clay, wastes,
fuels, oils, and bitumen into the ocean, water supplies, and surface waters. Special
precautions shall be taken in the use of construction equipment to conduct
operations in a manner that reduces erosion.
B.
BMP MAINTENANCE: Maintain BMPs to prevent violations of regulatory and permit
conditions. Sediment removed by maintenance activities should be incorporated in
the project at locations designated by the Officer-in-Charge or disposed of properly.
General minimum maintenance procedures and requirements are listed below.
However, maintenance activities are not limited to this list and additional
maintenance not listed may be required to ensure that BMPs operate as intended.
1.
Silt fence: Remove sediment when it has reached one third of the height of
the fence.
2.
Construction entrance/egress: Clean or replace crushed rock clogged by
sediment.
3.
Compost filter sock: Remove, clean and replace the sock and media once it
has become clogged with sediment.
4.
Rock Check Dam: Remove, clean and replace filter fabric and crushed rock
clogged by sediment. Remove sediment when it has reached half the height
of the check dam.
5.
Drain inlet protectors: Remove, clean and replace clogged filter fabric and
crushed rock. Remove sediment when it has reached half the height of the
filter.
4.
Curb inlet protectors: Remove sediment when it reaches half the height of
the protector.
5.
Turbidity/silt curtain: Inspect daily for tears or gaps and repair as needed.
If the turbidity/silt curtain is beyond
beyond repair, replace immediately. Check to
make sure the anchors are still in place. If turbid waters are escaping
beyond the curtain into the main water body, repair or adjust the curtain as
needed.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-11
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
C.
BMP REMOVAL: Upon completion of the project and after permanent BMPs have
been established, temporary BMPs and any accumulated sediments shall be
removed from the project site and disposed of properly.
D.
RAINFALL MONITORING: Monitor and record daily (7 days/week) rainfall at the same
or near the same time of the day continuous for the duration of the project. The
rainfall record shall be submitted to the Officer-in-Charge weekly.
E.
CITY INSPECTION: The Officer-in-Charge will periodically inspect BMPs to confirm that
the Contractor is maintaining these features.
F.
INSPECTION INTERVAL: The Contractor and Officer-in-Charge shall jointly inspect all
BMPs, and Contractor shall make any necessary repairs to all erosion and sediment
control measures continuously for the duration of the project at the following
intervals:
1.
Weekly during dry periods
2.
Within 24 hours of any rainfall event of 0.5-inch or greater occurring in a 24hour period.
3.
Daily during periods of prolonged rainfall.
4.
When existing erosion control measures are damaged or not operating
properly.
G.
INSPECTION AND REPAIR RECORD: Maintain a record of all inspections and repairs
made. Update records continuously for the duration of the project and submitted
weekly to the Officer-in-Charge.
H.
PROJECT COMPLETION INSPECTION: At the end of grading operations and at the
completion of the project, inspect all catch basins, drain inlets and drain manholes
potentially impacted by the project and remove any accumulated sediment and
debris found in the storm drain structures. Flushing of the sediment and debris into
the storm sewer system is prohibited.
I.
FAILURE TO CONFORM: Failure to conform to the above requirements shall be cause
for temporary or permanent suspension of operations. If operations are suspended
due to the Contractor’s failure to conform, the Contractor shall maintain the project
during the period of suspension at no cost to the City. The Officer-in-Charge further
reserves the right to employ outside assistance to address the necessary corrective
action and shall hold the Contractor responsible for associated costs.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-12
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
3.04
3.05
PERMANENT BMPs
A.
GENERAL: Install permanent BMPs as specified on the plans and maintain temporary
BMPs until the site is stabilized, permanent BMPs are established and are effectively
preventing sediment, dust, and other pollutants from leaving the site.
B.
RECP: Install RECP at locations specified on the Drawings. Overlap RECP by a
minimum of 3 inches. Staple per the manufacturer’s recommendations but not more
than every 3 feet in interior and 1 foot from the edge.
C.
HYDROMULCH AND SEED: Apply and maintain grass seed, hydromulch, and
fertilizer per Section 51 of the Standard Specifications for Public Works
Construction.
MEASUREMENT AND PAYMENT
A.
GENERAL: Water pollution, erosion, sediment, and dust control shall not be paid for
directly, but shall be considered incidental and included in the lump sum bids for the
respective line items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02270-13
ADDENDUM NO. 3
EROSION, SEDIMENTATION,
AND DUST CONTROL
SECTION 02465
DRILLED CAISSONS
PART 1--GENERAL
1.01
1.02
DESCRIPTION
A.
This section specifies the requirements for materials, installation, quality control
testing, and inspection of drilled caissons during construction.
B.
Because of the highly difficult and variable subsurface conditions anticipated for the
drilled caisson work and the specialized skills and experience required for this work,
all drilled caisson work must be planned and performed by an experienced and
qualified specialty drilled caisson contractor or subcontractor and work force. Submit
the qualifications of the drilled caisson contractor or subcontractor and key work
force personnel for the Officer-in-Charge's review and acceptance at least 90 days
prior to any mobilization of caisson drilling and foundation construction equipment
and personnel. Minimum qualification requirements for the drilled caisson contractor
or subcontractor and key personnel are listed in paragraph 1.06, "QUALITY
CONTROL", of this Section. The terms "caissons" and "shafts" are used
interchangeably in this Section and other contract documents.
MEASUREMENT AND PAYMENT
A.
BASIS OF BIDS: Base the bid on the total number and total lengths of 2-foot
diameter reinforced concrete caissons, with a minimum embedment as indicated on
the drawings. The bid shall also include installation and removal of temporary steel
casings and an overall 30 percent of over excavation and concrete over-pour due to
variable subsurface conditions anticipated. Adjustment of the contract will be made
in accordance with the contract clauses, should the total lengths of caissons installed
and approved be greater or less than the total lengths shown. The Contractor will not
receive payment for rejected caissons or for those not conforming to specifications.
B.
TESTS:
1.
Load Tests: The Contract includes two (2) load tests to be performed on
caissons supporting the Generator/MV Electrical Distribution Building to
verify the load bearing capacity of the caissons in general accordance with
ASTM D 1143 Procedure A (Quick Test). The specific caissons shall be load
tested to a minimum of 120 tons (240 kips) for the 60 ton caissons. Load
tests shall be performed in accordance with ASTM D1143 or using the
Osterberg caisson testing method. The tested caissons, if confirmed to be
acceptable by the load tests and not damaged by the test, shall be used as
production caissons to be part of the future building foundation. All piping
and instruments embedded in the caisson shall be fully grouted after testing
and acceptance of the caisson. The Officer-in-Charge reserves the right to
increase or decrease the number of load tests. Adjustments in the contract
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-1
ADDENDUM NO. 3
DRILLED CAISSONS
price will be made for each such increase or decrease at the contract unit
price for "Caissons - Load Test".
C.
D.
2.
Non-Destructive Low Strain Impact Integrity Test: Where required, the
Contract includes performing a low strain impact test on each of the selected
completed caissons. Fifty percent of all caissons shall be integrity tested
using low strain impact test methods. The caissons designated for integrity
testing shall be specified by the Officer-in-Charge after caisson installation.
3.
Concrete Coring Integrity Test: The Contract includes coring of a minimum 4inch diameter vertical core in selected completed caissons through the whole
lengths (or selected lengths as determined by the Officer-in-Charge).
SEPARATE UNIT PRICES:
1.
Additional Caisson Lengths: Additional caisson lengths will be paid for at the
contract unit price for "Caissons-Additional Depth" installed as approved. The
bid shall be based on units of 4 linear feet of additional approved caisson
lengths per caisson for a total of 940 linear feet.
2.
Omitted Caisson Lengths: The contract price will be reduced at the contract
unit price for "Caissons- Omitted Length" omitted as directed by the Officer-inCharge. The bid shall be based on 100 linear feet of omitted caisson lengths.
3.
Removal of Obstructions: Removal of obstructions within the limits of the
caissons which cannot be removed by using the special caisson drilling
equipment will be paid for at the contract unit price per linear foot for
"Caissons - Removal of Obstructions" for caisson installed and accepted by
the Officer-in-Charge. The bid shall be based on 100 linear feet "Caissons Removal of Obstructions". Hard cobbles 3 to 12 inches in size and boulders
of a maximum size potentially larger than the caisson diameter may be
encountered throughout the drill depths. All costs pertaining to drilling and
construction of caissons through such cobbly and bouldery ground are
considered incidental to the drilled caisson installation, and therefore will not
be paid for separately under this item. Drill tools lost in caisson holes are not
considered obstructions and the complete costs of removal including, but not
limited to, associated costs for contract delays and time extensions will not
be paid.
4.
Temporary Casings: Temporary casings are considered incidental to the
drilled caisson installation, and therefore will not be paid for separately.
BASIS OF PAYMENT:
1.
Unit Price: The Officer-in-Charge has the right to increase or decrease the
total lengths of drilled caissons to be furnished and installed by changing the
foundation caisson top and bottom elevations, thereby requiring the
installation of additional caissons or omission of caissons from the
requirements shown and specified. Whether or not such changes are made,
the Contractor will be paid at the contract unit price per linear foot (including
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-2
ADDENDUM NO. 3
DRILLED CAISSONS
test caissons) multiplied by the total linear feet of acceptable caissons
actually installed. In the event the Officer-in-Charge requires an increase or
decrease in the total lengths of caissons furnished and installed, the contract
unit price will be adjusted in accordance with the contract clauses.
1.03
2.
Full Compensation: Payment in accordance with the above paragraphs in
MEASUREMENT AND PAYMENT constitutes full compensation for furnishing,
delivering, handling, and/or installing (as applicable) all material, labor and
equipment(including, but not limited to, furnishing, installing, and removing
temporary steel casings) necessary to meet contract requirements applicable
to the drilled caissons. The Contractor will not be allowed payment for
rejected caissons.
3.
Load Tests: The Contract includes two load tests to verify the load bearing
capacity of the caissons in general accordance with ASTM D 1143 Procedure
A. The tested caissons, if confirmed acceptable by the load test, shall be
used as production caissons to be part of the future building foundation. All
piping and instruments embedded in the caisson shall be fully grouted after
testing and acceptance of the caisson. The Officer-in-Charge reserves the
right to increase or decrease the number of load tests. Adjustments in the
contract price will be made for such increases or decreases at the contract
unit prices for "Caissons - Load Test"
REFERENCES
A.
REFERENCES:
1.
This section contains references to the following documents. They are a part
of this section as specified and modified. Where a referenced document
contains references to other standards, those documents are included as
references under this section as if referenced directly. In the event of conflict
between the requirements of this section and those of the listed documents,
the requirements of this section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect at the time of Advertisement for Bids or Invitation to Bid
(or on the effective date of the Agreement if there were no Bids). If
referenced documents have been discontinued by the issuing organization,
references to those documents shall mean the replacement documents
issued or otherwise identified by that organization or, if there are no
replacement documents, the last version of the document before it was
discontinued. Where document dates are given in the following listing,
references to those documents shall mean the specific document version
associated with that date, regardless of whether the document has been
superseded by a version with a later date, discontinued or replaced.
Reference
Title
ACI 305R
Hot Weather Concreting
ASTM A36
Standard Specification for Carbon Structural Steel
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-3
ADDENDUM NO. 3
DRILLED CAISSONS
Reference
1.04
Title
ASTM A 53
Standard Specification for Carbon Structural Steel
ASTM A 500
Standard Specification for Cold-Formed Welded and
Seamless Carbon Steel Structural Tubing in Rounds and
Shapes
ASTM A615
Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement
ASTM C31
Standard Practice for Making and Curing Concrete Test
Specimens in the Field
ASTM C33
Standard Specification for Concrete Aggregates
ASTM C109
Standard Test Method for Compressive Strength of
Hydraulic Cement Mortars (Using 2-in. or (50-mm) Cube
Specimens)
ASTM C150
Standard Specification for Portland Cement
ASTM C618
Standard Specification for Coal Fly Ash and Raw or
Calcined Natural Pozzolan for Use in Concrete
ASTM C939
Standard Test Method for Flow of Grout for PreplacedAggregate Concrete (Flow Cone Method)
ASTM D1143
Standard Test Method for Deep Foundations Under
Static Axial Compressive Load
ASTM D 5882
Standard Test Method for Low Strain Impact Integrity
Testing of Deep Foundations
IBC
2006 International Building Code
SUBMITTALS
A.
Submit the following in accordance with Section 01300, Submittals:
1.
Preconstruction Submittals:
a.
b.
c.
d.
e.
2.
Drilled Caisson Installation Plan
Caisson Load Test Plan
Low Strain Impact Integrity Test Plan
Vibration Monitoring Plan
Pre-Construction Survey
Shop Drawings:
a.
b.
c.
Reinforcing Steel
Survey of caisson locations
Remedial Action Plan
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-4
ADDENDUM NO. 3
DRILLED CAISSONS
3.
Product Data
a.
b.
c.
4.
Test and Alarm Reports
a.
b.
c.
d.
5.
Concrete Mix Design
Packaged Grout
Grout Mix Design
Load Tests
Low Strain Impact Integrity Tests
Concrete Coring Integrity Tests
Vibration Alarm Report
Certificates:
a.
A certified copy of the survey. Establish lines, levels, and caisson
centerline locations, to be staked and maintained by a Hawaii
licensed professional land surveyor or professional civil engineer.
b.
Specialty Contractor or Subcontractor and Quality Control (QC) Staff
Qualifications and Experience including the following items:
1)
2)
3)
4)
5)
6)
1.05
C-35 License
Certificate of Insurance
Consent of Surety
Project reference list
Names and experience of on-site supervisors and drill rig
operators
Quality control staff list and qualification and experience of
the QC Geotechnical Engineer and the Integrity Testing
Engineer
6.
Survey of Caisson Locations: Submit a certified survey meeting the
requirements specified herein.
7.
Closeout Submittals: Detailed records for each caisson as specified in
paragraph titled "Records."
SPECIAL INSPECTION
A.
A Special Inspection Geotechnical Engineer, retained by the Officer In Charge, shall
observe and maintain records of caisson installation and testing. All caisson work
shall receive Special Inspection in accordance with Chapter 17 of the International
Building Code (IBC). The Special Inspection Geotechnical Engineer shall be qualified
to the satisfaction of the Officer-in-Charge in accordance with Chapter 17 of the IBC.
Notify the Officer-in-Charge at least 10 working days prior to the start of any caisson
installation or testing activities.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-5
ADDENDUM NO. 3
DRILLED CAISSONS
1.06
QUALITY CONTROL
A.
SPECIALTY CONTRACTOR OR SUBCONTRACTOR AND QUALITY CONTROL STAFF
QUALIFICATIONS:
1.
The Specialty Contractor or Subcontractor shall be licensed as a C-35 Pile
Driving, Pile and Caisson Drilling, and Foundation Contractor by the
Department of Commerce and Consumer Affairs in accordance with Hawaii
Administrative Rules, Title 16, Chapter 77.
2.
Submit four copies of C-35 License, Certificate of Insurance, and Consent of
Surety to the Officer-in-Charge for approval.
3.
At least 90 days prior to the start of mobilization of any caisson construction
equipment and/or personnel, submit four copies of a project reference list to
the Officer-in-Charge for approval, verifying the successful completion by the
Contractor or Subcontractor of at least three (3) separate foundation projects
within the last five (5) years with drilled shafts of similar size (diameter and
depth) and difficulty to those shown in the Contract Documents and with
similar subsurface geotechnical conditions to those described under this
Section.
4.
A complete description of each project and the owner's contact person's
name and current phone number shall be included for each listed project.
Include sufficient information for each listed project to demonstrate clearly
that the proposed contractor or subcontractor and work force meet or exceed
the qualification and experience requirements, including all claims and
disputes (whether settled, partially settled, being settled, or unsettled),
original contract price and final completion costs for each listed project. The
Contractor shall also submit at the same time a list of quality control staff for
drilled caisson construction monitoring.
5.
Experience and Personnel
a.
At least 90 days prior to the start of mobilization of any caisson
construction equipment and/or personnel, submit four copies of a list
identifying the Specialty Contractor or Subcontractor's on-site
supervisors and drill rig operators assigned to the project and a list
identifying the quality control staff for approval. The list shall contain
a detailed summary of each individual's qualification and experience
in drilled caisson excavation operations and/or construction
monitoring, and placement of assembled reinforcing cages and
concrete in drilled caissons.
b.
The Contractor shall hire a Quality Control (QC) Geotechnical Engineer
having a minimum of five (5) year experience in caisson load testing
as a Hawaii licensed professional civil engineer. If Osterberg testing
is performed, the QC Geotechnical Engineer shall have a minimum of
five (5) year experience in performance and supervision of Osterberg
Load testing as a US licensed professional engineer.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-6
ADDENDUM NO. 3
DRILLED CAISSONS
B.
c.
On-site supervisors shall have a minimum of five (5) year on-site work
experience in supervising construction of drilled caisson foundations
of similar size (diameter and depth) and difficulty to those shown in
the Contract Documents and with similar subsurface geotechnical
conditions to those described under this Section. The work
experience shall be direct supervisory responsibility for the on-site
drilled caisson construction operations. Project management-level
positions indirectly supervising on-site drilled caisson construction
operations are not acceptable for this experience requirement.
d.
Drill rig operators shall have a minimum of five (5) year experience in
construction of drilled caisson foundations of similar size (diameter
and depth) and difficulty to those shown in the Contract Documents
and with similar subsurface geotechnical conditions to those
described under this Section.
e.
Mobilization of caisson drilling equipment and/or personnel or
caisson work shall not be started on any drilled caisson until the
Specialty Contractor or Subcontractor and Quality Control Staff's
qualifications and field personnel are approved by the Officer-inCharge. The Officer-in-Charge may suspend the drilled caisson
construction if the Specialty Contractor or Subcontractor and/or
Quality Control Staff substitute any field personnel without prior
approval by the Officer-in-Charge. The Contractor shall be fully liable
for the additional costs resulting from the suspension of work, and no
adjustments in contract time resulting from such suspension of work
will be allowed.
DRILLED CAISSON INSTALLATION PLAN:
1.
At least two (2) months prior to the start of drilled caisson construction, the
Contractor shall submit four (4) copies of a Drilled Caisson Installation Plan in
narrative for acceptance by the Officer-in-Charge. In preparing the narrative,
the Contractor shall reference the available subsurface geotechnical data
provided in the Contract boring logs and the highly difficult and variable
subsurface conditions anticipated and described in this Section. This
narrative shall provide at a minimum the following information:
a.
Description of overall construction operation sequence and the
sequence of drilled caisson construction when in groups or along
lines.
b.
A list, with description and capacities, of the proposed equipment,
including but not limited to cranes, drills, augers, core barrels, rock
tools, air tools, bailing buckets, final cleaning equipment and drilling
unit. The narrative shall describe why the equipment was selected,
and describe equipment suitability to the anticipated site and highly
difficult subsurface conditions, the assumed drilling rate, and the
assumed production rate. The narrative shall include a project history
of the drilling equipment demonstrating the successful use of the
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-7
ADDENDUM NO. 3
DRILLED CAISSONS
equipment on drilled caissons of equal or greater sizes and depths in
similar subsurface geotechnical conditions to those described under
this Section and the actual drilling rates experienced in the qualifying
project records.
c.
Details of drilled caisson excavation methods, including proposed
drilling methods, methods for cleanout of the bottom of the
excavation hole, methods to be used if expansive soils swell into the
drilled shaft hole, and a disposal plan for excavated material. The
narrative shall include a review of method suitability to the
anticipated site and highly difficult subsurface geotechnical
conditions.
d.
Details of the method(s) to be used to ensure drilled shaft hole
stability (i.e., prevention of caving, bottom heave, etc. using
temporary casing, or other means) during excavation and concrete
placement. The details shall include a review of method suitability to
the anticipated site and highly difficult subsurface geotechnical
conditions.
e.
Describe methods to avoid caving in of surface soils to prevent a
cone (or necking) from forming along the drilled caisson at the near
surface where expansive soils can exert upward pressure onto the
cone.
f.
Describe methods to prevent soil loss below and undermining of
adjacent foundations.
g.
Reinforcing steel shop drawings, details of reinforcement placement
including type and location of all splices, reinforcement cage support
and centralization methods, type and location of all spacers, and
other instrumentation as required, and procedures for lifting and
setting the reinforcement cage.
h.
When using temporary casing, details of the method to extract the
temporary casing, maintain sufficient head on the concrete within the
casing to avoid extraneous materials from intruding and mixing with
the concrete, maintain shaft reinforcement in proper alignment and
location, and maintain the concrete slump to keep concrete workable
during casing extraction.
i.
Details of concrete placement, including proposed equipment and
procedures for delivering concrete to the drilled shaft, placement of
the concrete into the shaft including initial placement and the raising
of the temporary casing and the tremie or pump line during
placement, size of tremie and pump lines, operational procedures for
pumping, and a sample uniform yield form to be used by the
Contractor for plotting the volume of concrete placed versus the
depth of shaft for all caisson concrete placement.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-8
ADDENDUM NO. 3
DRILLED CAISSONS
2.
j.
The method to be used to form a horizontal construction joint during
concrete placement.
k.
When applicable, include a description of the material to be used to
temporarily backfill a drilled shaft excavation hole during a stoppage
of the excavation operation, as well as the method used to place and
remove the backfill material.
l.
Details of procedures to prevent loss of concrete into waterways,
sewers and other adjacent areas to be protected.
m.
Describe the method and materials that will be used to fill or
eliminate all voids below the top of shaft between the design shaft
diameter and the excavated shaft diameter.
n.
Describe the methods and materials that will be used to prevent
aggregate segregation in concrete, prevent thermal cracking of
concrete, and prevent excess bleed water channels.
o.
Details of any required load tests and integrity tests including
equipment, instrumentation, procedures, calibration data for test
equipment, calculations and drawings.
p.
Details and procedures for protecting existing adjacent structures,
utilities, roadways and other facilities during drilled shaft installation.
q.
A statement of verification that: 1) the project's Pre-installation
Conference (Preparatory) has been held, 2) the project's Contractor
Quality Control (CQC) Plan has been reviewed and approved by the
Officer-in-Charge and relevant portions of the CQC have been
incorporated into the Drilled Caisson Installation Plan.
r.
Other information required by the Plans or specified herein.
The Officer-in-Charge will evaluate the Drilled Caisson Installation Plan for
conformance with the Contract Plans and Specifications in accordance with
Section 01300, Submittals. At the option of the Officer-in-Charge, a Caisson
Installation Plan Submittal Meeting may be scheduled following review of the
Contractor's initial submittal of the Plan. This meeting is separate from the
Pre-installation Conference (Preparatory) and will be held specifically to
review the caisson shop drawing submittal and the Drilled Caisson
Installation Plan. Those attending the Caisson Installation Plan Submittal
Meeting, if held, shall include the following personnel from the Contractor,
the Specialty Subcontractor, and the Quality Control Staff:
a.
Superintendent, on-site supervisors, and other Contractor/Specialty
Subcontractor/Quality Control Staff personnel involved in the
preparation and execution of the Drilled Caisson Installation Plan.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-9
ADDENDUM NO. 3
DRILLED CAISSONS
3.
C.
D.
The Contractor shall submit any significant updates or modifications to the
Drilled Caisson Installation Plan whenever such updates or modifications are
proposed to the Officer-in-Charge. The Officer-in-Charge will evaluate the new
information for conformance with the Contract Plans and Specifications
within ten (10) working days after receipt of the submission.
PRE-INSTALLATION CONFERENCE (PREPARATORY): A caisson pre-installation
conference shall be held at least 15 working days prior to the Contractor beginning
any caisson construction work at the site to discuss investigative boring information,
construction procedures, personnel, and equipment to be used, and other elements
of the accepted Drilled Caisson Installation Plan as specified in this Specification.
Those attending from the Contractor, the Specialty Subcontractor, and the Quality
Control Staff shall include:
1.
Superintendent, on site supervisors, and other key personnel identified by the
Contractor as being in charge of drilling the caissons, placing and extracting
the casing as applicable, placing the steel reinforcing bars, and placing the
concrete.
2.
If the Contractor's key personnel change, or if the Contractor proposes a
significant revision of the approved Drilled Caisson Installation Plan, an
additional conference may be held at the request of the Officer-in-Charge
before any additional caisson construction operations are performed.
LOGS OF CAISSON CONSTRUCTION
1.
The Contractor's Quality Control Staff shall prepare inspection logs
documenting each caisson construction activity, including casing installation,
excavation, shaft wall and bottom inspection, and reinforcement inspection
performed with frequent reference to the date, time and casing/excavation
elevation. In addition, the Contractor shall prepare and submit the logs
documenting any subsurface investigation borings or rock core holes
performed for the Contract at drilled caisson foundation locations.
2.
The Contractor’s records for temporary casing shall include at least the
following information: identification number and location of the caisson;
diameter and wall thickness of the casing; dimensions of any casing
reinforcement; top and bottom elevations of the casing; method and
equipment used for casing installation and extraction; any problems
encountered during casing installation and extraction; and the name of the
inspector.
3.
The caisson excavation log shall contain at least the following information:
identification number, location and surface elevation of the caisson;
description and approximate top and bottom elevation of each soil or rock
material encountered; seepage or groundwater conditions; type and
dimensions of tools and equipment used, and any changes to the tools and
equipment; any problems encountered; elevation of any changes in the
caisson diameter; method used for bottom cleaning; final bottom elevation of
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-10
ADDENDUM NO. 3
DRILLED CAISSONS
the caisson; and the name of the inspector and the date, time and name of
any changes in the inspector.
E.
1.07
5.
The logs for each respective caisson construction activity shall be submitted
to the Officer-in-Charge within 24 hours of the completion of that activity. A
full set of caisson inspection logs for an individual drilled caisson shall be
signed by the Superintendent and submitted to the Officer-in-Charge within
48 hours of the completion of concrete placement at the shaft.
CONTRACTOR SUPERVISION AND QUALITY CONTROL MONITORING: Provide for the
supervision and quality control monitoring of all phases of drilled caisson
construction. Supervision and quality control monitoring are the Contractor's
responsibility as outlined in paragraph 1.06, Quality Control. Check each drilled shaft
excavation for its depth, water removal, cleanup, workmanship, and for all tolerance
requirements before any concrete is placed.
Deliver casings and appurtenant equipment to the job site in an undamaged and
ready to place condition. Deliver concrete in accordance with requirements of Section
03300.
PROJECT/SITE CONDITIONS
A.
1.09
Concrete placement records shall include at least the following information:
concrete mix used; time of start and end of concrete placement; volume and
start/end time for each truck load placed; truck number; batch ticket
number; concrete test results; concrete surface elevation and corresponding
tremie tip elevation periodically during concrete placement; concrete yield
curve (volume versus concrete elevation, actual and theoretical); and the
name of the inspector.
DELIVERY, STORAGE, AND HANDLING
A.
1.08
4.
SUBSURFACE DATA: Boring logs are shown on the contract drawings.
CAISSON DRILLING EQUIPMENT
A.
Provide caisson drilling equipment having a minimum torque capacity and downward
force capacity suitable and adequate for the complex contract site conditions.
Provide temporary casings that can be installed by mechanically rotated/twisted/
oscillated into the ground through the full range of subsurface conditions described
in this Section and indicated on the boring logs and probes to prevent the sidewall of
the excavated shaft from caving in during drilling and can be withdrawn without
becoming bound and/or causing damages to the caisson concrete and the
surrounding soils prior to and/or during concrete placement into the hole. At no extra
cost to the City, provide appropriate equipment as necessary to handle groundwater
seepage, perched water tables, and groundwater levels at any depth in the drilled
caisson hole prior to, during and/or after being cased.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-11
ADDENDUM NO. 3
DRILLED CAISSONS
PART 2--PRODUCTS
2.01
MATERIALS
A.
CONCRETE: Concrete materials and concrete characteristics, including mix design,
shall be in accordance with the requirements for Concrete Class “C-3” in section
03300.
B.
REINFORCING STEEL: Reinforcing steel shall be in accordance with Section 03200.
D.
CASING STEEL: ASTM A 36 with zinc coating conforming to ASTM A 123.
E.
GROUT: Grout shall be in accordance with Section 03600 Grout.
PART 3--EXECUTION
3.01
VIBRATION MONITORING PROGRAM
A.
VIBRATION MONITORING PLAN:
1.
At least two (2) months prior to the start of the drilled caisson construction,
the Contractor shall submit four (4) copies of the Vibration Monitoring Plan to
the Officer-in-Charge for review. The plan shall include the qualifications of
the Vibration Monitoring Subcontractor and shall include a description of the
vibration monitoring equipment that will be utilized. The plan shall have
sufficient detail to describe the locations of the vibration monitoring devices
in the existing construction, daily monitoring of equipment function, the
course of action to be taken if an alarm event occurs, and documentation of
an alarm event.
2.
Vibration Monitoring Subcontractor: The Contractor shall hire a geotechnical
engineer to oversee the vibration monitoring program. Submit a project
reference list verifying the successful completion by the subcontractor of at
least three (3) separate vibration monitoring programs within the last five (5)
years for projects in Hawaii. A description of each project and the owner's
contact person's name and current phone number shall be included for each
project listed. Include sufficient information to demonstrate clearly that the
proposed subcontractor and work force meet or exceed the qualification and
experience requirements, including all claims and disputes (whether settled,
partially settled, or unsettled), and expert testimony. At the same time,
submit a list of monitoring staff assigned to this project and their resumes.
3.
Equipment: Submit a listing of equipment owned by the vibration monitoring
subcontractor to be used for the vibration monitoring program including the
manufacturer's data sheet of the equipment description. Provide sufficient
information to describe the increment of measurement; method of recording,
storage, and retrieval of the vibration logs; alarm pre-sets; and notification
capabilities.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-12
ADDENDUM NO. 3
DRILLED CAISSONS
B.
VIBRATION MONITORING DEVICE PLACEMENT: After the completion of the preconstruction survey and prior to the start of the work, the vibration monitoring
subcontractor shall place vibration monitoring devices in the existing construction in
accordance with the approved vibration monitoring plan.
C.
VIBRATION MONITORING DEVICE CALIBRATION AND TESTING: After placement of the
devices and prior to the start of the work, the vibration monitoring devices shall be
calibrated and tested by the vibration monitoring subcontractor or equipment service
technician to assure proper function. Alarm pre-sets shall include a pre-alarm (as the
vibration velocity approaches the limit) and an alarm when the limit is met or
exceeded. The alarm pre-sets shall be tested and an email notification shall be
tested for each alarm pre-set.
1.
The vibration limit shall be a peak particle velocity of 0.39 inches per second
at the location of the monitoring devices.
2.
Email notification shall be made to two (2) personnel of each of the following
parties: the vibration monitoring subcontractor hired to perform the vibration
monitoring program, the excavation subcontractor or contractor, the drilled
caisson contractor or subcontractor, the general contractor, and the office of
the Officer-in-Charge.
D.
EQUIPMENT PROTECTION: It shall be the responsibility of the vibration monitoring
subcontractor to provide barricades to protect the vibration monitoring devices and
to provide warning signs describing the purpose of the equipment and stating that
the equipment shall not be moved by any personnel other than the vibration
monitoring subcontractor. Contact information, including cell phone and email, shall
be provided on the signage. Signage shall be written in English and shall display the
ISO graphical symbol for: Do Not Touch.
E.
DAILY EQUIPMENT CHECK: The vibration monitoring subcontractor shall perform and
record a daily check of the vibration monitoring devices to assure proper function and
recording.
F.
PRE-ALARM AND ALARM EVENTS:
1.
Vibration Alarm Report: Within 24 hours after an alarm event, provide a
report including:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Date
Time
Recorded vibration velocity
The vibration log indicating the recorded vibrations before and after
the event
Whether or not the vibration limit was exceeded
The length of time that the vibration limit was exceeded
A description of the construction activity at the time of occurrence
The distance of that activity from the recording device
The course of action taken
Report of damage survey performed on existing construction.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-13
ADDENDUM NO. 3
DRILLED CAISSONS
3.02
3.
Immediately following an alarm event, a meeting shall be held to identify the
potential source of the vibration, methods for reducing the vibration;
including, but not limited to, modification of construction technique (smaller
impact force, fewer drilling revolutions-per-minute, less pressure, a different
type of drilling bit or rock extraction method, different construction
equipment, etc.).
4.
As part of the vibration alarm report, a damage survey of the existing
construction shall be performed and the condition of the existing construction
shall be compared with the pre-construction survey. The vibration alarm
report shall indicate that a damage survey has been performed and shall
describe the results of that survey.
5.
After an alarm event, the vibration monitoring devices shall be tested to
assure proper calibration, alarm pre-set functionality, and email notification
capability.
At least two (2) weeks prior to the start of the drilled caisson construction, the
Contractor shall submit four (4) color copies of a pre-construction survey report to the
Officer-in-Charge documenting the condition of the existing construction.
Photography, video, and written description shall be used to document the existing
conditions. Care shall be taken to identify the location and date of each photograph
so that the pre-construction conditions can be compared with conditions during and
after construction. The contractor shall hire a professional engineer licensed in
Hawaii with experience in structural engineering, particularly forensics, to perform the
pre-construction survey, and prepare and submit the survey report signed by and
sealed by the same licensed professional engineer.
PROTECTION OF EXISTING UTILITIES
A.
3.04
If an alarm event occurs, the vibration monitoring subcontractor shall notify
the Officer-in-Charge, the contractor, the earthwork contractor or
subcontractor, and the drilled caisson contractor or subcontractor that an
alarm event has occurred, verify that each party has received a similar alarm
notification, shall seek to identify the source of the vibration causing the
alarm, and shall begin preparation of a vibration alarm report.
PRE-CONSTRUCTION SURVEY
A.
3.03
2.
Take all precautions necessary to protect existing utilities from damage in
accordance with SP 154. Repair any existing utilities damaged by caisson
construction immediately and at no additional costs to the City.
CAISSON DRILLING EQUIPMENT
A.
Provide caisson drilling equipment with minimum torque capacity and downward
force capacity suitable for the complex site conditions and the highly difficult and
variable subsurface conditions anticipated as shown on the Contract Documents and
as described in this Section, that can drill the caisson holes to the required size and
diameter (including casing thickness) and down to a depth of 10 feet or 20 percent
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-14
ADDENDUM NO. 3
DRILLED CAISSONS
beyond the minimum required depths of tip elevations shown in the contract
documents.
3.05
B.
SPECIAL DRILLING EQUIPMENT: Early or immediate use of special drilling equipment
including but not limited to rock core barrels with diamond or carbide teeth, rock
tools, air tools and/or other equipment and procedures may be necessary to drill
through hard cobbles and boulders.
C.
SIDEWALL OVER-REAMING: When the sidewall of a drilled shaft is deemed to have
softened, swelled, or degraded by the Officer-in-Charge, sidewall over-reaming is
required. Over-reaming thickness shall be a minimum of 1/2 inch and a maximum of
3.0 inches. The Contractor may over-ream with a grooving tool, over-reaming bucket,
and/or other appropriate tools deemed necessary for over-reaming in the highly
difficult subsurface conditions present at the softened, swelled, or degraded sidewall
that may be similar to those described under this Section. The thickness and
elevation of sidewall over-reaming shall be according to the contract or as directed by
the Officer-in-Charge. Over-ream sidewall and place additional concrete at no cost to
the City.
SEQUENCING
A.
CAISSON EXCAVATION
1.
Perform excavation of caissons or groups of caissons so that reinforcing steel
and concrete placement is a continuous operation performed the same day
that the excavation is completed. Do not leave excavations open overnight.
2.
If the drilled shaft excavation is not complete at the end of the shift or series
of continuous shifts, the drilled shaft excavation operation may be stopped,
provided the Contractor, before the end of the work day, protects the shaft as
indicated in this Section.
3.
Drilled shaft excavations shall not be left open overnight unless cased full
depth or otherwise protected against sidewall instability. An open shaft
excavation is defined as a drilled shaft that has not been filled with concrete,
or temporarily backfilled with a material approved by the Officer-in-Charge in
accordance with this Section and shall be protected in accordance with this
specification.
4.
The Contractor shall bear full responsibility for selection and execution of the
method(s) of stabilizing and maintaining the drilled shaft excavation. The side
wall and bottom of the drilled shaft excavation shall be protected to prevent
side wall caving and bottom heave from occurring, so that the soil adjacent to
the drilled shaft is not disturbed. The Contractor may excavate the drilled
shaft without excavation protection provided the Contractor can demonstrate
and obtain approval by the Officer-in-Charge in writing that the soil/rock is
stable and above the water table and zones of seepage. Acceptable
protection methods include the use of temporary casing and excludes the
use of water or slurry.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-15
ADDENDUM NO. 3
DRILLED CAISSONS
B.
3.06
ACCEPTANCE: Place concrete within 3 hours after approval of the completed
excavation by the Officer-in-Charge.
PREPARATION
A.
Excavate the caissons by drilling to the established tip elevations and/or minimum
embedment shown. The Officer-in-Charge shall determine if deeper shafts may need
to be drilled. Dispose of excavated material in accordance with specifications.
B.
Blasting will not be permitted for use to excavate the caissons.
C.
When drilling shafts, prevent undermining of adjacent foundations, and protect the
surrounding soil and the sidewalls against cave-ins, displacement of the surrounding
earth, and retention of groundwater, by means of temporary steel casings. Provide
casings with an outside diameter not less than the indicated caisson size and a
minimum thickness of 1/2 inch or greater as determined by the Contractor based on
the casing installation/extraction methods included in the approved Drilled Caisson
Installation Plan. Casings shall be smooth, watertight, and of ample strength to
withstand both handling and installation/oscillation/extraction stresses, and the
pressure of concrete and/or the surrounding earth materials. Additional concrete
required to fill oversized caisson holes will not be paid for. Do not remove casings if
the structural integrity of the caisson will be impaired, as approved by the Officer-inCharge. Withdraw temporary steel casings as the concrete is being placed,
maintaining sufficient head of concrete within the casing to prevent extraneous
material from falling in from the sides and mixing with the concrete. Casings may be
jerked upward a maximum of 4 inches to break the bottom seal, but remove
thereafter with a smooth, continuous motion.
D.
Thoroughly clean and oil the inside of steel casings before reuse.
E.
Leave the temporary casing in place from the top of the shaft to the ground surface
until the concrete has set if the elevation of the top of the caisson is below the
adjacent ground surface.
F.
Each caisson excavation shall be properly reamed and cleaned to the minimum
design diameter and required depths, and be inspected by the Officer-in-Charge prior
to placing concrete. A minimum of 50 percent of the base of each caisson shall have
less than 1.5 inch of sediment at the time concrete is placed. The maximum depth
of sediment or debris on the base of the caisson shall not exceed 3.0 inches. Keep a
record of all inspections, with related construction changes. If the bottom of the
caisson contains sediment exceeding the acceptable amounts prescribed herein, the
caisson may be over drilled such that the top of the sediment or debris is at least 2
feet deeper than the specified caisson bottom depth at no additional costs to the
City. Provide support personnel for inspection and testing procedures.
G.
Prior to concrete placement in the caissons, perform sonic caliper logging of the shaft
to evaluate the shaft verticality, volume, and diameter. Determine the in-situ volume
of the amount of concrete to be placed. No additional payment will be made for
concrete over-pour in drilled shafts. Concrete over-pour is defined as the excess
concrete volume placed beyond the calculated theoretical shaft volume (allowing for
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-16
ADDENDUM NO. 3
DRILLED CAISSONS
the casing and the interstitial space) or nominal shaft volume (based upon the
specified shaft diameter). The cost of sonic caliper logging shall be considered
incidental to the drilled caisson construction and will not be paid for separately.
3.07
3.08
INSTALLATION
A.
Clean reinforcement of loose rust, mill scale, earth, and other foreign materials. Set
wire ties with ends directed into the concrete, not toward the sidewall of the caisson.
B.
Provide reinforcing cages with centering devices, spacers and boots to clear the
caisson sidewall, to maintain concrete cover, and to maintain the cage in position
and alignment during concrete placement and casing withdrawal.
C.
Lower reinforcing cage into the drilled caisson in such a manner as to prevent
damage to the reinforcing cage or the walls of the excavation. Place, tie and/or clip
the reinforcing cage symmetrically about the axis of the caisson.
D.
Perform all concrete work in accordance with the requirements of Section 03300.
E.
Maximum concrete temperature in center of drilled caisson shall be 160 degrees F,
with a maximum temperature difference of 35 degrees F between the center and the
perimeter of the caisson.
F.
Continuously place concrete by methods that ensure against concrete segregation
and dislodging of excavation sidewalls, and completely fill the caisson. Place
concrete by pumping or drop chutes in dry holes and by tremie or pumping in wet
holes. Keep the discharge a minimum of 3 feet below the fresh concrete surface
during placement. Drilling of caissons or driving of casings shall not be conducted
within 20 feet of another drilled caisson with concrete placed within the last 3 days.
G.
Bring concrete to a true level surface inside the caisson and a full width cross key
formed, or dowels installed, if it becomes necessary to interrupt placing concrete in
any caisson. Prior to placing additional concrete, clean surfaces of laitance and slush
with one-to-one Portland cement grout, having a water-cement ratio not exceeding
that of the concrete.
H.
Vibrate concrete for full depth of caisson. Do not use rebar vibrators.
TOLERANCES
A.
Correct any caisson out of center or plumb beyond the tolerance specified as
necessary to comply with the tolerances. Any corrective cost including but not limited
to project delay costs is the responsibility of the Contractor.
B.
Make cross sections of caissons not less than design dimensions.
C.
Install caissons with top elevation deviating not more than 3 inches from centerline
locations.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-17
ADDENDUM NO. 3
DRILLED CAISSONS
D.
3.09
Install vertical caissons plumb deviating not more than 1-1/2 inches for the first 10
feet and l/2 inch for each 10 feet of additional depth.
LOAD TESTS
A.
GENERAL REQUIREMENTS
1.
Prior to concrete placement in the test caissons, perform sonic caliper
logging of the shafts to evaluate the shaft verticality, volume, and diameter.
Determine the in-situ volume of the amount of concrete to be placed. No
additional payment will be made for concrete over-pour in drilled shafts. Use
the results of sonic caliper logging to analyze the load tests. The cost of sonic
caliper logging shall be considered incidental to the drilled caisson
construction and will not be paid for separately.
2.
Secure the Officer-in-charge approval of the tests prior to commencement of
work by submitting a Caisson Load Test Plan indicating the test method, test
equipment and apparatus, and test caisson locations. The Caisson Load Test
Plan shall be signed and sealed by the contractor retained QC Geotechnical
Engineer.
3.
Perform load tests as specified in the approved Caisson Load Test Plan,
under supervision of the Quality Control (QC) Geotechnical Engineer in the
presence of the Officer-in-Charge. Caissons used for load tests may be used
as production caissons if the Quality Control (QC) Geotechnical Engineer
determines that the caissons were not damaged during testing.
4.
Apply load in concentric manner with magnitude of load accurately
determined and controlled.
5.
Laterally support the top of caisson during entire load test.
6.
Load caissons to a minimum of 120 tons (240 kips) for the 60-ton caissons
but do not exceed ultimate concrete strength at the time of loading. Perform
load tests in accordance with ASTM D 1143, Procedure A.
7.
Load test reports shall be signed and sealed by the same QC Geotechnical
Engineer that prepared the Caisson Load Test Plan and supervised the load
test. Submit 4 copies of the test reports to the Officer-in-Charge.
8.
Tested installations will be considered of adequate design and construction if:
a.
No apparent distress occurs in caisson construction.
b.
Residual settlement, after test load is removed, does not exceed
1/2 inch.
c.
The design load does not cause a gross settlement of more than
1 inch.
KAILUA RWWTP TUNNEL INFLUENT
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02465-18
ADDENDUM NO. 3
DRILLED CAISSONS
B.
3.10
REPLACEMENTS: Replace and retest test caissons found inadequate because of
non-compliance with the minimum required allowable vertical capacity, improper
instrumentation, testing, or construction procedures, at no additional cost to the City.
Time extensions will not be granted for retesting and any resulting project delay costs
shall be borne solely and entirely by the Contractor.
INTEGRITY TESTS
A.
Perform integrity testing using non-destructive low-strain impact (LSI) tests and
concrete coring tests on selected, completed drilled caissons for verification of
soundness and integrity.
B.
Non-Destructive Low Strain Impact Tests
1.
Submit a test plan including details of the low strain impact tests and criteria
to evaluate the test results. Obtain the Officer-in-Charge approval of the test
plan prior to performing the tests.
2.
Equipment for Low Strain Impact Tests shall be suited to perform the tests
and shall meet the following minimum requirements:
a.
The analog to digital resolution shall be at least 24 bits,
b.
The sampling frequency shall be at least 25,000 Hz.
c.
Data shall be stored such that additional processing or further wave
analysis is possible.
d.
Data shall be displayed in the field for evaluations of preliminary data
quality and interpretation.
e.
The equipment shall allow attachment of a motion sensing device
capable of measuring acceleration, velocity or displacement due to
the impact of the pile top with a hand held hammer.
3.
Perform and interpret LSI tests on selected completed drilled caissons
including the load test caissons under supervision of a US licensed
professional engineer (with a minimum of 3 year experience of performing
and interpreting non-destructive low strain pile integrity testing) provided by
the Contractor. Perform test in accordance with ASTM D 5882.
4.
The LSI test shall be performed on a completed drilled caisson no earlier than
seven (7) days and no later than twenty (20) days after complete placement
of concrete into the drilled caisson unless otherwise directed by the Officer-inCharge.
5.
The cost of performing the non-destructive low strain pile integrity testing
(including the time and all associated costs to perform the tests and
preparing the test reports) shall be considered incidental to the drilled
caisson construction and will not be paid for separately.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-19
ADDENDUM NO. 3
DRILLED CAISSONS
6.
Within five (5) calendar days after field testing is complete, submit four (4)
copies of the LSI test report signed and sealed by the same professional
engineer described above. The test report should include; but, not be limited
to, the following:
a.
Title sheet with project number and phase, date of report, date of test
and names of onsite personnel performing the LSI test.
b.
Description of the apparatus for obtaining impact measurements and
apparatus for recording, reducing and displaying data, and of test
procedure including description and location of the motion sensor
attachment.
c.
Site and subsurface conditions.
d.
Caisson details including:
1)
2)
7.
Discussion of installation and available QC logs and data.
Observation of caisson conditions including spalled areas and
head surface conditions.
e.
Graphical presentation of motion and force (optional) measurements
in the time domain which shall include data enhancements used in
the evaluation; frequency domain presentation is optional for PEM
evaluation but required for TRM evaluation.
f.
Averaged, amplified velocity versus time record including the wave
speed of the test pile and how it was determined or estimated.
g.
Length of caisson, as cast, embedded, or below apparatus for
obtaining dynamic measurements.
h.
Results and conclusions, including description of any defects.
i.
Comments on the integrity of the caisson, including when appropriate
how the soil stratigraphy or installation methods, or both, have
influenced the constructed shape as determined by the
measurements.
If the Officer-in-Charge determines a caisson is unacceptable, submit
remedial measures for review. No compensation will be made for remedial
work or losses or damage due to remedial work of caissons found defective
or not in accordance with this section. Modifications to the drilled caisson
design or any load transfer mechanisms required by the remedial action shall
be designed by a licensed professional structural engineer registered in
Hawaii. Include supporting calculations and drawings signed and sealed by a
licensed professional structural engineer registered in Hawaii for all
foundation elements affected. Do not begin remedial action work until the
Officer-in-Charge has reviewed and accepted the remedial action plan. Allow
5 working days after submitting the remedial work plan for the Officer-in-
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-20
ADDENDUM NO. 3
DRILLED CAISSONS
Charge to review and provide direction. Furnish all materials and work
necessary to correct defective caissons at no cost to the City.
8.
C.
D.
3.11
The Officer-in-Charge will require five (5) working days to evaluate the LSI test
report and determine whether or not the caisson is acceptable. Evaluation of
LSI test reports, with significant reflections from locations above the caisson
bottom and without a clear caisson toe reflection may require further
investigation and additional time for review and analysis of the data. Where
no clear toe reflection is apparent, the experienced test engineer shall state
to which shaft depth the test appears to be conclusive. Where reflections
from locations with significant reductions in caisson area or material strength
or stiffness above the caisson toe are observed, the caisson has a serious
defect. If the record is complex, the results may be deemed inconclusive and
concrete coring shall be performed.
CONCRETE CORING TESTS
1.
Perform concrete coring tests on selected completed drilled caissons
including the load test caissons by using a qualified drilling subcontractor
(with a minimum of three (3) year experience of concrete caisson coring)
provided by the Contractor. Perform 4 concrete core tests
tests including two on
test piles at Generator/MV Electrical Distribution Building and two on
production piles at the Kailua Odor Control Foundation. Secure Officer-inCharge approval of the test locations (and depths as appropriate) seven (7)
days after submittal of the CSL testing results and prior to commencement of
the concrete coring tests.
2.
Coring shall be performed at the approved locations in the presence of the
Officer-in-Charge. The Contractor shall cut a minimum 4-inch diameter
vertical core through the entire length of a caisson unless otherwise directed
by the Officer-in-Charge. The core hole shall be centrally located and drilled
vertically. Selected samples of the 4-inch diameter core will be tested for
compressive strength as determined by the Officer-in-Charge. After the core
is removed, the core holes shall be filled with grout.
3.
Coring, testing, and backfill of the core holes shall be considered incidental to
the drilled caisson construction and will not be paid for separately.
4.
Submit four (4) copies of the test reports directly to the Officer-in-Charge. The
costs of preparing the concrete coring test reports shall be considered
incidental to the drilled caisson construction and will not be paid for
separately.
REPLACEMENTS: Replace and retest caissons found inadequate by integrity test at
no additional cost to the City.
PROTECTION
A.
Provide protection around top of the excavation to prevent debris from being
dislodged into the excavation and concrete.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-21
ADDENDUM NO. 3
DRILLED CAISSONS
3.12
RECORDS
A.
Keep complete and accurate records of all caisson installations. Include locations,
shaft diameters, top and bottom elevations, casing dimensions, concrete strength,
concrete volume, quantity of rock excavation, excavation condition, dates of
excavation and concrete placement, soil/rock strata description, and subsurface
water conditions. Base location on the survey of the licensed professional land
surveyor or professional civil engineer provided by the Contractor. Tabulate all
records, including corrective measures. Upon completion of caisson work, provide a
record of centerline locations based on the survey of the licensed surveyor or
engineer provided by the Contractor. In addition, also record corrective measures.
Deliver a complete tabulation of all records pertaining to approved caissons to the
Officer-in-Charge within two (2) weeks after acceptance of the last production shaft
by the Officer-in-Charge.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02465-22
ADDENDUM NO. 3
DRILLED CAISSONS
SECTION 02602
TREE BOX BIOFILTER
PART 1--GENERAL
1.01
1.02
SUMMARY
A.
SCOPE: This Section specifies the requirements for the design, manufacture, and
installation of a tree box biofilter.
B.
DESCRIPTION: The tree box biofilter shall consist of an underground precast
concrete structure that intercepts and removes pollutants from stormwater. The
structure houses a biofilter that consists of a tree or shrub and biofiltration soil
mixture. The biofiltration unit shall also contain an internal bypass mechanism that
diverts flows that exceed the capacity of the treatment components so as to prevent
scour and washout of previously captured pollutants.
QUALITY ASSURANCE
A.
REFERENCES:
1.
This Section contains references to the following documents. They are a part
of this Section as specified and modified. Where a referenced document
contains references to other standards, those documents are included as
references under this Section as if referenced directly. In the event of conflict
between the requirements of this Section and those of the listed documents,
the requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect at the time of Advertisement for Bids. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or otherwise
identified by that organization or, if there are no replacement documents, the
last version of the document before it was discontinued. Where document
dates are given in the following listing, references to those documents shall
mean the specific document version associated with that date, regardless of
whether the document has been superseded by a version with a later date,
discontinued or replaced.
Reference
Title
AASHTO
Standard Specifications for Highway Bridges
ACI 318
Building Code Requirements for Structural Concrete
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-1
ADDENDUM NO. 3
TREE BOX BIOFILTER
Reference
Title
ANSI Z60.1
American Standard for Nursery Stock
ASTM A48
Standard Specification for Gray Iron Castings
ASTM C39
Standard Test Method for Compressive Strength of
Cylindrical Concrete Specimens
ASTM C858
Standard Specification for Underground Precast Concrete
Utility Structures
ASTM C857
Standard Practice for Minimum Structural Design Loading
for Underground Precast Concrete Utility Structures
ASTM C891
Standard Practice for Installation of Underground Precast
Concrete Utility Structures
ASTM D3977
Standard Test Methods for Determining Sediment
Concentrations in Water Samples
Standard Details
Standard Details for Public Works Construction,
Department of Public Works, City and County of Honolulu
Standard
Specifications
Standard Specifications for Public Works Construction,
Department of Public Works, City and County of Honolulu
B.
FACTORY QUALITY CONTROL: The Contractor shall furnish manufacturer’s test
results for all products as required herein and by the reference specifications.
C.
FIELD QUALITY CONTROL: The Contractor shall comply with manufacturer’s handling
and installation instructions.
D.
VEGETATION PLANTING QUALITY CONTROL:
1.
General: Plantings shall be healthy, vigorous, well-formed, and balanced
stock grown under climatic conditions similar to the project site. Vegetation
plantings shall also be free of disease, insects, weeds, eggs, larvae, defects,
injuries, or disfigurements.
2.
Removal and replacement: Vegetation that dies immediately, or are in
distressed or unhealthy condition as determined by the Officer-in-Charge,
shall be removed and replaced.
3.
Warranty Period: Shall extend 1 year from the date of final project
acceptance as defined in the general conditions.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-2
ADDENDUM NO. 3
TREE BOX BIOFILTER
1.03
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
Calculations: Provide structural design and buoyancy calculations performed
by a qualified Engineer licensed by the State of Hawaii. Calculations shall be
performed per the design requirements specified in Section 02601 and
ASTM C857.
2.
Shop drawings: Include elevations, dimensions, pipe invert elevations,
concrete reinforcement, piping locations, appurtenance locations, foundation
details, vegetation and biofilter soil mixture (media) placement, and
connection details.
3.
Product information: Provide information for all materials to be installed
including biofilter media, vegetation, fittings, appurtenances, sealants,
concrete, concrete reinforcement, access hatches and grates, and other
internal components.
4.
Tests: Provide total suspended solids removal efficiency tests results for the
biofiltration media.
5.
Operation and maintenance manuals.
PART 2--PRODUCTS
2.01
TREE BOX BIOFILTER:
A.
GENERAL:
1.
Design: The tree box biofiltration unit shall be designed by the manufacturer
to capture stormwater and provide treatment of stormwater pollutants via
biofiltration. The filter shall consist of a precast concrete vault that
incorporates a curb inlet and inlet bay that is separate from the biofiltration
bay. The biofiltration component shall be comprised of a biofiltration soil
mixture (media) and vegetation. The units shall be designed such that storm
water flows through the biofiltration mixture is controlled by an outlet flow
control device that maintains the specified maximum infiltration rate. Flows
in excess of the design water quality flow shall be bypassed via an internal
weir and overflow structure.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-3
ADDENDUM NO. 3
TREE BOX BIOFILTER
B.
C.
2.
Manufacturer: UrbanGreen™ BioFilter, Model UGBF0816-49” Depth,
manufactured by Contech Engineered Solutions, LLC, or approved equal.
3.
Design flow: The unit shall be capable of treating the design flow shown on
the drawings.
4.
Overflow: Each filtration unit shall include an internal overflow weir that
conveys flows in excess of the design water quality flow rate directly to the
outlet chamber without passing through the biofiltration media. The weir
shall have a minimum capacity of 2.0 cfs with no greater than a 1 inch depth
of flow at the curb face.
PRECAST CONCRETE VAULT:
1.
Design and manufacture standards: Design and manufacture in accordance
with ASTM C857 and C858. The vault shall be designed and stamped by a
qualified Engineer licensed by the State of Hawaii. Provide all stamped
calculations and design drawings.
2.
Concrete: Type C-2 as specified in Section 03300.
3.
Reinforcement: As specified in Section 03200.
4.
Floor slope: Minimum 1% to outlet.
5.
Anti-flotation/buoyancy: The vault design shall include structure buoyancy
calculations by a qualified Engineer licensed by the State of Hawaii. Perform
calculations and provide design drawings in accordance with Section 02601
and provide anti-flotation ballast or appurtenances with vault if required.
SEALANTS:
1.
Vault joints: As specified in Section 02601.
2.
Interior wall joints: Polyurethane construction sealant rated for submerged
use. Sikaflex®-1a manufactured by Sika Corporation, or approved equal.
D.
GROUT: As specified in Section 02601.
E.
PIPING: ABS manifold pipe and fittings shall meet ASTM F628. PVC manifold and
fittings shall meet ASTM D1785.
F.
GRATES, FRAMES AND COVERS: Withstand AASTO H-20 loading requirements, and
constructed according to ASTM A48. Manhole covers to be provided per the
Standard Details.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-4
ADDENDUM NO. 3
TREE BOX BIOFILTER
G.
2.02
BIOFILTRATION SOIL MIXTURE (MEDIA): Biofiltration media type and composition
shall be provided as recommended by the manufacturer and shall have the following
minimum characteristics:
1.
Infiltration capacity: A minimum of100 in/hr
2.
Organic Content: 10% - 15% by volume and shall be a stable granular
material.
3.
Water retention: 80 oz/cf by volume after 1 hour of gravity drainage
4.
Cation exchange capacity: 20 meq/g
5.
Bulk density: 50 – 75 pcf
6.
Performance: Media shall be capable of 80% removal of Sil-Co-Sil 106
ground silica at the design infiltration rate. Silica gradation shall have 100%
of the particles be smaller the 212 microns in diameter and 50% of the
particles be less than 25 microns in diameter. Total suspended solids
removal shall be tested per ASTM D3977-97 by a qualified laboratory.
H.
INTERNAL BYPASS: 14 gauge carbon steel or vacuum formed ABS.
I.
PIPE CONNECTIONS TO VAULT: Flexible boot-type connectors as specified in Section
02601.
VEGETATION PLANTINGS:
A.
GENERAL: Vegetation plantings shall be provided by the manufacturer. The species
shall be native to the region, suitable for well-drained soil, be able to withstand full
sun exposure and be drought tolerant. Plantings shall conform with all applicable
local, state and federal laws and regulations.
B.
SIZE: Plantings shall be between 2ft and 5 ft in height and be provided in a Class 3
container as defined by ANSI Z60.1 for type and height of tree or shrub required.
C.
SPECIES: ‘A‘ali‘i (Dodonaea viscosa), or approved equal. Stock shall be sourced from
the island of Oahu and grown in climatic conditions similar to the installed location of
the biofilter.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-5
ADDENDUM NO. 3
TREE BOX BIOFILTER
PART 3--EXECUTION
3.01
VAULT INSTALLATION:
A.
1.
Install temporary erosion sediment and dust control best management
practices (BMP’s) as required in Section 02270.
2.
Sawcut, demolish, remove and dispose of adjacent section of existing curb,
gutter and asphalt concrete (AC) pavement as shown on the drawings.
B.
EXCAVATION: Per Section 02200
C.
BEDDING AND LEVELING COURSE: Per Section 02601.
D.
VAULT PLACEMENT: Per Section 02601. Set top of vault flush with top of adjacent
curb. Vault floors shall drain to outlet.
E.
OUTLET CONNECTIONS: Install outlet pipe and connections to existing stormwater
system.
F.
VAULT ANTI-FLOTATION MEASURES: Install as required.
G.
BACKFILL: Per Section 02200.
H.
RESTORATION:
I.
3.02
PREPARATION:
1.
Remove and dispose of all excess or foreign materials.
2.
Install new curb, gutter and inlet gutter depression per the
Standards Details.
3.
Install AC pavement per Section 02500.
4.
Hydromulch and seed all adjacent disturbed areas per Section 02270.
BIOFILTER MATERIAL INSTALLATION: The manufacturer shall install all vault
appurtenances and vegetation plantings.
STARTUP AND ACTIVATION
A.
GENERAL: The tree box biofilter shall not be activated or used to intercept and treat
stormwater flows until all final BMP’s specified in Section 02270 and the drawings
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-6
ADDENDUM NO. 3
TREE BOX BIOFILTER
are in place, all other construction is complete, and the site is stabilized. Plug all
inlets and outlets to the unit until activation.
B.
3.03
ACTIVATION: The unit shall be activated by the manufacturer.
MEASUREMENT AND PAYMENT
A.
GENERAL: The tree box biofilter shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective line items in the
Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
02602-7
ADDENDUM NO. 3
TREE BOX BIOFILTER
SECTION 08331
OVERHEAD COILING DOORS
PART 1 - GENERAL
1.01
SUMMARY
A.
Section Includes:
1.
Service doors.
2.
Insulated service doors.
3.
Fire-rated, insulated service doors.
B.
Related Requirements:
1.
Section 05500 "Metal Fabrications" for miscellaneous steel supports.
1.02
SUBMITTALS
A.
Product Data: For each type and size of overhead coiling door and accessory.
B.
Shop Drawings: For each installation and for special components not dimensioned or
detailed in manufacturer's product data.
1.
Include points of attachment and their corresponding static and dynamic loads
imposed on structure.
2.
Show locations of controls, locking devices, detectors or replaceable fusible links,
and other accessories.
3.
Include diagrams for power, signal, and control wiring.
C.
Samples: For each exposed product and for each color and texture specified.
D.
Maintenance data.
1.03
QUALITY ASSURANCE
A.
Installer Qualifications: An entity that employs installers and supervisors who are trained
and approved by manufacturer for both installation and maintenance of units required for
this Project.
B.
Fire-Rated Door Assemblies: Assemblies complying with NFPA 80 that are listed and
labeled by a qualified testing agency, for fire-protection ratings indicated, based on testing
at as close to neutral pressure as possible according to NFPA 252 or UL 10B.
1.
Smoke Control: Where indicated, provide doors that are listed and labeled with the
letter "S" on the fire-rating label by a qualified testing agency for smoke- and draftcontrol based on testing according to UL 1784; with maximum air-leakage rate of 3.0
cfm/sq. ft. of door opening at 0.10-inch wg for both ambient and elevated
temperature tests.
C.
Contractor shall perform Field STC tests of doors installed improperly with visible damage
to sound seals; misaligned frames, doors, or sound seals; visible gaps in sound seals; or
unlabeled door assemblies.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 1
ADDENDUM NO. 3
OVERHEAD COILING DOORS
PART 2 - PRODUCTS
2.01
PERFORMANCE REQUIREMENTS
A.
Structural Performance, Exterior Doors: Capable of withstanding the design wind loads.
1.
Design Wind Load: As indicated on Drawings.
2.
Testing: According to ASTM E 330.
B.
Windborne-Debris Impact Resistance: Provide impact-protective overhead coiling doors that
pass missile-impact and cyclic-pressure tests according to ASTM E 1996 for Wind Zone 1.
1.
Large-Missile Test: For overhead coiling doors located within 30 feet of grade.
C.
Seismic Performance: Overhead coiling doors shall withstand the effects of earthquake
motions determined according to ASCE/SEI 7 .
D.
Design overhead coiling doors to meet sound classification as indicated in the drawings,
complete with sound seals and trims. The voids shall be filled with sound insulating
material for sound transmission loss of in decibels of not less than 40, when tested in
accordance with ASTM E 90. Door shall be acoustically sealed at the head, jambs and sills.
2.02
DOOR ASSEMBLY
A.
Service and Insulated Service Door: Overhead coiling door formed with curtain of
interlocking metal slats. Double overhead coiling doors (one door installed on the exterior
side and one door installed on the interior side of an opening), where indicated in the
drawings, to meet higher STC ratings.
B.
Operation Cycles: Door components and operators capable of operating for not less than
100,000.
C.
Curtain R-Value: 8.0 deg F x h x sq. ft./Btu.
D.
Door Curtain Material: Stainless steel.
E.
Door Curtain Slats: Flat profile slats of 3 inches center-to-center height.
1.
Insulated-Slat Interior Facing: Stainless steel.
F.
Insulated Door Minimum Sound Transmission Class (STC) rating of 27 as tested per ASTM
E90. Results must be indicative of testing a complete/operable door assembly. Double
overhead coiling doors (one door installed on the exterior side and one door installed on
the interior side of an opening), where indicated in the drawings, to meet higher STC
ratings.
G.
Endlocks and Windlocks for Service Doors: The ends of each slat or each alternate slat
shall have malleable iron or galvanized steel endlocks of manufacturer's stock design. In
addition to endlocks, exterior doors which are more than 16 feet wide or which have a
design wind load of more than 20 pounds per square foot, shall have windlocks of
manufacturer's standard design. Windlocks shall prevent curtain from leaving guide
because of deflection from windpressure or other forces.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 2
ADDENDUM NO. 3
OVERHEAD COILING DOORS
H.
Bottom Bar: Two angles, each not less than 1-1/2 by 1-1/2 by 1/8 inch thick; fabricated
from stainless steel and finished to match door .
I.
Curtain Jamb Guides: Stainless steel with exposed finish matching curtain slats.
J.
Hood: Stainless steel.
1.
Mounting: Face of wall.
K.
Locking Devices: Equip door with locking device assembly and chain lock keeper.
1.
Locking Device Assembly: Single-jamb side locking bars, operable from inside and
outside with cylinders.
L.
Electric Door Operator:
1.
Usage Classification: Standard duty, up to 25 cycles per hour and up to 90 cycles per
day.
2.
Safety: Listed according to UL 325 by a qualified testing agency for commercial or
industrial use.
3.
Motor Exposure: Interior, wet, and humid.
4.
Emergency Manual Operation: Chain type.
5.
Obstruction-Detection Device: Automatic electric sensor edge on bottom bar.
6.
Control Station(s): Where shown on Drawings.
7.
Other Equipment: Audible and visual signals.
M.
Curtain Accessories: Equip door with weatherseals.
N.
Door Finish:
1.
Stainless-Steel Finish: No. 4 (polished directional satin) .
2.
Interior Curtain-Slat Facing: Match finish of exterior curtain-slat face.
2.03
FIRE-RATED DOOR ASSEMBLY
A.
Fire-Rated Insulated Service Door: Overhead fire-rated coiling door formed with curtain of
interlocking metal slats. Double overhead coiling doors (one door installed on the exterior
side and one door installed on the interior side of an opening), where indicated in the
drawings, to meet higher STC ratings.
B.
Operation Cycles: Door components and operators capable of operating for not less than
100,000.
C.
Fire Rating: As indicated in the Drawings.
D.
Curtain R-Value: 8.0 deg F x h x sq. ft./Btu.
E.
Door Curtain Material: Stainless steel.
F.
Door Curtain Slats: Flat profile slats of 3 inches center-to-center height.
1.
Insulated-Slat Interior Facing: Metal.
G.
Insulated Door Minimum Sound Transmission Class (STC) rating of 27 as tested per ASTM
E90. Results must be indicative of testing a complete/operable door assembly. Double
overhead coiling doors (one door installed on the exterior side and one door installed on
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 3
ADDENDUM NO. 3
OVERHEAD COILING DOORS
the interior side of an opening), where indicated in the drawings, shall have a minimum STC
rating of 40. Design overhead coiling doors complete with sound seals and trims. The voids
shall be filled with sound insulating material for sound transmission loss of in decibels of
not less than 40, when tested in accordance with ASTM E 90. Door shall be acoustically
sealed at the head, jambs and sills.
H.
Endlocks and Windlocks for Service Doors: The ends of each slat or each alternate slat
shall have malleable iron or galvanized steel endlocks of manufacturer's stock design. In
addition to endlocks, exterior doors which are more than 16 feet wide or which have a
design wind load of more than 20 pounds per square foot, shall have windlocks of
manufacturer's standard design. Windlocks shall prevent curtain from leaving guide
because of deflection from windpressure or other forces.
I.
Curtain Jamb Guides: Stainless steel with exposed finish matching curtain slats.
J.
Hood: Stainless steel.
1.
Mounting: Face of wall.
K.
Locking Devices: Equip door with locking device assembly and chain lock keeper.
1.
Locking Device Assembly: Single-jamb side locking bars, operable from inside and
outside with cylinders.
L.
Electric Door Operator:
1.
Usage Classification: Heavy duty, 25 or more cycles per hour and over 90 cycles per
day.
2.
Safety: Listed according to UL 325 by a qualified testing agency for commercial or
industrial use.
3.
Motor Exposure: Interior, wet, and humid.
4.
Emergency Manual Operation: Chain type.
5.
Obstruction Detection Device: Automatic electric sensor edge on bottom bar.
6.
Control Station(s): Where shown on Drawings.
7.
Other Equipment: Audible and visual signals.
M.
Curtain Accessories: Equip door with weatherseals.
N.
Door Finish:
1.
Stainless-Steel Finish: No. 4 (polished directional satin) <Insert finish>.
2.
Interior Curtain-Slat Facing: Match finish of exterior curtain-slat face.
2.04
MATERIALS, GENERAL
A.
Electrical Components, Devices, and Accessories: Listed and labeled as defined in
NFPA 70, by a qualified testing agency, and marked for intended location and application.
B.
Stainless Steel shall conform to ASTM A666, Type 316.
2.05
A.
DOOR CURTAIN MATERIALS AND CONSTRUCTION
Door Curtains: Fabricate overhead coiling-door curtain of interlocking metal slats, designed
to withstand wind loading indicated, in a continuous length for width of door without
splices. Unless otherwise indicated, provide slats of thickness and mechanical properties
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 4
ADDENDUM NO. 3
OVERHEAD COILING DOORS
recommended by door manufacturer for performance, size, and type of door indicated, but
no less than 0.032 inch minimum sheet thickness, and as follows:
1.
Insulation: Fill slats for insulated doors with manufacturer's standard thermal
insulation complying with maximum flame-spread and smoke-developed indexes of
75 and 450, respectively, according to ASTM E 84 or UL 723. Enclose insulation
completely within slat faces.
2.
Metal Interior Curtain-Slat Facing: Match metal of exterior curtain-slat face, with
minimum steel thickness of 0.032 inch.
B.
Windlocks and Endlocks: Provide end and/or wind locks of Grade B cast steel conforming
to ASTM A27/A27M, galvanized in accordance with ASTM A653/A653M,ASTM
A153/A153M and ASTM A924/A924M.
C.
Curtain Jamb Guides: Manufacturer's standard angles or channels and angles of same
material and finish as curtain slats unless otherwise indicated, with sufficient depth and
strength to retain curtain, to allow curtain to operate smoothly, and to withstand loading.
Slot bolt holes for guide adjustment. Provide removable stops on guides to prevent
overtravel of curtain.
2.06
A.
2.07
HOODS
General: Form sheet metal hood to entirely enclose coiled curtain and operating
mechanism at opening head, of same material and finish as curtain slats unless otherwise
indicated. Contour to fit end brackets to which hood is attached. Roll and reinforce top and
bottom edges for stiffness. Form closed ends for surface-mounted hoods and fascia for any
portion of between-jamb mounting that projects beyond wall face. Equip hood with
intermediate support brackets as required to prevent sagging.
LOCKING DEVICES
A.
Locking Device Assembly: Fabricate with cylinder lock, spring-loaded dead bolt, operating
handle, cam plate, and adjustable locking bars to engage through slots in tracks.
1.
Lock Cylinders: Cylinders standard with manufacturer and keyed to building keying
system.
2.
Keys: Five for each cylinder.
B.
Chain Lock Keeper: Suitable for padlock.
C.
Safety Interlock Switch: Equip power-operated doors with safety interlock switch to
disengage power supply when door is locked.
2.08
CURTAIN ACCESSORIES
A.
Weatherseals for Exterior Doors: Equip each exterior door with weather-stripping gaskets
fitted to entire exterior perimeter of door for a weather-resistant installation unless
otherwise indicated.
B.
Astragal for Interior Doors: Equip each door bottom bar with a replaceable, adjustable,
continuous, compressible gasket of flexible vinyl, rubber, or neoprene as a cushion bumper.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 5
ADDENDUM NO. 3
OVERHEAD COILING DOORS
C.
2.09
Automatic-Closing Device for Fire-Rated Doors: Equip each fire-rated door with an
automatic-closing device or holder-release mechanism and governor unit complying with
NFPA 80 and an easily tested and reset release mechanism. Automatic-closing device shall
be designed for activation by the following:
1.
Replaceable fusible links with temperature rise and melting point of 165 deg F
interconnected and mounted on both sides of door opening.
2.
Building fire-detection, smoke-detection, and -alarm systems.
COUNTERBALANCING MECHANISM
A.
General: Counterbalance doors by means of manufacturer's standard mechanism with an
adjustable-tension, steel helical torsion spring mounted around a steel shaft and contained
in a spring barrel connected to top of curtain with barrel rings. Use grease-sealed bearings
or self-lubricating graphite bearings for rotating members.
B.
Brackets: Manufacturer's standard mounting brackets of either cast iron or cold-rolled steel
plate.
2.10
ELECTRIC DOOR OPERATORS
A.
General: Electric door operator assembly of size and capacity recommended and provided
by door manufacturer for door and operation-cycles requirement specified, with electric
motor and factory-prewired motor controls, starter, gear-reduction unit, solenoid-operated
brake, clutch, control stations, control devices, integral gearing for locking door, and
accessories required for proper operation.
1.
Comply with NFPA 70.
2.
Control equipment complying with NEMA ICS 1, NEMA ICS 2, and NEMA ICS 6, with
NFPA 70 Class 2 control circuit, maximum 24-V ac or dc.
B.
Usage Classification: Electric operator and components capable of operating for not less
than number of cycles per hour indicated for each door.
C.
Motors: Reversible-type motor with controller (disconnect switch) for motor exposure
indicated.
1.
Electrical Characteristics:
a.
Phase: Three phase.
b.
Volts: 460 V.
c.
Hertz: 60.
2.
Motor Size: Large enough to start, accelerate, and operate door in either direction
from any position, at a speed not less than 8 in./sec. and not more than 12 in./sec.,
without exceeding nameplate ratings or service factor.
3.
Operating Controls, Controllers, Disconnect Switches, Wiring Devices, and Wiring:
Manufacturer's standard unless otherwise indicated.
D.
Obstruction Detection Devices: External entrapment protection consisting of indicated
automatic safety sensor capable of protecting full width of door opening. For non-fire-rated
doors, activation of device immediately stops and reverses downward door travel.] For firerated doors, activation delays closing.
1.
Photoelectric Sensor: Manufacturer's standard system designed to detect an
obstruction in door opening without contact between door and obstruction.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 6
ADDENDUM NO. 3
OVERHEAD COILING DOORS
a.
2.
3.
Self-Monitoring Type: Designed to interface with door operator control circuit to
detect damage to or disconnection of sensing device. When self-monitoring
feature is activated, door closes only with sustained or constant pressure on
close button.
Electric Sensor Edge: Automatic safety sensor edge, located within astragal or
weather stripping mounted to bottom bar. Contact with sensor activates device.
Connect to control circuit using manufacturer's standard take-up reel or self-coiling
cable.
a.
Self-Monitoring Type: Four-wire configured device designed to interface with
door operator control circuit to detect damage to or disconnection of sensor
edge.
Pneumatic Sensor Edge: Automatic safety sensor edge, located within astragal or
weather stripping mounted to bottom bar. Contact with sensor activates device.
E.
Control Station: Three-button control station in fixed location with momentary-contact pushbutton controls labeled "Open" and "Stop" and sustained- or constant-pressure push-button
control labeled "Close."
1.
Interior-Mounted Units: Full-guarded, surface-mounted, heavy-duty type, with generalpurpose NEMA ICS 6, Type 1 enclosure.
F.
Emergency Manual Operation: Equip each electrically powered door with capability for
emergency manual operation. Design manual mechanism so required force for door
operation does not exceed 25 lbf.
G.
Emergency Operation Disconnect Device: Equip operator with hand-operated disconnect
mechanism for automatically engaging manual operator and releasing brake for emergency
manual operation while disconnecting motor without affecting timing of limit switch. Mount
mechanism so it is accessible from floor level. Include interlock device to automatically
prevent motor from operating when emergency operator is engaged.
H.
Motor Removal: Design operator so motor may be removed without disturbing limit-switch
adjustment and without affecting emergency manual operation.
I.
Audible and Visual Signals: Audible alarm and visual indicator lights in compliance with
regulatory requirements for accessibility.
J.
Hazardous Locations: Electrical materials, equipment, and devices for installation in
hazardous locations, as defined by NFPA 70, shall be specifically approved by Underwriters
Laboratories or an independent testing agency using equivalent standards, for the
particular chemical group and the class and division of hazardous location involved.
PART 3 - EXECUTION
3.01
INSTALLATION
A.
Install overhead coiling doors and operating equipment complete with necessary hardware,
anchors, inserts, hangers, and equipment supports; according to manufacturer's written
instructions and as specified.
B.
Power-Operated Doors: Install according to UL 325.
KAILUA RWWTP TUNNEL INFLUENT
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FACILITY, JOB NO. W1-13
08331 - 7
ADDENDUM NO. 3
OVERHEAD COILING DOORS
C.
3.02
A.
3.03
A.
Adjust hardware and moving parts to function smoothly so that doors operate easily, free of
warp, twist, or distortion. Lubricate bearings and sliding parts as recommended by
manufacturer. Adjust seals to provide tight fit around entire perimeter.
DEMONSTRATION
Engage a factory-authorized service representative to train Owner's maintenance personnel
to adjust, operate, and maintain overhead coiling doors.
MEASUREMENT AND PAYMENT
All work specified in this section shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08331 - 8
ADDENDUM NO. 3
OVERHEAD COILING DOORS
SECTION 08346
SOUND-CONTROL DOOR ASSEMBLIES
PART 1 - GENERAL
1.01
A.
1.02
SUMMARY
Section Includes:
1.
Steel sound-control doors.
2.
Steel frames and sound-control seals.
SUBMITTALS
A.
Product Data: For each type of product indicated. Include sound ratings, construction
details, material descriptions, core descriptions, fire-resistance rating, and finishes.
B.
Shop Drawings: Include the following:
1.
Elevations of each door design.
2.
Details of sound-control seals, door bottoms, and thresholds.
3.
Details of doors, including vertical and horizontal edge details and metal thicknesses.
4.
Frame details for each frame type, including dimensioned profiles and metal
thicknesses.
5.
Locations of reinforcement and preparations for hardware.
6.
Details of each different wall opening condition.
7.
Details of anchorages, joints, field splices, and connections.
8.
Details of accessories.
9.
Details of moldings, removable stops, and glazing.
C.
Samples for Verification:
1.
Finishes: For each type of exposed finish required, prepared on Samples of not less
than 3 by 5 inches.
2.
Doors: Include section of vertical-edge, top, and bottom construction; automatic door
bottom or gasket; core construction; glazing; and hinge and other applied hardware
reinforcement.
3.
Frames: Include profile, corner joint, floor and wall anchors, and seals. Include
separate section showing fixed sound panels if applicable.
D.
Schedule: Provide a schedule of sound-control door assemblies prepared by or under the
supervision of supplier, using same reference numbers for details and openings as those
on Drawings. Coordinate with the Door Hardware Schedule.
E.
Qualification Data: For qualified Installer, manufacturer, and acoustical testing agency.
F.
Product Certificates: For each type of sound-control door assembly, from manufacturer.
G.
Product Test Reports: Based on evaluation of comprehensive tests performed by a
qualified testing agency, for each type of sound-control door assembly.
H.
Field quality-control reports.
KAILUA RWWTP TUNNEL INFLUENT
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FACILITY, JOB NO. W1-13
08346 - 1
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
I.
Warranty: Samples of special warranty.
J.
Maintenance Data: For sound-control door assemblies to include in maintenance manuals.
1.03
QUALITY ASSURANCE
A.
Installer Qualifications: Manufacturer's authorized representative who is trained and
approved for installation of units required for this Project.
B.
Acoustical Testing Agency Qualifications: An independent agency accredited as an
acoustical laboratory according to the National Voluntary Laboratory Accreditation Program
of NIST.
C.
Source Limitations: Obtain sound-control door assemblies, including doors, frames, soundcontrol seals, hinges (when integral for sound control), thresholds, and other items
essential for sound control, from single source from single manufacturer.
D.
Sound Rating: Provide sound-control door assemblies identical to those of assemblies
tested as sound-retardant units by an acoustical testing agency, and have the following
minimum rating:
1.
STC Rating: As indicated on Drawings, as determined by ASTM E 413 when tested in
an operable condition according to ASTM E 90 and ASTM E 1408.
E.
Fire-Rated Door Assemblies: Assemblies listed and labeled by a qualified testing agency,
for fire-protection ratings indicated, based on testing at positive pressure according to
NFPA 252 or UL 10C.
1.
Oversize Fire-Rated Door Assemblies:
For units exceeding sizes of tested
assemblies, provide certification by a qualified testing agency that doors comply with
standard construction requirements for tested and labeled fire-rated door assemblies
except for size.
F.
Smoke- and Draft-Control Door Assemblies: Where indicated , provide an assembly with
gaskets listed and labeled for smoke and draft control by a qualified testing agency
acceptable to authorities having jurisdiction, based on testing according to UL 1784 and
installed in compliance with NFPA 105.
G.
Preinstallation Conference: Conduct conference at Project site.
1.
Review required field quality-control procedures.
2.
Review procedures for coordinating frame and anchor installation with wall
construction.
3.
Review frame grouting procedures.
H.
Contractor shall perform Field STC tests of doors installed improperly with visible damage
to sound seals; misaligned frames, doors, or sound seals; visible gaps in sound seals; or
unlabeled door assemblies.
1.04
A.
DELIVERY, STORAGE, AND HANDLING
Deliver doors and frames palletized, wrapped, or crated to provide protection during transit
and Project-site storage. Do not use nonvented plastic.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08346 - 2
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
1.
Provide additional protection to prevent damage to finish of factory-finished wood
doors.
B.
Shipping Spreaders: Deliver welded frames with two removable spreader bars across
bottom of frames, tack welded or mechanically attached to jambs and mullions.
C.
Store doors and frames under cover at Project site. Place units in a vertical position with
heads up, spaced by blocking, on minimum 4-inch- high, wood blocking. Avoid using
nonvented plastic or canvas shelters that could create a humidity chamber.
1.
If wrappers on doors become wet, remove cartons immediately. Provide a minimum
of 1/4-inch space between each stacked door to permit air circulation.
1.05
A.
1.06
A.
1.07
A.
PROJECT CONDITIONS
Field Measurements: Verify actual dimensions of openings by field measurements before
fabrication.
COORDINATION
Coordinate installation of anchorages for sound-control door assemblies. Furnish setting
drawings, templates, and directions for installing anchorages, including sleeves, inserts,
anchor bolts, and items with integral anchors. Deliver such items to Project site in time for
installation. Provide coordination of door hardware in section 08710, to include hinges,
locksets, closers and flush bolts as necessary.
WARRANTY
Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or
replace components of sound-control door assemblies that fail in materials or workmanship
within specified warranty period.
1.
Failures include, but are not limited to, the following:
a.
Failure to meet sound rating requirements.
b.
Faulty operation of sound seals.
c.
Deterioration of metals, metal finishes, and other materials beyond normal use
or weathering.
2.
Warranty Period for Steel Doors: Five years from date of Substantial Completion.
PART 2 - PRODUCTS
2.01
A.
STEEL SOUND-CONTROL DOORS
Description: Provide flush-design sound-control doors, minimum 1-3/4 inches thick, of
seamless construction; with manufacturer's standard sound-retardant core as required to
provide STC and fire rating indicated. Construct doors with smooth, flush surfaces without
visible joints or seams on exposed faces or stile edges. Fabricate according to
ANSI/NAAMM-HMMA 865.
1.
Exterior Doors: Fabricate from stainless steel sheet 0.062-inch nominal thickness, or
thicker as required to provide STC rating indicated.
2.
Interior Doors: Fabricate from metallic-coated steel sheet unless otherwise
indicated, 0.0635-inch nominal thickness, or thicker as required to achieve STC
rating indicated.
KAILUA RWWTP TUNNEL INFLUENT
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08346 - 3
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
3.
4.
5.
Loose Stops for Glazed Lites in Doors: Same material as face sheets.
Top and Bottom Channels: Closed with continuous channels of same material as
face sheets, spot welded to face sheets not more than 6 inches o.c.
Hardware Reinforcement: Same material as face sheets.
B.
Exterior Doors: Provide doors fabricated with thermal-resistance value (R-value) of not less
than 2.1 deg F x h x sq. ft./Btu when tested according to ASTM C 1363.
C.
Interior doors shall meet opening force requirements of no more than 5 lbs of force to push
or pull open the door. These forces do not apply to the force required to retract latch bolts
or disengage other devices that hold the door in a closed position.
D.
Materials:
1.
Stainless-Steel Sheet: ASTM A 666, austenitic stainless steel, Type 316.
2.
Metallic-Coated Steel Sheet: ASTM A 653/A 653M, Commercial Steel (CS), Type B,
with G90 zinc (galvanized) coating designation.
3.
Glazing: As required by sound-control door assembly manufacturer to comply with
sound-control and fire-rated-door labeling requirements.
2.02
A.
SOUND-CONTROL FRAMES
Description: Fabricate sound-control door frames with corners mitered, reinforced, and
continuously welded full depth and width of frame. Fabricate according to ANSI/NAAMMHMMA 865.
1.
Weld frames according to NAAMM-HMMA 820.
2.
Exterior Frames: Fabricate from stainless steel sheet 0.079-inch nominal thickness,
or thicker as required to provide STC rating indicated.
3.
Interior Frames: Fabricate from metallic-coated steel sheet unless otherwise
indicated, 0.0785-inch nominal thickness, or thicker as required to provide STC
rating indicated.
4.
Sound-Control Panel Stops: Formed integral with frames, a minimum of 5/8 inch
high, unless otherwise indicated.
5.
Hardware Reinforcement: Fabricate according to ANSI/NAAMM-HMMA 865 of same
material as face sheets.
6.
Head Reinforcement: Reinforce frames with metallic-coated steel channel or angle
stiffener, 0.108-inch nominal thickness, welded to head.
7.
Jamb Anchors:
a.
Masonry Type: Adjustable strap-and-stirrup or T-shaped anchors to suit frame
size, not less than 0.064-inch nominal thickness metallic-coated steel with
corrugated or perforated straps not less than 2 inches wide by 10 inches long;
or wire anchors not less than 0.156 inch thick.
b.
Stud-Wall Type: Designed to engage stud, welded to back of frames; not less
than 0.048-inch nominal thickness uncoated steel unless otherwise indicated.
c.
Postinstalled Expansion Type for In-Place Concrete or Masonry: Minimum 3/8inch- diameter, metallic-coated steel bolts with expansion shields or inserts.
Provide pipe spacer from frame to wall, with throat reinforcement plate, welded
to frame at each anchor location.
8.
Floor Anchors: Not less than 0.079-inch nominal thickness metallic-coated steel,
and as follows:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08346 - 4
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
a.
9.
B.
2.03
Monolithic Concrete Slabs: Clip-type anchors, with two holes to receive
fasteners.
b.
Separate Topping Concrete Slabs: Adjustable-type anchors with extension
clips, allowing not less than 2-inch height adjustment. Terminate bottom of
frames at finish floor surface.
Ceiling Struts: Minimum 3/8-inch-thick by 2-inch- wide uncoated steel unless
otherwise indicated.
Plaster Guards: Metallic-coated steel sheet, not less than 0.026 inch thick. Materials:
1.
Stainless-Steel Sheet: ASTM A 666, austenitic stainless steel, Type 316.
2.
Metallic-Coated Steel Sheet: ASTM A 653/A 653M, Commercial Steel (CS), Type B,
with G90 zinc (galvanized) coating designation.
3.
Supports and Anchors: After fabricating, galvanize units to be built into exterior walls
according to ASTM A 153/A 153M, Class B.
4.
Inserts, Bolts, and Fasteners: Provide items to be built into exterior walls, hot-dip
galvanized according to ASTM A 153/A 153M or ASTM F 2329.
5.
Powder-Actuated Fasteners in Concrete: Fastener system of type suitable for
application indicated, fabricated from corrosion-resistant materials, with clips or
other accessory devices for attaching sound-control door frames of type indicated.
6.
Mineral-Fiber Insulation: Insulation composed of rock-wool fibers, slag-wool fibers, or
glass fibers.
FINISHES
A.
Metallic-Coated Steel Finishes:
1.
Prime Finish: Apply manufacturer's standard primer immediately after cleaning and
pretreating.
a.
Shop Primer: Manufacturer's standard, fast-curing, lead- and chromate-free
primer complying with ANSI/SDI A250.10 acceptance criteria; recommended
by primer manufacturer for substrate; compatible with substrate and fieldapplied coatings despite prolonged exposure.
B.
Stainless Steel Finishes: Comply with NAAMM's "Metal Finishes Manual for Architectural
and Metal Products" for recommendations for applying and designating finishes. Remove
tool and die marks and stretch lines or blend into finish.
1.
Grind and polish surfaces to produce uniform, directionally textured, polished finish
indicated, free of cross scratches.
a.
Grain for Doors: Vertical (long dimension of door).
b.
Grain for Frame Jambs: Vertical (long dimension of jamb).
c.
Grain for Frame Heads: Vertical.
2.
Protect mechanical finishes on exposed surfaces from damage by applying a
strippable, temporary protective covering before shipping.
3.
Finish stainless-steel doors and frames after assembly.
4.
Sheet finish designations below are frequently used to specify finishes applied after
fabrication.
5.
Directional Satin Finish: No. 4 finish.
6.
When polishing is completed, passivate and rinse surfaces. Remove embedded
foreign matter and leave surfaces chemically clean.
KAILUA RWWTP TUNNEL INFLUENT
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08346 - 5
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
2.04
SOUND-CONTROL HARDWARE
A.
Description: Provide manufacturer's standard sound-control system, including head and
jamb seals, door bottoms, hinges, and thresholds, as required by testing to achieve
STC and fire rating indicated.
1.
Compression Seals: One-piece units; consisting of closed-cell sponge neoprene seal
held in place by metal retainer; with retainer cover of same material as door frame;
attached to door frame with concealed screws.
2.
Magnetic Seals: One-piece units; consisting of closed-cell sponge neoprene seal and
resiliently mounted magnet held in place by metal retainer; with retainer cover of
same material as door frame; attached to door frame with concealed screws.
3.
Automatic Door Bottoms: Neoprene or silicone gasket, held in place by metal
housing, that automatically drops to form seal when door is closed; mounted to
bottom edge of door with screws.
a.
Mounting: Mortised or semimortised into bottom of door as required by testing
to achieve STC rating indicated.
4.
Door Bottoms: Neoprene or silicone gasket held in place by metal housing; mortised
into bottom edge of door.
5.
Cam-Lift Hinges: Full-mortise template type that raises door 1/2 inch when door is
fully open; with hardened pin; fabricated from stainless steel if required.Deleted.
6.
Thresholds: Flat, smooth, unfluted type as recommended by manufacturer;
fabricated from stainless steel.
7.
Astragal Sound Seals. Manufacturer’s standard type.
B.
Other Hardware: Comply with requirements in Section 08710 "Door Hardware."
2.05
SOUND-CONTROL ACCESSORIES
A.
Glazing: Comply with requirements in Section 08800 "Glazing."
B.
Grout: Comply with ASTM C 476, with a slump of not more than 4 inches as measured
according to ASTM C 143/C 143M.
C.
Corrosion-Resistant Coating: Cold-applied asphalt mastic, compounded for 15-mil dry film
thickness per coat. Provide inert-type noncorrosive compound free of asbestos fibers,
sulfur components, and other deleterious impurities.
2.06
A.
FABRICATION
Sound-Control Door Fabrication: Sound-control doors to be rigid and free of defects, warp,
or buckle. Accurately form metal to required sizes and profiles, with minimum radius for
thickness of metal.
1.
Seamless Edge Construction: Fabricate doors with faces joined at vertical edges by
welding; welds shall be ground, filled, and dressed to make them invisible and to
provide a smooth, flush surface.
2.
Exterior Doors: Close top edges flush and seal joints against water penetration.
Provide weep-hole openings in bottom of exterior doors to permit moisture to escape.
3.
Glazed Lites: Factory install glazed lites according to requirements of tested
assembly to achieve STC rating indicated. Provide fixed stops and moldings welded
on secure side of door.
KAILUA RWWTP TUNNEL INFLUENT
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08346 - 6
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
4.
5.
B.
Hardware Preparation: Factory prepare sound-control doors to receive templated
mortised hardware; include cutouts, reinforcement, mortising, drilling, and tapping,
according to the Door Hardware Schedule.
a.
Reinforce doors to receive nontemplated mortised and surface-mounted door
hardware.
b.
Locate door hardware as indicated, or if not indicated, according to NAAMMHMMA 831, "Recommended Hardware Locations for Custom Hollow Metal
Doors and Frames."
Tolerances: Fabricate doors to tolerances indicated in ANSI/NAAMM-HMMA 865.
Sound-Control Frame Fabrication: Fabricate sound-control frames to be rigid and free of
defects, warp, or buckle. Accurately form metal to required sizes and profiles, with
minimum radius for thickness of metal. Where practical, fit and assemble units in
manufacturer's plant. To ensure proper assembly at Project site, clearly identify work that
cannot be permanently factory assembled before shipment.
1.
Weld flush face joints continuously; grind, fill, dress, and make smooth, flush, and
invisible. Where frames are fabricated in sections due to shipping or handling
limitations, provide alignment plates or angles at each joint, fabricated from same
thickness metal as frames.
2.
Provide countersunk, flat- or oval-head exposed screws and bolts for exposed
fasteners unless otherwise indicated.
3.
Floor Anchors: Weld anchors to bottom of jambs and mullions with at least four spot
welds per anchor.
4.
Jamb Anchors: Provide number and spacing of anchors as follows:
a.
Masonry Type: Locate anchors not more than 18 inches from top and bottom
of frame. Space anchors not more than 32 inches o.c. and as follows:
1)
Two anchors per jamb up to 60 inches in height.
2)
Three anchors per jamb from 60 to 90 inches in height.
3)
Four anchors per jamb from 90 to 96 inches in height.
4)
Four anchors per jamb plus one additional anchor per jamb for each 24
inches or fraction thereof more than 96 inches in height.
b.
Stud Wall Type: Locate anchors not more than 18 inches from top and bottom
of frame. Space anchors not more than 32 inches o.c. and as follows:
1)
Three anchors per jamb up to 60 inches in height.
2)
Four anchors per jamb from 60 to 90 inches in height.
3)
Five anchors per jamb from 90 to 96 inches in height.
4)
Five anchors per jamb plus one additional anchor per jamb for each 24
inches or fraction thereof more than 96 inches in height.
5)
Two anchors per head for frames more than 42 inches wide and
mounted in metal stud partitions.
c.
Postinstalled Expansion Type: Locate anchors not more than 6 inches from top
and bottom of frame. Space anchors not more than 26 inches o.c.
5.
Head Reinforcement: For frames more than 48 inches wide, provide continuous
head reinforcement for full width of opening, welded to back of frame at head.
6.
Hardware Preparation: Factory prepare sound-control frames to receive templated
mortised hardware; include cutouts, reinforcement, mortising, drilling, and tapping,
according to the Door Hardware Schedule.
a.
Reinforce frames to receive nontemplated mortised and surface-mounted door
hardware.
KAILUA RWWTP TUNNEL INFLUENT
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08346 - 7
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
b.
7.
8.
Locate hardware as indicated, or if not indicated, according to NAAMMHMMA 831, "Recommended Hardware Locations for Custom Hollow Metal
Doors and Frames."
Plaster Guards: Weld guards to frame at back of hardware cutouts and glazing-stop
screw and sound-control seal preparations to close off interior of openings in frames
to be grouted.
Tolerances: Fabricate frames to tolerances indicated in ANSI/NAAMM-HMMA 865.
PART 3 - EXECUTION
3.01
EXAMINATION
A.
Examine substrates, areas, and conditions, with Installer present, for compliance with
requirements for installation tolerances and other conditions affecting performance of
sound-control door assemblies.
B.
Examine roughing-in for embedded and built-in anchors to verify actual locations of soundcontrol door frame connections before frame installation.
C.
Proceed with installation only after unsatisfactory conditions have been corrected.
3.02
PREPARATION
A.
Remove welded-in shipping spreaders installed at factory. Restore exposed finish by
grinding, filling, and dressing, as required to make repaired area smooth, flush, and
invisible on exposed faces.
B.
Prior to installation and with installation spreaders in place, adjust and securely brace
sound-control door frames to the following tolerances:
1.
Squareness: Plus or minus 1/16 inch, measured at door rabbet on a line 90 degrees
from jamb perpendicular to frame head.
2.
Alignment: Plus or minus 1/16 inch, measured at jambs on a horizontal line parallel
to plane of wall.
3.
Twist: Plus or minus 1/16 inch, measured at opposite face corners of jambs on
parallel lines, and perpendicular to plane of wall.
4.
Plumbness: Plus or minus 1/16 inch, measured at jambs on a perpendicular line
from head to floor.
C.
Drill and tap doors and frames to receive nontemplated mortised and surface-mounted
door hardware.
3.03
INSTALLATION
A.
General: Install sound-control door assemblies plumb, rigid, properly aligned, and securely
fastened in place; comply with manufacturer's written instructions.
B.
Frames: Install sound-control door frames in sizes and profiles indicated.
1.
Set frames accurately in position; plumbed, aligned, and braced securely until
permanent anchors are set. After wall construction is complete, remove temporary
braces, leaving surfaces smooth and undamaged.
a.
At fire-rated openings, install frames according to NFPA 80.
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08346 - 8
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
b.
2.
3.
4.
5.
6.
7.
C.
At openings requiring smoke and draft control, install frames according to
NFPA 105.
c.
Where frames are fabricated in sections due to shipping or handling
limitations, field splice at approved locations by welding face joint
continuously; grind, fill, and dress; make splice smooth, flush, and invisible on
exposed faces.
d.
Install sound-control frames with removable glazing stops located on secure
side of opening.
e.
Remove temporary braces only after frames or bucks have been properly set
and secured.
f.
Check squareness, twist, and plumbness of frames as walls are constructed.
Shim as necessary to comply with installation tolerances.
g.
Apply corrosion-resistant coatings coating to backs of frames to be filled with
mortar, grout, and plaster containing antifreezing agents.
Floor Anchors: Provide floor anchors for each jamb and mullion that extends to floor
and secure with postinstalled expansion anchors.
a.
Floor anchors may be set with powder-actuated fasteners instead of
postinstalled expansion anchors, if so indicated and approved on Shop
Drawings.
Metal-Stud Partitions: Solidly pack mineral-fiber insulation behind frames.
In-Place Concrete or Masonry Construction:
Secure frames in place with
postinstalled expansion anchors. Countersink anchors, and fill and make smooth,
flush, and invisible on exposed faces.
Ceiling Struts: Extend struts vertically from top of frame at each jamb to supporting
construction above, unless frame is anchored to masonry or to other structural
support at each jamb. Bend top of struts to provide flush contact for securing to
supporting construction above. Provide adjustable wedged or bolted anchorage to
frame jamb members.
Grouted Frames: Solidly fill space between frames and substrate with grout. Take
precautions, including bracing frames, to ensure that frames are not deformed or
damaged by grout forces.
Installation Tolerances: Adjust sound-control door frames for squareness, alignment,
twist, and plumbness to the following tolerances:
a.
Squareness: Plus or minus 1/16 inch, measured at door rabbet on a line 90
degrees from jamb perpendicular to frame head.
b.
Alignment: Plus or minus 1/16 inch, measured at jambs on a horizontal line
parallel to plane of wall.
c.
Twist: Plus or minus 1/16 inch, measured at opposite face corners of jambs
on parallel lines, and perpendicular to plane of wall.
d.
Plumbness: Plus or minus 1/16 inch, measured at jambs on a perpendicular
line from head to floor.
Doors: Fit sound-control doors accurately in frames, within clearances indicated below.
Shim as necessary.
1.
Non-Fire-Rated Doors: Fit non-fire-rated doors accurately in frames with the following
clearances:
a.
Jambs: 1/8 inch.
b.
Head with Butt Hinges: 1/8 inch.
c.
Head with Cam-Lift Hinges: As required by manufacturer, but not more than
3/8 inch.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08346 - 9
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
2.
d.
Sill: Manufacturer's standard.
e.
Between Edges of Pairs of Doors: 1/8 inch.
Fire-Rated Doors: Install fire-rated doors with clearances according to NFPA 80.
D.
Sound-Control Seals: Where seals have been prefit and preinstalled in the factory and
subsequently removed for shipping, reinstall seals and adjust according to manufacturer's
written instructions.
E.
Install hinges according to manufacturer's written instructions.
F.
Thresholds: Set thresholds in full bed of sealant complying with requirements in
Section 07920 "Joint Sealants."
G.
Glazing: Comply with installation requirements in Section 08800 "Glazing" and with soundcontrol door assembly manufacturer's written instructions.
1.
Secure stops with countersunk flat- or oval-head machine screws spaced uniformly
not more than 9 inches o.c., and not more than 2 inches o.c. from each corner.
3.04
ADJUSTING AND CLEANING
A.
Final Adjustments: Check and adjust seals, door bottoms, and other sound-control
hardware items right before final inspection. Leave work in complete and proper operating
condition.
B.
Remove and replace defective work, including defective or damaged sound seals and doors
and frames that are warped, bowed, or otherwise unacceptable.
1.
Adjust gaskets, gasket retainers, and retainer covers to provide contact required to
achieve STC rating.
C.
Clean grout off sound-control door frames immediately after installation.
D.
Prime-Coat Touchup: Immediately after erection, sand smooth rusted or damaged areas of
prime coat and apply touchup of compatible air-drying primer.
E.
Metallic-Coated Surfaces: Clean abraded areas of doors and repair with galvanizing repair
paint according to manufacturer's written instructions.
3.05
A.
MEASUREMENT AND PAYMENT
All work specified in this section shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
08346 - 10
ADDENDUM NO. 3
SOUND-CONTROL DOOR ASSEMBLIES
SECTION 11002
RIGID EQUIPMENT MOUNTS
PART 1--GENERAL
1.01
DESCRIPTION
A.
B.
SUMMARY:
1.
This Section specifies minimum requirements for rigid equipment mounts.
Completed equipment mounts shall consist of equipment pads, equipment
anchors, and mounting plates (baseplates, soleplates, or fabricated steel
frames) set in grout.
2.
Equipment mounts shall conform to the requirements specified in the
Equipment Mounting Schedule included in this specification. Where
equipment mounting requirements are not specifically identified in the
Equipment Mounting Schedule, the default mounting configuration for
equipment shall consist of Pad Anchored Equipment Pads per Standard
Detail A/M-006, mounting plates leveled within 0.005 inch/foot, anchored to
the equipment pad with adhesive anchors per Standard Detail C/M-007.
3.
If a conflict exists between this Section and requirements of individual
equipment manufacturers, the more restrictive requirements shall prevail.
4.
Requirements for non-rigid equipment mounts (vibration isolation systems)
are specified in individual equipment specifications. Rigid equipment mounts
conforming to the requirements of this Section shall be furnished for the
equipment pad and other equipment mounting components supporting the
vibration isolation system.
5.
Alignment of equipment installed on rigid equipment mounts is specified in
Section 11005.
DEFINITIONS: Specific equipment mounting terminology used in this Section
conforms to the following definitions:
1.
BASEPLATE: A mounting plate configured with a cavity above the horizontal
plane at the bottom edge of the mounting plate.
2.
SOLEPLATE: A machined or pre-formed mounting plate with a uniform
horizontal surface across the entire underside of the mounting plate,
excepting shear lugs/keys, grout pour holes, vent holes, and attachment
hardware (nuts, bolts, tapped holes, etc.).
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-1
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
3.
FABRICATED STEEL FRAME: An equipment mounting plate constructed of
rolled steel shapes and plates welded into a frame.
4.
EQUIPMENT PAD: Concrete foundation (block or slab) supporting and
elevating mounting plates above the supporting structural floor slab or local
grade.
5.
MOUNTING PADS: Milled/machined areas of baseplates, soleplates, and
fabricated steel frames where the feet or mounting surfaces of mounted
equipment and drivers are bolted to the baseplate, soleplate, or fabricated
steel frame.
6.
LEVELING BLOCKS: Steel blocks temporarily placed under baseplates,
soleplates, or fabricated steel frames at leveling positions (at equipment
anchors) for the purpose of leveling baseplates, soleplates, or fabricated
steel frames prior to grouting.
7.
SHIMS: Thin stainless steel plates of uniform thickness used for fine
adjustment of level. Shims are used on top of leveling blocks for mounting
plate leveling or used between equipment drivers and baseplates, soleplates,
or fabricated steel frames for equipment alignment.
8.
WEDGES: Pairs of uniformly tapered metal blocks that are stacked with the
tapered surfaces reversed (relative to the other wedge) so that the top and
bottom surfaces of the wedges are parallel. Wedges are used between
equipment pads and baseplates, soleplates, or fabricated steel frames for
the purpose of leveling mounting plates.
9.
MOUNTING STUD: Threaded rod or bolts anchored to baseplates, soleplates,
or fabricated steel frames for the purpose of mounting equipment or ancillary
devices onto baseplates, soleplates, or fabricated steel frames.
10.
REINFORCEMENT DOWELS OR REINFORCEMENT HOOKS: Steel
reinforcement rods embedded in concrete, across a cold joint, for the
purpose of transferring loads or force across the joint.
11.
LEVELING POSITION: A location on the top of a concrete equipment pad
where leveling tools and equipment will be temporarily installed or used for
the purpose of leveling baseplates, soleplates, and fabricated steel frames
prior to grouting.
12.
GROUT MANUFACTURER: Refers to the manufacturer of the grout product
used for installation of rigid equipment mounts.
13.
GROUT MANUFACTURER’S TECHNICAL REPRESENTATIVE(S): Refers to the
technical representative(s) of the Grout Manufacturer.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-2
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
1.02
QUALITY ASSURANCE
A.
REFERENCE STANDARDS:
1.
This Section incorporates by reference the latest revisions of the following
documents. They are part of this Section insofar as specified and modified
herein. In the event of conflict between the requirements of this Section and
those of the listed documents, the requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect on the effective date of the Agreement. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or
otherwise identified by that organization or, if there are no replacement
documents, the last version of the document before it was discontinued.
Reference
Title
ACI 318, Appendix D
Building Code and Commentary, Anchorage to Concrete
ANSI/HI 1.4
Centrifugal Pumps – Installation, Operation and
Maintenance
ANSI/HI 2.4
Vertical Pumps – Installation, Operation and Maintenance
API RECOMMENDED
PRACTICE 686
Recommended Practices for Machinery Installation and
Installation Design
ASTM E329
Inspection and Testing Agencies for Concrete, Steel, and
Bituminous Materials as Used in Construction
ASTM F593
Stainless Steel Bolts, Hex Cap Screws, and Studs
ASTM F1554
Anchor Bolts, Steel, 36, 55 and 105 ksi Yield Strength
SSPC
Society for Protective Coatings Specifications, Vol. 2
IBC
International Building Code (including local amendments)
B.
CONTRACTOR QUALITY CONTROL:
1.
To demonstrate conformance with the specified requirements for rigid
equipment mounts, provide the services of an independent testing laboratory
that complies with the requirements of ASTM E329. The testing laboratory
shall sample and test materials installed as part of rigid equipment mounts
as specified in this Section. Costs of testing laboratory services shall be
borne by the Contractor.
2.
Where epoxy grout is specified in individual equipment specifications, furnish
the services of a grout manufacturer’s technical representative that has been
factory trained by the grout manufacturer. The grout manufacturer’s
technical representative shall perform training and quality control of epoxy
grout installation for rigid equipment mounts as specified in this Section.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-3
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
1.03
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations from
Section requirements.
2.
Name, employer and certificates or other information documenting
compliance with the journeyman qualifications requirements for millwrights
who will install rigid equipment mounts, as specified in this Section.
3.
Certificates or other documentation issued by the epoxy grout manufacturer
that demonstrates that the grout manufacturer’s technical representative has
been factory trained on installation of epoxy grout for equipment mounts.
4.
Shop drawings for equipment pads, equipment anchors, and baseplate,
soleplate or fabricated steel frame details. Shop drawings shall depict size
and location of equipment pads and reinforcement; equipment drains;
equipment anchor, size, location, and projection; expansion joint locations;
elevation of top of grout and grout thickness; elevation of top of baseplate,
soleplate, or mounting block; size and location of electrical conduits; and any
other equipment mounting features embedded in equipment pads. Shop
drawings for equipment pads, equipment anchors, and baseplate, soleplate,
or fabricated steel frames shall be numbered and marked (specification
number and equipment number) for inclusion (filing) with the associated
equipment submittal requirements.
5.
Results of grout strength tests, as specified in this Section.
6.
Completed Rigid Equipment Mount Installation Inspection Checklist Forms
(46 05 29-A).
7.
List of equipment installation staff that has completed epoxy grout
manufacturer’s grout installation training specified in this Section.
8.
Equipment anchor calculations demonstrating compliance with this Section.
PART 2—PRODUCTS
2.01
GENERAL
A.
Equipment mounts shall conform to the requirements specified in the Equipment
Mounting Schedule.
B.
Equipment and drivers shall be rigidly mounted on a common mounting plate and
grouted into place on a concrete equipment pad unless alternate requirements are
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-4
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
specified in the Contract Drawings or the Equipment Mounting Schedule in this
Section. Unless otherwise specified in the individual equipment specification,
mounting plates shall be anchored to equipment pads with a layer of grout between
the equipment pad and the mounting plate.
C.
EQUIPMENT MOUNTING SCHEDULE:
Equipment mounting
system
Pad detail
Mounting
plate
leveling
tolerance
(inch/foot)
Default (1)
A/M-006
0.005
C/M-007
no sleeve
non-shrink
Group A
C/M-006
0.0005
A/M-007
15 Φ
epoxy
Group B
B/M-006
0.0005
A/M-007
15 Φ
epoxy
Group C
A/M-006
0.02
C/M-007
not
required
non-shrink
Group D
A/M-006
0.02, no
plate
C/M-007
no sleeve
non-shrink
Group E
No pad
0.02
A/M-007
not
required
epoxy
Group F
A/M-006
not
applicable
C/M-007
not
required
not
required
Equipment
anchor bolt
detail
Equipment
anchor
sleeve
length
Grout type
(1) Default when Equipment Mounting System is not specified in the individual equipment specification.
2.02
EQUIPMENT PADS
A.
B.
MATERIALS
1.
Equipment pads shall be reinforced concrete as shown in Standard Details
A/M-006, B/M-006, and C/M-006.
2.
Minimum dimensions for equipment pads are shown on structural drawings
where the equipment pad is required to provide a minimum mass for
vibration dampening.
EQUIPMENT PAD DRAINAGE:
1.
Equipment pads shall be furnished with 2-inch drains.
2.
Locate equipment pad drains at drainage outlets from equipment or
mounting plates
3.
Route equipment drainage outlets or mounting plate drainage outlets to
equipment pad drains
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-5
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
2.03
4.
Route equipment pad drains to the floor drainage collection system.
5.
Drainage piping for equipment pads shall be routed below the finished floor
elevation.
6.
Exposed drain lines mounted on the floor are not acceptable.
EQUIPMENT ANCHORS
A.
EQUIPMENT ANCHOR MATERIALS:
1.
Equipment anchors shall be all thread rod with heavy hex welded nuts, heavy
hex bolts, drilled anchors (wedge, sleeve, undercut, expansion, and adhesive
anchors), or adjustable canister anchors as specified in the Equipment
Mounting Schedule.
2.
Drilled anchors (wedge, sleeve, undercut, expansion, and adhesive anchors)
shall conform to the requirements of Section 05501..
3.
Adjustable canister anchors shall be cast-in-place pre-manufactured
adjustable anchor inserts. Adjustable canister anchors shall provide a
minimum of 6 inches of vertical bolt height adjustment and lateral
adjustment of the anchor bolt while maintaining the anchor bolt in a true
vertical orientation. Adjustable canister anchors shall be Jakebolts as
manufactured by Unisorb, Heavy Duty Adjustable Anchors as manufactured
by Deco, Rowan Adjustable Canister Anchor Bolt, or approved substitute.
4.
Equipment anchor materials shall conform to the following table for the area
exposure condition where the equipment is installed. Section 01800
specifies area exposure conditions by process area.
Area exposure
Equipment anchor materials
Indoor, Dry
316 Stainless, ASTM F593, Cond. CW. Stainless steel
nuts and bolts shall be fully passivated. Stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or
approved substitute.
Indoor, Wet
316 Stainless, ASTM F593, Cond. CW. Stainless steel
nuts and bolts shall be fully passivated. Stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or
approved substitute.
Outdoor
316 Stainless, ASTM F593, Cond. CW. Stainless steel
nuts and bolts shall be fully passivated. Stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or
approved substitute.
Submerged, Immersed
316 Stainless, ASTM F593, Cond. CW. Stainless steel
nuts and bolts shall be fully passivated. Stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or
approved substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-6
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
Area exposure
Equipment anchor materials
Process Corrosive
316 Stainless, ASTM F593, Cond. CW. Stainless steel
nuts and bolts shall be fully passivated. Stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or
approved substitute.
Chemical Corrosive
316 Stainless, ASTM F593, Cond. CW. Stainless steel
nuts and bolts shall be fully passivated. Stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or
approved substitute.
B.
EQUIPMENT ANCHOR DESIGN:
Structural design and anchorage requirements shall be in accordance with Section
01900 STRUCTURAL DESIGN AND ANCHORAGE REQUIREMENTS FOR
NONSTRUCTURAL COMPONENTS AND NONBUILDING STRUCTURES
C.
EQUIPMENT ANCHOR TENSION:
1.
Unless alternate bolt torque/tension requirements are specified by the
equipment manufacturer, equipment anchors shall be tightened to provide a
final clamping force that produces a tensile stress of 15,000 psi in each
equipment anchor. Adjustable canister anchors shall be tightened to the
manufacturer’s maximum safe working load. Equipment anchors consisting
of drilled anchors shall be tightened to manufacturer’s recommendations.
2.
Bolt torque values required to produce the specified bolt tension based on
well lubricated plain finish national coarse thread bolts are presented in the
following table. Revise bolt torque values per equipment manufacturer’s
recommendations for alternate thread patterns, thread lubrication, bolt
material, or bolt finish.
Bolt diam. (in.)
Final bolt torque for
15,000 psi bolt
stress (ft*lbs)
3.
Anchor diam.
(in)
Pull test load
(kips)
D.
3/8
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
8
15
30
50
80
125
180
250
400
Prior to leveling and grouting mounting plates, grouted equipment anchors
(standard detail C/M-007) shall be pull tested to the values specified in the
following table.
3/8
½
5/8
3/4
7/8
1
1-1/8
1-1/4
1-1/2
2.1
3.8
6.1
9.1
13
17
22
28
43
ANCHOR SLEEVES:
1.
Equipment anchors shall be fitted with sleeves as specified in the Equipment
Mounting Schedule. Sleeve length for equipment anchors shall be 15 times
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-7
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
the bolt diameter unless otherwise specified in the Equipment Mounting
Schedule. Sleeves may be installed at the Contractor’s option if not specified
in the Equipment Mounting Schedule.
2.04
2.
Adjust equipment anchor length/embedment depth shown in Standard Detail
A/M-006 and Standard Detail C/M-007 if sleeves are not required.
3.
Anchor sleeves shall be flexible polyurethane foam, steel cylinder/tubes, or
ribbed plastic sleeves.
4.
Fill steel cylinders/tubes and ribbed plastic sleeves with a flexible room
temperature vulcanizing (RTV) sealant prior to embedment/installation.
MOUNTING PLATES
A.
GENERAL:
1.
All baseplates, soleplates, and fabricated steel frames shall have edges of
surfaces bearing on grout rounded to a radius of not less than 0.25 inch.
2.
Perimeter corners of baseplates, soleplates, or fabricated steel frames shall
be rounded to a radius of not less than two inches to avoid producing stress
risers on the grouted foundation.
3.
Excepting pre-grouted baseplates, all baseplates and soleplates shall be
furnished with grout pouring holes and grout relief/air release vent holes.
Grout pouring holes and grout relief/air release vent holes may be omitted
from pre-grouted baseplates.
4.
Grout pouring holes (minimum 4 inches in diameter for epoxy grout,
minimum 2 ½ inches in diameter for cementitious non-shrink grout) shall be
provided in all baseplates and soleplates and all baseplates and soleplates
shall have air release holes.
5.
Grout relief or vent holes (minimum 1 inch in diameter) shall be provided in
all baseplates and soleplates.
6.
Mounting holes for equipment anchors shall be drilled through baseplates,
soleplates, and fabricated steel frames.
7.
Mounting holes for equipment anchors shall be drilled. Mounting holes shall
not be burned out and they shall not be open slots.
8.
Terminations requiring connections to baseplates and soleplates shall be
acorn nuts welded to the under side of the baseplate or soleplate or nuts
welded to the underside of the baseplate or soleplate and plugged with cork,
plastic plugs or grease.
9.
In no case shall the fastener terminate only into the baseplate, soleplate, or
fabricated steel frame.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-8
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
B.
10.
Where baseplates, soleplates, or fabricated steel frames are leveled using
jackscrews, jackscrew threads shall be tapped in thickened pads or
otherwise in sufficient metal to provide ease in adjusting level.
11.
Mounting pads and/or mounting surfaces for baseplates, soleplates, and
fabricated steel frames shall be milled flat after all welding and stress
relieving and shall be coplanar within 0.0005 inch per foot in all directions.
Baseplates shall be pre-grouted prior to milling.
12.
Baseplates, soleplates, and fabricated steel frames shall provide common
support for the equipment and driver (and flywheel, if one is specified).
13.
Baseplates, soleplates, and fabricated steel frames for equipment with
drivers 20 horsepower and greater shall be furnished with transverse
alignment (horizontal) positioning jackscrews for alignment of equipment
drivers on horizontal surfaces of baseplates.
14.
Alignment/positioning jackscrews shall be in perpendicular directions in a
horizontal plane at the mounting position for each corner or foot of the
equipment driver. (Additional jackscrews shall be provided for transverse
alignment of the flywheel, if flywheels are specified in the equipment
specification.)
15.
Where specified in individual equipment specifications; baseplates,
soleplates, and fabricated steel frames shall be fitted with RK Fixators as
manufactured by Unisorb, or approved substitute.
a.
Fixators shall be installed at mounting surfaces for drivers.
b.
Fixators shall be a three piece wedge leveling adjustment device
incorporating a spherical washer assembly to provide true level height
adjustment at each mounting surface for the equipment driver.
FABRICATED STEEL FRAMES:
1.
Fabricated steel frames shall be plate or fabricated structural steel mounting
plates with thickened steel mounting pads for bolting equipment to the
baseplate.
2.
Fabricated steel frames shall be rectangular in shape, excepting fabricated
steel frames for centrifugal refrigeration machines and pumps which may be
“T” or “L” shaped fabricated steel frames to accommodate the equipment
driver and accessories.
3.
Fabricated steel frames for split case pumps shall include supports for
suction and discharge elbows, if required by the specified configuration.
4.
Perimeter members shall be I-beams or C-channel with a minimum depth
equal to 1/10th of the longest dimension of the fabricated steel frame.
Beam depth need not exceed 14 inches provided that the deflection and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
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11002-9
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
misalignment is kept within acceptable limits as determined by the
manufacturer.
C.
D.
5.
Fabricated steel frames shall be furnished with mounting pads welded to the
fabricated steel frame.
6.
Surfaces of fabricated steel frames in contact with grout shall be sandblasted
to white metal per SSPC SP-5.
7.
Apply a high strength epoxy primer as specified in 11002-2.06 within 8 hours
of sandblasting the fabricated steel frame.
BASEPLATES:
1.
Baseplates shall be welded steel, cast steel, or cast iron with thickened
mounting pads for bolting equipment to the baseplate.
2.
Internal stiffeners shall be provided on all cast and fabricated baseplates and
shall be designed to allow free flow of grout from one section of the
baseplate to another.
3.
The minimum acceptable opening in cross bracing and stiffeners shall be 2inches high by 6-inches in width.
4.
All welds shall be continuous and free from skips, blowholes, laps and
pockets.
5.
Baseplates shall be pre-grouted at the factory after all welding has been
completed and prior to machining the mounting pads on the baseplate.
6.
The underside of baseplates shall be sandblasted to white metal per SSPC
SP-5 prior to pre-grouting.
7.
Pre-grouting shall be completed within 8 hours of sandblasting.
8.
Pre-grouting shall fill the underside of the baseplate to the bottom edges of
the baseplate.
9.
Cast iron baseplates shall be sealed to prevent surface bleeding prior to
shipment to the project site.
10.
Exposed surfaces of cast iron baseplates shall be sealed in accordance with
the requirements for bleeding surfaces specified in Section 09900 prior to
shipment to the project site.
PLATE STEEL SOLEPLATES:
1.
Plate steel soleplates shall be not less than 1.0 inch thick for equipment with
drivers greater than 30 horsepower.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-10
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
E.
F.
2.
Plate steel soleplates shall be furnished with grout keys/lugs or stiffeners on
the underside of the soleplate.
3.
Excepting grout keys, grout pour holes, vent holes, and attachment hardware
(nuts, bolts, tapped holes, etc.) the underside of plate steel soleplates shall
be a flat uniform horizontal surface.
4.
The underside of plate steel soleplates shall be scribed with the words “THIS
SIDE DOWN” using welding rod material prior to milling the mounting pads for
equipment or mounting surfaces.
5.
Plate steel soleplates without grout pouring holes are acceptable provided
that no dimension of the soleplate (width or length) exceeds 18 inches.
6.
Surfaces of plate steel soleplates in contact with grout shall be sandblasted
to white metal per SSPC-SP-5 prior to shipment to the project site.
7.
Apply a high strength epoxy primer as specified in 11002-2.06 within 8 hours
of sandblasting the underside of plate steel soleplates.
8.
Where equipment is fabricated or cast with feet or mounting surfaces that
are not fastened to a common baseplate or soleplate, as in dry-pit bottom
suction pumps, the equipment may be supported on individual concrete piers
or equipment pads in lieu of mounting on a common equipment pad and
soleplate. In such instances, the equipment shall be supported at the feet or
mounting surfaces on individual plate steel soleplates, which shall be leveled
and grouted into place on the individual piers or equipment pads as specified
in this Section. Where multiple soleplates are installed for an equipment
installation, soleplates shall be installed coplanar within 0.002 inch/foot.
POLYMER CONCRETE SOLEPLATES:
1.
Polymer Concrete Soleplates shall be pre-cast soleplates consisting of
polymer concrete with stainless steel inserts for equipment mounting.
2.
Mounting surfaces on Polymer Concrete Soleplates shall be coplanar within
0.002 inch/foot. Polymer Concrete Soleplates shall be furnished with a
uniform horizontal surface over the entire underside of the mounting plate.
3.
Excepting grout keys, grout pour holes and vent holes, the underside of
soleplates shall provide a flat uniform horizontal surface.
4.
Polymer Concrete Soleplates shall be PoxyBase as manufactured by Basetek,
Chembase as manufactured by Goulds, or approved substitute.
CORROSION RESISTANT FRP BASEPLATES
1.
Corrosion Resistant FRP Baseplates shall be pre-formed fiber reinforced
plastic fabrications.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-11
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
2.
2.05
2.06
Corrosion Resistant FRP Baseplates shall be products of the manufacturer of
the equipment that is mounted on the baseplate.
GROUT FOR EQUIPMENT PADS
A.
EPOXY GROUT FOR EQUIPMENT MOUNTING: Where epoxy grout is specified in the
Equipment Mounting Schedule, grout for setting bearing surfaces of baseplates,
soleplates, and fabricated steel frames on equipment pads shall be Epoxy Grout for
Equipment Mounting as specified in Section 03600. Where the term epoxy grout is
used in the context of details and specifications for equipment mounting it shall
mean Epoxy Grout for Equipment Mounting as specified in Section 03600.
B.
CEMENTITIOUS NONSHRINK GROUT: Where non-shrink grout is specified in the
Equipment Mounting Schedule, Cementitious Non-shrink Grout, specified in Section
03600, may be used for setting bearing surfaces of baseplates, soleplates, or
fabricated steel frames. Where the term non-shrink grout or cementitious grout is
used in the context of details and specifications for equipment mounting it shall
mean Cementitious Non-shrink Grout as specified in Section 03600. Training and
quality control by the grout manufacturer’s technical representative is not required
for rigid equipment mounts installed with cementitious non-shrink grout.
EPOXY PRIMER
A.
Epoxy primer shall be a high strength, lead free, chrome free, and rust inhibiting twocomponent epoxy primer specifically designed for use on metal substrates and in
conjunction with epoxy grout. The epoxy primer’s bond strength to sandblasted metal
shall not be less than 1,500 psi. Epoxy primer shall be Phillybond Phillyclad 1000
Series, or approved substitute.
PART 3--EXECUTION
3.01
GENERAL
A.
GENERAL REQUIREMENTS:
1.
Roughen the underside of soleplates and fabricated steel frames and wipe
with a residue free solvent as recommended by the epoxy primer
manufacturer before placement of the baseplate, soleplate, and fabricated
steel frames on the equipment pad for leveling.
2.
Prior to placement on the equipment pad for leveling, exposed grout surfaces
of pre-grouted baseplates shall be roughened and wiped with a residue free
solvent as recommended by the manufacturer of the epoxy grout used for
pre-grouting.
3.
Prepare the underside of corrosion resistant FRP baseplates and polymer
concrete baseplates per the baseplate manufacturer’s recommendations
prior to placement of the baseplate on the equipment pad for leveling.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-12
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
B.
4.
Grout for equipment mounting shall be as specified in the Equipment
Mounting Schedule.
5.
Grouting for installation of equipment on equipment pads shall take place
prior to connecting any field piping or electrical and instrumentation systems.
6.
Unless the Officer-in-Charge accepts an alternate installation procedure in
writing, baseplates, soleplates, and fabricated steel frames shall be leveled
and grouted with the equipment removed.
7.
Pumps shall be installed in accordance with this Section and ANSI/HI 1.4 or
ANSI/HI 2.4, as appropriate for the type of pumping equipment installed.
8.
Connecting piping with flexible connections and/or expansion joints shall be
anchored such that the intended function of these joints are maintained in
the piping system without imposing strain on the equipment connections.
ALTERNATE PIPING CONNECTIONS: Where an equipment manufacturer’s installation
requirements include a rigid connection between the machine and connecting piping
systems, delete any flexible coupling (including equipment connection fittings) shown
on the drawings and install the equipment in the following manner, in lieu of
installing the flexible coupling:
1.
The equipment pad shall be installed as shown on the detail specified in the
Equipment Mounting Schedule.
2.
The baseplate, soleplate, or fabricated steel frames supporting the
equipment shall be installed, leveled, and grouted in place as specified in this
Section.
3.
The equipment shall be installed and aligned in place as specified in Section
11005..
4.
The piping shall be installed and aligned to the equipment connections and
the field piping connections without welding one of the joints for one section
of pipe between the equipment connection and the field piping and all
valving. All flanged joints shall be bolted up and pressure tested.
5.
All piping shall be fully supported by supports designed to accept their full
weight and thrust forces.
6.
The final sections of piping shall be aligned with the equipment and field
connections without the use of jacks, chain falls or other devices to force it
into alignment.
7.
The final piping joints shall be welded only after the previous steps have been
completed and accepted by the Officer-in-Charge.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-13
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
3.02
EPOXY GROUT TRAINING AND QUALITY CONTROL
A.
EPOXY GROUT TRAINING: Prior to commencing rigid equipment mount installation
work on equipment pads, furnish the services of a grout manufacturer’s technical
representative to conduct a training school for the workers that will be using epoxy
grout for rigid equipment mount installations. The school shall be not less than 4
hours in length and shall cover all aspects of using the products, including form
construction for each equipment installation, surface preparation, mixing,
application, void prevention/elimination, and clean up. This requirement, however,
shall not be construed as relieving the Contractor of overall responsibility for this
portion of the work. The epoxy grout manufacturer shall furnish a list of school
attendees that have been satisfactorily trained to perform epoxy grout installation for
equipment mounting.
B.
EPOXY GROUT QUALITY CONTROL:
1.
For equipment mounted with epoxy grout, the epoxy grout manufacturer’s
technical representative shall provide quality control services for epoxy grout
installation in rigid equipment mounts. The epoxy grout manufacturer’s
technical representative shall be on site to inspect and verify that the
installation personnel have successfully performed surface preparation,
epoxy grout application, and Quality Control Inspection in accordance with
these specifications for a representative portion of the epoxy grout
installation work.
2.
Specifically, the epoxy grout manufacturer’s technical representative shall
perform the following services for at least one rigid equipment mount
installation for each equipment type and size installed with epoxy grout:
a.
Inspect ambient conditions during various phases of epoxy grouting
installation for conformance with the epoxy grout manufacturer’s
requirements.
b.
Inspect the surface preparation of concrete substrates onto which
epoxy grout materials are to be applied, for conformance to the
specified application criteria, including but not limited to substrate
profile, degree of cleanliness, and moisture.
c.
Inspect the surface preparation of the metallic substrates onto which
the epoxy primer is to be applied.
d.
Inspect the epoxy-primed metallic substrate for coverage and
adhesion.
e.
Inspect preparation and application of epoxy grout form work for
conformance to the specifications.
f.
Inspect and record that the “pot life” of epoxy grout materials is not
exceeded during installation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-14
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
3.03
g.
Inspect epoxy grout for cure.
h.
Inspect and record that localized repairs made to grout voids are in
conformance with the specification requirements.
i.
Conduct a final review of completed epoxy grout installation for
conformance to these specifications.
j.
Attest to conformance of the work by signing appropriate entries in
the “Rigid Equipment Mount Inspection Checklist,” form 11002-A in
Section 01999.
INSTALLATION
A.
CONCRETE EQUIPMENT PAD PREPARATION:
1.
Roughen the top of the equipment pad after the concrete has reached its 28
day compressive strength.
2.
Remove all laitance and defective or weak concrete.
3.
Roughened surface profile shall be 0.25 inch amplitude, minimum.
4.
Expose broken aggregate without dislodging unbroken aggregate from the
cement matrix and without fracturing concrete and aggregate below the
concrete surface.
5.
Roughen using a light duty, hand held pneumatic chipper with a chisel type
tool.
6.
Abrasive blast, bush-hammer, jack hammers with sharp chisels, heavy
chipping tools, or needle gun preparation of concrete surfaces to be grouted
are not acceptable.
7.
Demonstrate removal of defective or weak concrete to the Officer-in-Charge
prior to leveling.
8.
The chipped surface of the concrete shall be such that the final elevation of
the equipment pad provides the grout manufacturer’s recommended
thickness between the surface of the equipment pad and the lower baseplate
flange, underside of the soleplate or underside of the fabricated steel frame.
9.
All dust, dirt, chips, oil, water, and any other contaminants shall be removed
and the surface protected with plastic sheeting until grout is installed.
10.
Concrete equipment pad surfaces that have been finished smooth and level
for use as leveling positions shall be protected from damage during chipping
activities. Alternatively, leveling positions may be restored on chipped
surfaces. Leveling positions shall be restored by installing leveling blocks or
leveling plates for jackscrews on a high compressive strength epoxy putty
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-15
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
(Philadelphia Resins, Phillybond Blue 6A, or equal). Leveling blocks and
leveling plates shall be installed level on the epoxy putty.
B.
LEVELING:
1.
Except where union rules require installation by another trade, all machinery
shall be mounted and leveled by journeyman millwrights.
2.
Use precision surveying equipment for leveling.
3.
Machinists’ spirit levels will not be permitted for leveling purposes for any
baseplate, soleplate, or fabricated steel frame with a plan dimension greater
than 4 feet.
4.
Baseplates, soleplates, and fabricated steel frames shall be leveled to the
tolerance specified in the Equipment Mounting Schedule or as otherwise
required by the equipment manufacturer, if more stringent.
5.
An anti-seize or anti-galling compound specified in paragraph 11002-2.07
shall be applied to all equipment anchor threads prior to beginning
baseplate, soleplate, or fabricated steel frame leveling.
6.
All baseplates, soleplates, and fabricated steel frames shall be leveled
against steel surfaces (jackscrew plates, leveling blocks, leveling nuts,
support plates, or other steel surfaces). Use of other materials for leveling
purposes is strictly and specifically prohibited.
7.
Leveling equipment and tools shall be stainless steel leveling blocks and
shims, steel wedges, or jackscrews bearing on leveling plates.
8.
Leveling nuts may be used for leveling baseplates, soleplates, and fabricated
steel frames weighing less than 200 pounds (including the weight of the
equipment if leveled with the equipment on the mounting plate).
9.
Leveling blocks shall be stainless steel, four inches square and 1-1/2 inches
thick with an open-ended slot terminating in the center for the equipment
anchor.
10.
Leveling blocks shall be machined flat on all horizontal surfaces and placed
under the baseplate or soleplate at each equipment anchor.
11.
Shims shall be pre-cut stainless steel, slotted for removal after grouting.
Leveling blocks and shims shall be coated with a light oil just prior to
beginning the leveling and grouting work. Shims shall be placed so the tabs
on the shims are easily accessible.
12.
Clamp baseplates, soleplates, or fabricated steel frames in position (after
leveling) by installing the equipment anchor nuts and washers.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-16
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
C.
13.
Bolt tension to fix the position of mounting plates during grouting shall be 30
to 60 percent of the final clamping force applied to clamp the mounting plate
to the equipment pad.
14.
Prior to grouting, verify that the correct level and position of the baseplate,
soleplate, or fabricated steel frame has been maintained after clamping it to
the equipment pad.
GROUTING:
1.
Design forms for a minimum of 6 inches hydrostatic head above the final
elevation of the grout.
2.
Install grout expansion joints at four to six foot intervals, perpendicular to the
centerline of baseplates. Design expansion joints in accordance with the
grout manufacturer’s written instructions.
3.
Coat forms with three coats of paste wax on all areas of the forms that will be
in contact with the grout.
4.
Wax forms before assembly.
5.
Prevent accidental application of wax to surfaces where the grout is to bond.
6.
Remove any foreign material, such as oil, sand, water, wax, grease, etc., from
concrete surfaces that will contact grout before forms are installed.
7.
Forms shall be liquid-tight. Seal any open spaces or cracks in forms, or at the
joint between forms and the foundation using sealant, putty, or caulking
compound.
8.
Vertical and horizontal edges of the grout shall have 45-degree chamfers as
specified in equipment pad details. The 45-degree perimeter chamfer strip
shall be located at the final elevation of the grout.
9.
Match chamfers in concrete portions of the equipment pad.
10.
Install block outs at all leveling positions to allow removal of leveling
equipment and leveling nuts to be backed off after the grout has cured.
11.
Coat jackscrews with a light oil or other acceptable bond-breaking compound
prior to grouting.
12.
Final elevation of grout on fabricated steel frames shall be at the top of the
lower flange of the perimeter I-beams or C-channel.
13.
Top of grout elevation for baseplates and soleplates shall be at least 0.125
inch but not more than 0.5 inch above the bottom or underside of the
perimeter edge of the baseplate or soleplate.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-17
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
14.
Seal equipment anchor sleeves to protect the sleeved length of the anchor
from contact with grout.
15.
Wrap exposed portions of equipment anchors with duct tape to protect them
from grout splatter and to prevent bonding to grout.
16.
Adjust ambient temperature to maintain mounting plate, foundation, and
grout temperatures to grout manufacturer’s recommended temperature.
17.
Mix grout for equipment mounting in accordance with the grout
manufacturer's written recommendations.
18.
Epoxy grout shall be placed in a manner that avoids air entrapment, using a
head box to pour grout into the grout holes.
19.
Place grout at one end of the baseplate or soleplate and work grout toward
the opposite end to force the air out from beneath the baseplate or soleplate.
20.
Pour grout through a head box into grout pouring holes.
21.
When the head box is moved to the next grout hole, a 6-inch high standpipe
shall be placed over the grout hole and filled with grout.
22.
Use of vibrating tools and/or jarring (rapping or tapping) forms to facilitate
grout flow is not permitted during placement of epoxy grout.
23.
Never allow the grout in the head box to fall below the top of the baseplate or
soleplate once the grout has made contact with the baseplate or soleplate.
24.
Grout placement shall be continuous until all portions of the space beneath
the baseplate, soleplate, or fabricated steel frame have been filled.
25.
Prepare subsequent batches of grout prior to depleting the preceding batch.
26.
Maintain grout height in standpipes after the space under the baseplate,
soleplate, or fabricated steel frame has been filled.
27.
When the grout has started to take an initial set (typically this is determined
by a noticeable increase in temperature and no flow of grout at the vent
holes) the standpipes shall be removed and excess grout cleaned from all
surfaces.
28.
Check for leaks throughout grout pours. Leaks shall be repaired immediately
to prevent formation of voids.
29.
Check baseplate, soleplate, or fabricated steel frame level and elevation
before the grout sets.
30.
Cure grout in accordance with grout manufacturer’s written instructions.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-18
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
31.
D.
Where specified in the individual equipment specifications, a grout sample
shall be taken for each equipment pad.
a.
Samples shall be placed in a cylinder of sufficient size to yield three
two-inch cubes as test samples.
b.
Samples shall be tagged with project name, date, time, the
equipment number and ambient temperature at the time of
placement.
c.
Place samples next to the foundation of the equipment being grouted
and cure for 48 hours.
d.
Test grout samples in accordance with the grout manufacturer’s
recommendations.
e.
Grout samples shall be tested by the independent testing laboratory
specified in paragraph 11002-1.02 B.
f.
Test results shall be reported directly to the Officer-in-Charge.
COMPLETION:
1.
Upon acceptance by the Officer-in-Charge and the equipment manufacturer’s
representative and after the grout has reached sufficient strength, grout
forms and block outs at leveling positions shall be removed. Leveling blocks
and shims or wedges and support plates shall be removed, leveling nuts and
jack screws shall be backed off to allow the grout to fully support the
baseplate, mounting block, or soleplate. Take care not to damage the grout
during removal of extended shimming material or leveling equipment and
tools.
2.
The equipment anchor nuts shall be tightened, using calibrated indicating
torque wrenches, to develop the full bolt tension specified in 11002-2.03 C.
3.
Equipment anchor nuts shall be tightened in increments of not more than 25
percent of the final torque value in an alternating pattern to avoid stress
concentration on the grout surface. After tightening equipment anchor nuts
to final values, apply additional wax, grease, or mastic to all exposed portions
of the equipment anchor beneath the baseplate, soleplate, or mounting
block.
4.
After applying additional wax or mastic to exposed portions of equipment
anchors, block outs (pockets) for access to leveling nuts, leveling blocks and
shims, or wedges shall be filled with the grout material installed under
baseplates, soleplates, or fabricated steel frames and pointed after the
equipment anchor nuts have been tightened to final values. Jackscrews shall
be removed and holes in the baseplate, soleplate, or fabricated steel frames
filled with a flexible sealant (silicone rubber) or a short cap screw.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-19
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
3.04
Check for baseplate, soleplate, or fabricated steel frame movement (soft
foot) by individually loosening and re-tightening each equipment anchor.
Vertical movement at each equipment anchor shall be measured and
recorded during loosening and retightening and shall not exceed 20
micrometers (0.001 inch). Vertical movement shall be measured using a
magnetic-based dial indicator on the baseplate, soleplate, or fabricated steel
frame referenced to the epoxy grout surface of the equipment pad or other
approved method. Soft foot conditions shall be sufficient cause for removal
and reinstallation of grout and baseplates, soleplates, or fabricated steel
frames.
6.
Check for grout voids by tapping along the upper surfaces of the baseplate,
soleplate, or mounting block. Grout voids shall be sufficient cause for
removal and reinstallation of grout and baseplates, soleplates, or fabricated
steel frames. Grout voids shall be marked. At the discretion of the Officer-inCharge, grout voids may be repaired as specified in Chapter 5, Section 3.16
of API RP 686.
FINAL INSPECTION
A.
3.05
5.
The Officer-in-Charge will conduct a final inspection with the Contractor for
conformance to requirements of this section.
MEASUREMENT AND PAYMENT
A.
Rigid equipment mounts shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11002-20
ADDENDUM NO. 3
RIGID EQUIPMENT MOUNTS
SECTION 11081
LOW VOLTAGE DIESEL ENGINE STANDBY GENERATOR SET
PART 1--GENERAL
1.01
SUMMARY
A.
This Section specifies a diesel engine-generator set that will be operated to provide
standby power. The engine-generator set includes, but is not limited to, the following
components: Diesel engine; generator; grounding resistor, current and potential
transformers; electric starter, starting and control batteries and chargers; cooling
system equipment; day tank system with duplex transfer pumps and level controls;
super critical grade exhaust silencing system; operating and safety shutdown
controls; free-standing engine generator control panel; intake air cleaner; lubrication
system; engine block heater; and vibration isolation base and connectors.
B.
TYPE: The generation unit shall be driven by a heavy-duty, four-stroke, 1,800 rpm,
turbocharged, diesel-powered, internal combustion engine suitable for standby
operation at constant speed under the specified conditions. The unit may run
continuously for several days. The generator shall be a three-phase, three-wire, six
lead, wye-connected, grounded system, revolving field, brushless, permanent magnet
excited, synchronous type.
C.
EQUIPMENT LIST:
Item
Equipment Numbers
Generator Components
Generator 1
Engine Generator
GEN 800,101
Battery Charger
CHGR 800,642
Battery
BATT 800,842
Exhaust Silencer
S 800,681
Engine Block Heater
HTR 800,105
Generator Control Panel
ICP 800,101
Fuel Systems
Day Tank
T 800,621
Day Tank Control Panel
ICP 800,621
Fuel Transfer Pump 3
P 800,622
Fuel Transfer Pump 4
P 800,623
Fuel Storage Tank
T 800,601
Fuel Storage Tank Control Panel
ICP 800, 611
Fuel Transfer Pump 1
P 800,611
Fuel Transfer Pump 2
P 800,612
Leak Detection/Inventory Panel
ICP 800,601A
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-1
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
D.
GENERAL REQUIREMENTS:
Generator rating, kW
125
Day tank, gallons/location
1.02
25/remote
Fuel suction lift required, feet
12.5
Radiator mounting
Skid
QUALITY ASSURANCE
A.
REFERENCED STANDARDS: This Section incorporates by reference the latest
revisions of the following documents. In case of conflict between the requirements of
this Section and the listed documents, the requirements of the Contract
Specifications shall prevail.
Reference
Title
ANSI C57.13
Requirements for Instrument Transformers
ASME PTC 17
Performance Test Code - Reciprocating Internal
Combustion Engines
IBC
International Building Code
IFC
International Fire Code
NEMA MG1
National Electrical Manufacturers Association Standards
Publication MG-1
NFPA 37
Standard for the Installation and Use of Stationary
Combustion Engines and Gas Turbines
NFPA 30
Flammable and Combustible Liquids Code
NFPA 70
National Electrical Code (NEC)
NFPA 110
Emergency and Standby Power Systems
SAE J 1349
Society of Automotive Engineers Engine Power Test Code
B.
GENERAL REQUIREMENTS FOR MANUFACTURERS: Equipment shall be in current
production as a standard series. All material and parts in this unit shall be new and
unused, of current manufacture, of the highest grade, and free from all defects
affecting performance. The vendor shall have available 24-hour-per-day service by
factory-trained technicians and shall have a manufacturer's authorized dealer's parts
and service facility located within 50 miles of the job site.
C.
UNIT RESPONSIBILITY:
1.
The provider of the diesel generators shall be the responsible distributor and
have unit responsibility for the components specified in this Section.
2.
A Certificate of Unit Responsibility, Form 11000-C, shall be provided. The
certificate shall be signed by an officer of the manufacturer's corporation and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-2
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
shall be notarized. No other submittal material will be processed until a
Certificate of Unit Responsibility has been received and found to be
satisfactory. Failure to provide acceptable proof that the unit responsibility
requirement has been satisfied will result in withholding approval of progress
payments for the subject equipment even though the equipment may have
been installed in the Work.
D.
FACTORY TEST:
1.
General: The factory tests shall be completed as part of this Contract. Each
engine-generator set shall be subject to both static and operating testing as
described below. In addition, the generator shall be factory tested as
described below. The Contractor shall submit copies of the results of the
factory test(s) to the Officer-in-Charge for approval. Shipment of the
generator set from the factory shall not be approved until factory test results
and certification documents are accepted and approved by the Officer-inCharge.
2.
Static Testing: The entire unit, including control panels and accessories, shall
be adequately tested on a major components basis, using static methods to
ensure that all safety devices and control circuits are properly installed,
aligned and connected. All trim piping shall be pressure tested, and all
regulators, solenoid valves, etc., tested for proper function.
3.
Operating Tests:
a.
The engine-generator unit shall be set up in a test cell and operated
to determine its operating characteristics under various loads. The
tests shall be conducted in accordance with SAE J 1349 and NEMA
MG-1.
b.
Engine and generator monitoring systems shall be verified to be
operating accurately. Control panel instrumentation, gauges, back
lighting, switches, etc., shall be confirmed to be operating correctly.
c.
The engine generator test shall include full load steady-state and
transient response testing including engine and generator voltage dip
and load data via step loading. The engine generator shall be factory
tested under the following cumulative step loading conditions:
i.
ii.
iii.
iv.
v.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Step Load 1: Resistive load equivalent to 25 percent of
engine kW rating.
Step Load 2: Resistive load equivalent to 25 percent of
engine kW rating.
Step Load 3: Resistive load equivalent to 25 percent of
engine kW rating.
Step Load 4: Resistive load equivalent to 25 percent of
engine kW rating.
The maximum allowable voltage dip shall be 20 percent for
each loading step. The voltage dip shall recover to 2 percent
of rated voltage within 2 seconds.
11081-3
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
d.
The complete unit shall be subjected to a continuous operating test of
at least 8 hours with 2 hours at half load, 2 hours at three quarters
load, and 4 hours at full load.
e.
Records, in addition to the information required by SAE J 1349, shall
be provided for all specified tests. In addition to the tests required by
SAE J 1349 and NEMA MG-1, testing shall minimally include the
following tests:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
Average starting time for not less than five cold starts.
Records shall include test cell temperature and number of
cranking cycles before successful start.
Fuel consumption at 50, 75, and 100 percent rated load.
Voltage and frequency transients upon application and
removal of rated load. Values shall be recorded on high
speed charts to provide accurate definition of response.
Voltage regulation.
Rated power.
Maximum power.
Winding resistance.
Winding insulation resistance.
Open circuit saturation.
Current balance on windings.
Voltage balance on windings.
Regulator range test.
Phase sequence.
Mechanical balance.
Emissions conformance. Each engine will not be individually
emissions tested but will have a label affixed certifying EPA
emissions conformance.
All alarms, indicators, and protective functions specified in
this section.
f.
In addition to the specified testing, a torsiograph analysis shall be
performed to verify that the engine-generator set, as configured, is
free from harmful torsional stress.
g.
The results of the factory tests shall be certified by the quality control
department as overseen by factory-engineering group of the
manufacturer's.
h.
The Factory Testing shall be witnessed by two representatives of the
City. The Contractor shall pay air fare, rental car, hotel and meal
expenses for the representatives of the City to travel to and from the
test site and to witness the test, minimum of two days. A project test
schedule and copy of proposed test procedures shall be provided at
least 60 days in advance of test data. The Officer-in-Charge shall be
given 14 days notice and confirmation of actual test date(s).
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-4
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
E.
1.03
PROFESSIONAL ENGINEER DESIGN REQUIREMENTS:
1.
Foundation: The engine-generator anchoring system and anchor bolt design
as specified within this Section shall be performed under the direct
supervision of a Hawaii registered professional engineer routinely engaged in
this type of work and shall follow the design guidelines in Section 01900.
2.
Mass Elastic System and Critical Speeds: The mass elastic system,
consisting of engine, flywheel, generator, intermediate couplings and
accessories attached to the power train, shall be designed to be free from
dangerous torsional vibratory criticals and critical speeds from 25 percent
below to the unit's operating synchronous speed. All necessary torsional
calculations and the evaluation of the mass elastic system shall be
performed under the direct supervision of a registered professional engineer
routinely engaged in this type of work. The registered professional engineer
shall produce a sealed and signed report setting forth the results of the
analysis and recommendations, if any, for controlling torsional vibration and
critical speeds. The report shall be submitted as part of the factory operating
tests as specified within this Section.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
GENERAL:
1.
A Certificate of Unit Responsibility as specified within this Section.
2.
A copy of the factory test report as specified within this Section.
3.
Outline and installation drawings (plans and sections) for the complete
engine generator set, day tank system, exhaust system, and generator
control panel showing the location, size and other details for the mounting of
the set and electrical and monitoring connections.
4.
Wet weight of complete unit and of heaviest single component.
5.
Mass elastic system calculations.
6.
Foundation, mounting and isolation requirements and vibration isolation
system transmissibility calculations.
7.
Calculations of vent sizes per IFC 2012 signed and approved by the local fire
marshal.
8.
Manufacturer template locations for stub-up of conduits at the engine
generator equipment pad, engine generator control panel, and automatic
transfer switch.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-5
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
C.
9.
Field test procedures for approval 14 days prior to testing.
10.
Seismic design drawings, calculations, and data as specified in Section
01900.
ENGINE:
1.
Torque, brake horsepower, and fuel consumption curves for the specified
conditions.
2.
Complete fuel piping schematics for day tank and engine-mounted auxiliaries
showing the relative position of all piping, filters, valving, and appurtenances
and including fuel regulatory data. Provide catalog information and operating
description of day tank fuel storage and transfer system. Provide day tank
control schematics.
3.
Details of governing system.
4.
Cooling system design data, including heat rejection to jacket water,
intercooler, lube oil, ambient air, and exhaust.
5.
Complete lube oil piping schematics showing the relative positions of all
valving, pumps, filters, temperature and pressure detectors.
6.
Complete cooling water piping schematics, showing the relative position of all
pumps, temperature and level detectors, remote radiator, heat exchangers
and safety devices, and the rate of flow in all cooling water circuits.
7.
Complete details of all safety devices and pressure, temperature, and level
switches.
8.
Manufacturer’s model number and descriptive information.
9.
Sound pressure level data by octave band for engine casing plus radiator,
generator, and engine exhaust components at 50 feet distance.
10.
Engine starting:
a.
b.
c.
d.
e.
Engine cranking voltage.
Number of batteries.
Battery rating of completed bank, amp-hour.
Battery dimensions.
Recommended size of battery cables, AWG.
11.
Radiator airflow and static pressure (external to radiator).
12.
Exhaust gas flow rate, in acfm, and temperature at rated condition.
13.
Exhaust silencer pressure drop versus air flow.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-6
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
D.
E.
14.
Exhaust silencer sound insertion losses and selfself-generated noise per octave
band.
15.
Heat rejection to atmosphere from generator engine casing and generator.
16.
Circuit information for engine block heater.
GENERATOR:
1.
Weight.
2.
Stator and field ratings including temperature rise at full load and overload
conditions.
3.
Complete description of insulation system.
4.
Generator impedances: Xd, Xq, Xd', Xd", X2, Xo.
5.
Catalog data showing kVA, full load amperes, etc.
6.
Generator decrement curve.
7.
Available fault current.
8.
Generator nameplate data.
ENGINE GENERATOR CONTROLS AND POWER DISTRIBUTION:
1.
A copy of the complete wiring, panel, elementary and
process/instrumentation diagrams for the generator engine control, power
distribution, voltage regulation and excitation circuitry showing identified
terminals and identified conductors. The diagrams shall show any addenda
updates that apply to the equipment in this Section marked to show specific
changes necessary for the supplied equipment. If no changes are required,
the drawing shall be marked, "No Changes Required."
2.
Catalog information for all panel face instruments, meters, gauges, switches,
devices, skid mounted termination boxes, terminal strips, the control panel
lighting configuration and method.
3.
Complete step-by-step functional descriptions of the operation of each
control circuit.
4.
Conduit stub-out locations.
5.
Network configuration
configuration files (such as electronic data sheet, EDS) for data
exchange with the plant’s process control system.
system.
6.
Network diagrams detailing the network linking between Vendor panel(s) and
the plant’s process control system.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-7
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
1.04
F.
Operation and maintenance information specified in Section 01730, including parts
list.
G.
Copies of all generator test documentation.
H.
Finalized, complete as-constructed, electrical wiring, panel, elementary and
process/instrument diagrams showing connection and interconnection of identified
terminals and identified conductors to components of the complete electrical system.
I.
Warranty as specified within this Section.
J.
Manufacturer’s certification of installation with Reference Form 11000-A.
K.
Manufacturer's instruction certification with Reference Form 11000-B.
L.
Each engine shall have a label affixed certifying EPA conformance.
M.
Seismic design drawings, calculations, and data as specified in Section 01900.
SYSTEM DESCRIPTION
A.
GENERAL: The generator set shall include the capability of automatically controlling
generator set operation. After starting, the unit will attain rated speed and voltage,
and accept rated load. Generator set speed shall be controlled by the engine
governor, while generator output voltage regulation shall be a function of the
generator automatic voltage regulator. Manual adjustment of generator speed and
voltage at the generator control panel shall be provided. The generator set start,
stop, and cool-down sequences shall be initiated manually or automatically by the
closing or opening of a contact. The control system shall automatically engage the
cranking motor, sense engine starting speed, disengage the motor, and arm the
engine protection circuit.
B.
AUTOMATIC MODE: The engine-generator shall operate as follows in automatic AUTO
mode. Upon receipt of a start/run signal (closed dry contact), the engine shall
immediately start. The engine controls shall bring the engine up to operating speed and
stabilize it at a generator frequency of 60 Hz.
C.
RUN MODE: Operation of the engine-generator in the MANUAL mode shall be the
same as in the automatic mode except that the engine start/stop signals shall be
manually initiated from the engine control panel. When manual engine-generator
operations are no longer desired, the generator’s control panel selector switch shall
be placed in automatic and aligned for engine starting by automatic means from the
auto transfer scheme upon loss of normal power.
D.
TEST MODE: The generators shall start and run in response to a “Test Run”
command. Test runs may be conducted with either no load or plant load.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-8
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
E.
ENGINE DESIGN REQUIREMENTS:
1.
General: The engine shall be rated as follows:
a.
b.
c.
d.
e.
Maximum piston speed: 2,500 feet per minute
Rotational speed: 1,800 rpm, maximum
Fuel: Diesel No. 2, low sulfur
Minimum external fan backpressure: 0.5 in wc capability minimum
(after radiator)
Fuel consumption, maximum gallons per hour: 20
2.
Exhaust Silencing: The engine-generator shall be provided with one Critical
Application Series exhaust silencer. The engine exhaust silencer shall be
supported above the engine as shown and shall be of the horizontal, multichamber, tuned port type unless otherwise shown. The combination of
exhaust piping design and silencers shall provide a minimum sound level
attenuation per this section.
3.
Exhaust Emissions: The engine shall be specifically designed to minimize the
discharge of gaseous pollutants to the atmosphere. The engine shall be
certified EPA emissions conformance Tier 3.
4.
Fuel Control Systems: Fuel control systems shall be capable of continuously
monitoring engine operating performance and adjusting the operating
parameters to obtain optimum emissions and fuel consumption levels
without loss or dip in power. Such adjustments shall be accomplished in a
manner that will not reduce engine efficiency or result in greater pollutant
emissions. The engines shall operate efficiently from 50 to 100 percent of
the specified rated output; exhaust emission characteristics must be
maintained at all engine loading conditions without manual engine
adjustments. The use of a catalytic converter is not acceptable.
5.
Service Piping: The engine vendor shall be responsible for properly sizing the
service piping within the engine and cooling water systems. The engine
vendor shall also be responsible for all flexible connections between the
engine-driven pump set and field piping. All service piping to and from the
engines shall be routed along and anchored to the engine subbase. The
connection to field piping shall be made with flexible metal hoses at the
backs or sides of the engines. No valves or pressure regulators shall be
installed on the engine side of the flexible connections.
6.
Skid-Mounted Radiator Engine Cooling: Each engine cooling system specified
with a skid-mounted radiator in this Section shall be a closed-loop, air-cooled,
front-mounted radiator type. Engine jacket water and auxiliary water from the
closed-loop cooling system shall be circulated through the engine jacket, and
all auxiliary circuits, through a generator-set-mounted radiator by an enginedriven pump. Radiator size and water flow rate shall be calculated to limit
temperature rise in the room to 13 degrees Fahrenheit.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-9
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
F.
7.
Block Heater: The engine cooling water system shall include an electric
heater for the engine jacket coolant, which shall keep the engine block warm
to facilitate quick starts and immediate application of full load.
8.
Vibration Isolation: The engine/generator skid shall include vibration isolation
between the skid frame and the structure. Isolation shall be Type F per
Section 11021.
GENERATOR DESIGN REQUIREMENTS:
1.
2.
3.
General: The generator shall be rated as follows:
a.
Rated kW: As specified within this Section at 1,800 rpm with 0.8
power factor.
b.
Output voltage: 480Y/277V, three-phase, three-wire, six lead, wye
connected, with center tap grounded as shown in the Drawings.
c.
Insulation: Class H, with Class F temperature rise.
Voltage: The following voltage requirement shall be provided:
a.
Steady-state nominal voltage at rated kW: 480V, three-phase, threewire.
b.
Manual adjustment: ±5 percent of nominal.
c.
Regulation: Not to exceed 1 percent.
d.
Steady-load bandwidth: Not to exceed ±0.5 percent.
e.
Transient response: The transient voltage response shall not exceed
20 percent and the recovery shall not exceed 2 seconds
f.
Voltage waveform distortion from no load to full linear load shall not
exceed 5 percent total harmonic distortion. No single harmonic shall
exceed 3 percent.
Frequency: The following frequency requirements shall be provided:
a.
Steady-state nominal frequency at rated kW: 60 Hz.
b.
Manual adjustment: 56 to 64 Hz.
c.
Synchronous operating speed at nominal frequency: 1,800 rpm.
d.
Regulation, no load to full load: Isochronous: ±0.25 percent.
e
Steady-load bandwidth: Not to exceed ±0.5 percent.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-10
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
f.
Transient response: Based upon 25 percent load steps.
1)
2)
G.
Dip, with step application of loads as indicated above, shall
not exceed 3 percent.
Recovery time: Not to exceed 2 seconds.
ENGINE-GENERATOR CONTROL PANEL DESIGN REQUIREMENTS:
1.
Electrical Diagrams: Furnish complete wiring, panel, elementary and
process/instrumentation diagrams shown in point-to-point fashion for the
engine-generator engine control, power distribution, and voltage regulation.
The vendor shall be responsible for determining conduit and conductor sizes
for all devices and controls furnished under this Section. Elementary
diagrams, schematics, and one-lines, shall show the scheme or sequence in
which the devices of the generator engine control system, , power
distribution, voltage regulation, and excitation circuitry are connected in
relation to each other. Panel diagrams shall show the physical location of the
parts of an electrical system. In each case, every conductor and terminal
shall be labeled and identified.
2.
Electrical Energy Source: Normal electric power for control shall be 12 VDC
from the control batteries. The engine vendor shall be responsible for
providing any voltage transformation equipment required.
3.
Engine Controls and Instrumentation: All engine control and instrumentation
systems shall be integrated into the engine generator control panel which
shall be bottom fed. All conductors and cables that interface with devices
mounted on the generator skid to devices mounted off the skid shall leave
the generator skid from grouped termination boxes. Provide labeled terminal
strips and conductors at the engine-generator control panel and at the
termination boxes for these circuits. Conductors entering the control panel
shall land on labeled terminal strips prior to final connections on the discrete
components. Operator control devices, gauges, meters, machine monitoring,
etc., associated with engine shall be face-mounted in the control panel.
Terminal boxes shall be provided on the engine generator set for interfacing
power, control, and monitoring circuits between the control panel and the
engine generator set. All terminal boxes shall utilize labeled terminal strips
and conductors.
4.
Provide auxiliary relays for control of the motorized dampers as specified on the
wiring diagrams. Dry contacts from the auxiliary relays shall signal when the
engine receives a run signal. Dry contacts rated 120VAC, 10 amp inductive
minimum.
5.
All indication, gauges, meters shall be 12 VDC back lighted devices or the
control panel shall be provided with 12 VDC control panel face lighting that
shall be mounted at the top of the panel and provide suitable lighting for
clear and easy viewing of the panel face mounted devices.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-11
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
1.05
ENVIRONMENTAL CONDITIONS
A.
1.06
1.07
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. Contractor shall design the structural
components, seismic attachment, braces, and anchors to the structure for all parts
or elements of the mechanical and electrical systems in accordance with Section
01900.
B.
Vibration Isolation: The engine/generator skid shall include vibration isolation
between the skid frame and the structure. Isolation shall be Type F per Section
11021.
SHIPMENT, STORAGE, AND HANDLING
A.
1.08
Equipment shall be installed in locations as shown on the Drawings. Refer to Section
01800 for environmental design conditions.
The equipment to be furnished under this Section shall be shipped to the site with
weathertight covers on all piping and electrical connections. All shaft housing
penetrations shall be sealed in a manner that shall protect against damage from the
elements and deterioration of the equipment due to moisture, corrosive gases, dirt
and debris. Additionally, each individual shipment shall be packaged in a manner
designed to protect the equipment against damage caused by sudden acceleration
or deceleration, and shall have an accelerometer affixed to the unit prior to
shipment.
EXTENDED WARRANTY
A.
In addition to the warranty specified in Section 01730, the manufacturer's and
dealer's extended warranty shall in no event be for a period of less than five years
from date of initial start-up of the system or 1,500 operating hours, whichever comes
first. It shall include a local cylinder head exchange program, repair parts, labor,
reasonable travel expense necessary for repairs at the job site, and expendables
(lubricating oil, filters, antifreeze, and other service items made unusable by the
defect) used during the course of repair. Applicable deductible costs shall be
specified in the manufacturer's warranty. Submittals received without written
warranties as specified will be rejected in their entirety. A warranty nameplate of not
less than 152 mm x 203 mm (6 in x 8 in) must be affixed to the generator set with
the following data:
1.
2.
3.
4.
5.
6.
7.
Warranty Period:
Start-up Date:
Termination Date:
Vendor Name:
Vendor Address:
24-Hour Emergency Number:
Preventive maintenance to be performed by:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-12
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
PART 2--PRODUCTS
2.01
2.02
ACCEPTABLE PRODUCTS
A.
GENERAL: The following candidate manufacturers are capable of producing
equipment and/or products that will satisfy the requirements of this Section. This
statement, however, shall not be construed as an endorsement of a particular
manufacturer’s products, nor shall it be construed that named manufacturers’
standard equipment or products will comply with the requirements of this section.
B.
ENGINE: Candidate manufacturers include Caterpillar, Cummins, or approved
substitute.
C.
GENERATOR: Candidate manufacturers include Caterpillar and Cummins, or
approved substitute.
D.
SILENCER: Candidate manufacturers include Beaird, Maxim, Nelson, or approved
substitute.
E.
DAY TANKS: Candidate manufacturers include Simplex, Tramont, Pryco, or approved
substitute.
F.
JACKET WATER HEATER: Candidate manufacturers include Kim Hotstart, Chromalox,
or approved substitute.
G.
FUEL COMPUTER: Candidate manufactures include Flowscan series 8500/8600, or
approved substitute.
ENGINE COMPONENTS
A.
GENERAL:
1.
Each diesel engine-generator set shall consist of a skid-mounted engine
radiator system and heat exchanger(s), engine-mounted accessories, and
direct-connected generator, all mounted on a rigid base and frame. All
engine accessories shall be installed by the engine vendor. The frame shall
be supported by steel spring isolators rated for not less than 98 percent
isolation efficiency (2-inch static deflection). Anchor bolts shall be provided
and designed as specified in Section 01900.
2.
Flexible couplings for jacket water, lube oil, fuel, and exhaust piping shall be
provided. Water connectors braided, fiber jacketed rubber hoses. Oil and fuel
connectors shall be braided stainless steel jacketed rubber hoses. All hoses
shall be, at a minimum, 150 psig working pressure. Fuel connectors shall
bear the Underwriters Laboratories label. The exhaust connector shall be
unbraided, stainless steel, suitable for temperatures up to 1,300 degrees F.
3.
Engine couplings shall be as follows:
a.
Exhaust flex will be stainless steel bellows with carbon steel turbo
and muffler connections.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-13
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
B.
b.
Fuel flex connections will be rubber lined with stainless braiding on
the outside.
c.
Radiator hoses will be rubber with fiber braiding.
ENGINE:
1.
General: The engine shall be a four-stroke cycle, turbocharged, water-cooled,
diesel fuel unit capable of meeting the design and performance requirements
operating on No. 2 diesel fuel.
2.
Base and Frame:
a.
The engine base shall be of rigid construction with heavy transverse
girders formed to support the crankshaft main bearings.
b.
The engine frame shall be a suitable box shape to provide
longitudinal and transverse rigidity.
3.
Cylinders: Cylinders shall be cast with the engine block. Engine block shall
be cast iron with replaceable wet liners. All cylinder liners shall be finished to
give a straight bore, shall be machined and honed.
4.
Cylinder Heads: Cylinder heads shall be of the individual valve-in-head type
constructed of cast iron with valve guides and plug sockets fully jacketed for
efficient cooling. Renewable hardened steel inserts shall be provided for all
valve stem guides. Valve seats shall be made of hardened steel selected
specifically for high temperature service.
5.
Crankshaft: The crankshaft shall be made from a single forged steel billet
and heat treated. The crankshaft shall be sized to provide a liberal margin of
safety against abnormal strains. Journals shall be hardened and
micropolished. The shaft shall be finished all over, drilled and ported for
pressure lubrication of all bearings and statically and dynamically balanced
after fabrication. If of two-piece design, the crankshaft shall be machined
and balanced as a single unit.
6.
Main Crankshaft Bearings: The main crankshaft bearings shall be amply
sized and shall be arranged for replacement without removing the
crankshaft. To provide proper support for the flywheel, the bearing at the
flywheel end of the engine shall be of greater area than the intermediate
crankshaft bearings. Bearing caps shall be fitted into place and bolted to the
frame.
7.
Connecting Rods and Crank Pin Bearings: The connecting rods shall be
made of heat-treated steel forgings. The crank end of the rod shall be of tee
foot design for use with two-piece babbitted or sleeved crank pin boxes.
Provision shall be made for the use of large through bolts to securely fasten
the crank pin boxes to the foot of the rod. The design shall permit removal of
the piston and connecting rod through the cylinder liner. Oil jets shall supply
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-14
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
piston cooling and lubricating oil; drilled connecting rod passages will not be
permitted.
8.
Flywheel: The flywheel shall be of heavy-duty design and one-piece
construction and shall be made of high-grade close-grained cast iron.
Torsional dampers, if required, shall be of the viscous type.
9.
Pistons: Pistons shall be of the oil-cooled made of close-grained cast iron or
aluminum alloy accurately machined to size. The piston shall be long in
proportion to the diameter and shall be fitted with not less than two
compression and one oil control rings. The oil control rings may be located in
the piston skirt or above the wrist pin.
10.
Piston Pins: Piston pins shall be made of high-grade steel, hardened and
ground to ensure a fine running fit. They shall be either of the type that are
fitted into the pistons so as to prevent rotation in the pistons but permitting
free expansion of both pistons and pins, or of the full floating type held
longitudinally by retaining rings fitted into the wrist pin bore of the piston.
11.
Valves and Valve Gear: Inlet and exhaust valves shall be precision machined
and shall be made of the highest grade heat-resisting material. Valve seats
shall be replaceable, of heat resistant high alloy steel. Valves shall be the
largest possible diameter so as to produce the greatest volumetric efficiency
and adequate scavenging of the cylinders in order to keep valve maintenance
to a minimum. All valve mechanisms shall be constructed so as to provide
positive action with utmost rigidity. Two intake and exhaust valves shall be
provided in each cylinder head.
12.
Camshaft: Camshafts shall be alloy steel forgings with integral cams,
machined, heat-treated and ground with polished bearing and contact
surfaces. The camshafts shall be chain driven or driven through gears front
and back.
13.
Gear Train: Gears shall be lapped and shaved for uniform loading and quiet
operation.
14.
Exhaust Manifold: Exhaust manifolds shall be single-outlet or, if in pairs,
shall be joined to provide a single exhaust outlet for the engine. A flexible
stainless steel expansion bellows shall be provided at the outlet whose style
shall be coordinated with the location of the silencer mounting as shown.
Exhaust manifolds shall be shielded or insulated to reduce surface
temperature to a level that would prevent injury.
15.
Engine/Crankcase Breather: The engine breather(s) shall be equipped with
crankcase ventilation filter(s) to remove oil mist coming from the crankcase
breather vent. Neither oil fumes nor condensed liquid oil shall be discharged
to the room. Return connection point from the filter shall be as directed by
the engine manufacturer. Connections of liquid or gas lines to the engine’s
exhaust air plenum, if any, shall be separated by flexible connectors. Product
shall be similar to Nelson Ecovent Recirculator.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-15
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
C.
16.
Turbocharger and Aftercooler: The engine combustion air shall be
pressurized using exhaust gas driven centrifugal compressor(s). An
aftercooler, selected specifically for use with the closed loop engine cooling
system, shall be provided for cooling the combustion air.
17.
Air Filters: The engine shall obtain the necessary volume of combustion air
through inlet air filters of the dry panel type with replaceable filter cartridges
and service indicator. Separate filters shall be provided for each cylinder
bank. The filters shall be mounted on the engine or engine skid so that they
are easily maintained yet do not block maintenance of other engine parts.
FUEL OIL SYSTEM:
1.
General: The engine manufacturer shall be responsible for both design and
provision of a fuel oil delivery system meeting the functional requirements of
this paragraph. The system shall contain the features specified, and
additional components as necessary to provide a complete and operable
system. The fuel oil system shall provide for fuel return to the bulk tank from
the day tank, and fuel delivery from the day tank to the engine. Major
components include a double-walled day tank with duplex return pumps, level
and pump controls, engine driven injector pump, and fuel filtration. Fuel oil
piping is specified in Section 15050. Flexible connections shall be provided
at fuel piping connections to the engine.
2.
Remote Day Tank:
a.
Day Tank Fuel Transfer System: The day tank and fuel transfer
system shall be specifically designed for operation with above grade
bulk storage tanks. The system shall prevent siphoning or back
siphoning of fuel between the day tank and the bulk storage tank.
The system shall return any day tank overflow to the bulk storage
tank with the use of transfer pumps and without pressurizing the day
tank and supply feed to the engine greater than recommended by the
engine manufacturer. The system shall include a day tank; duplex
electric fuel transfer pumps; and a day tank control panel with all
controls and accessories to automatically operate the transfer pumps
(from day tank to storage tank and from storage tank to day tank),
indicate status conditions, and transmit information to the engine
generator control panel and meets the specification requirements of
Section 17110. The size of the day tank and equipment numbers for
the tank, control panel, suction lift, and pumps shall be as specified
within this Section. Accessories shall be listed to provide for a
complete and functional system.
b.
Day Tank: Day tank shall have a capacity as specified within this
Section. Tank shall comply with NFPA 30, NFPA 37, and be UL 142
and UL 508 rated. It shall be an above-ground, double-wall steel tank
pressure tested to 5 psig. Tank shall be heavy gauge steel,
continuous seam welded with internal reinforcement, and suitable for
diesel fuel application, with welded pipe fittings of the sizes shown for
fuel transfer (from day tank to storage tank and from storage tank to
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-16
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
day tank), overflow, vent and drain, and machine formed fuel supply
suction tube. Tank shall be provided with heavy gauge steel channel
feet with mounting holes, all necessary mounting attachments, and a
removable steel top cover. The tank exterior shall be shop primed
and painted with epoxy enamel to match the generator set. Tank
elevation shall be as required by the engine manufacturer to prevent
flooding of the engine. Tank shall include the following features:
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
Manual fill port with lockable cap and drop tube.
Manual hand pump inlet.
Day tank level indicator and control.
Day tank temperature indicator and control.
Leak detector switch between inner and outer walls.
Three-valve bypass on each solenoid and strainer.
Drain with hand valve.
Vent line.
Vent cap.
Atmospheric vent.
Emergency vent.
Secondary containment drain with valve.
Gravity drain for overflow basin.
Level control panel (UL 508).
Duplex fuel transfer pumps.
Check valve for each pump.
Fuel line isolation and automatic closing, fusible link
(165 degrees F) valves.
One capped 2” diameter spare connection without dip tube.
c.
Fuel Transfer Pumps (from day tank to storage tank): Pumps shall be
pressure loaded, self-compensating, positive displacement gear
pumps. Pump motors shall be 120v TEFC, 1,200 or 1,725 rpm as
needed, continuous duty 40 degrees C ambient, Class B insulation
equipped with overload protection. Fuel transfer pumps (from
storage tank to day tank) are specified in Section 13210.
d.
Day Tank Control Panel: Day tank control panel shall be 120V with all
necessary transformers to reduce voltage as needed by other day
tank components. The day tank control panel shall automatically
maintain the proper fuel level in the day tank and prevent siphoning
or back siphoning of fuel between day and bulk storage tanks. It shall
automatically operate the transfer pumps (from day tank to storage
tank and from storage tank to day tank). For the transfer pumps from
the day tank to the storage tank the day tank panel shall alternate
their starting, indicate status conditions, and transmits information to
the engine generator control panel and plant control system (PCS).
The day tank control panel shall include fuel transfer pump running
indicators, pump fail alarm output, high/low/leak alarm conditions,
day tank level indication, and shall allow for manual operation of fuel
transfer pumps. All wiring for instrumentation, control, and power
shall be provided and terminated at termination strips. Provide
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-17
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
control power transformer. Controls shall be housed in a NEMA 12
enclosure that can be field-mounted and meets the specification
requirements of Section 17110.
e.
Day Tank Sequence of Operation: The day tank panel transfers fuel
from the day tank to the storage tank, and signals the storage tank
panel to transfer fuel from the storage tank to the day tank. The
storage tank panel transfers fuel from the storage tank to the day
tank. Day tank control panel and the storage tank panel shall provide
the following control sequence.
Day Tank Level
(percent capacity)
Control Response
Low Low (10%)
In the day tank panel:
a) The trouble alarm contact closes.
b) The critical low fuel contact closes.
c) The critical low level indicator light illuminates
Low (70%)
The day tank panel signals the storage tank panel
to start a pump.
At the storage tank panel: a) The lead pump
starts. If lead pump does not start, start the lag
pump and open the trouble contact. b) Pump
running indicator light illuminates and pump
running contact closes.
High (100%)
The day tank panel signals the storage tank panel
to turn off the pump.
The storage tank panel turns the pump off, the
pump running contact opens, and the pump
running indicator light de-illuminate
High High (106%)
The day tank panel starts a pump.
The pump running indicator light illuminate
High level trouble alarm
If lead return pump does not start, start lag return
pump
High (100%)
The day tank panel turns off the pump
The pump running indicator light de-illuminate
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-18
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
f.
Day Tank Alarms: Day tank control panel shall provide the following
alarms.
Alarm
Location
Fuel in rupture basin
Local and Engine-generator control panel
Critical low level
trouble
Local and Engine-generator control panel
High level trouble
alarm
Local and Engine-generator control panel
Pump failure alarm
Local and Engine-generator control panel
Control system trouble
Local
Status
3.
4.
5.
Location
Pump Running
Local and Engine-generator control panel
Pump Running
Local and Engine-generator control panel
Day tank level
(gallons)
Local and Engine-generator control panel
Fuel Appurtenances:
a.
Pressure gauge: 4-1/2-inch premium grade, glycerin filled units with
Bourdon tube element, 270-degree milled stainless steel movement,
stainless steel case, stainless steel bourdon tube, and shatterproof
glass window. Range: 0-15 psi.
b.
Gauge Valves: Machined from ASTM A276 bar stock. Use with 1/2inch NPT connections and integral bleed valve.
Fuel Metering System:
a.
The fuel metering system shall be integral with the engine. It shall
include fuel filter, transfer pump, injection pumps, lines, and nozzles.
The transfer pump shall deliver fuel under low pressure to individual
injection pumps, one for each cylinder. The pumps shall be of a
variable displacement type to alter the volume of fuel delivered to the
spray nozzles according to load demand.
b.
Fuel filters shall be of the replaceable microglass element type
designed for long service life.
Fuel Computer:
a.
Meet EPA reporting requirements fro tracking NOx emissions.
b.
Track operation time and fuel consumption.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-19
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
D.
E.
F.
c.
Digital LCD Engine Hour Meter, Tachometer, Fuel Flowmeter, and Fuel
Totalizer.
d.
Switch that resets totalizer reading.
LUBRICATION SYSTEM:
1.
The engine shall be of the wet sump type, provided with a full pressure
lubricating oil system arranged to distribute oil to all moving parts of the
engine. The lubrication oil pump shall be a positive displacement type that is
integral with the engine and gear driven from the engine gear train. The
system shall incorporate full flow filtration with bypass valve to continue
lubrication in the event of filter clogging. The bypass valve must be integral
with the engine filter base or receptacle. Systems where bypass valves are
located in the replaceable oil filter are not acceptable. The filter shall be
provided with inlet and discharge pressure taps. Pressure gauges shall be
oil-filled, suitable for engine service. The oil filter shall be provided with
differential pressure indicators and shall be mounted on the subbase.
2.
Engine shall be equipped with a lubricating oil cooler, sized to cool the oil as
recommended by the manufacturer. Jacket water shall be circulated through
the water side of the oil cooler.
SPEED GOVERNING SYSTEM:
1.
The engine governor shall control engine speed and transient load response
within commercial and ISO 8528 tolerances. It shall be selected, installed,
and tested by the generator set manufacturer. The engine governor shall be
a microprocessor based speed control fuel control governor. In the event of a
dc power loss, the forward acting actuator shall move to the minimum fuel
position.
2.
Engine governing shall maintain steady-state speed regulation of 0.25
percent. Speed drop shall be adjustable from 0 (isochronous) to 10 percent
from no load to full rated load. Ramping to rated speed during start-up shall
be delayed until engine oil pressure is assured, with rate of acceleration
controlled. Rate of acceleration during start-up shall be manually adjustable.
ELECTRIC STARTING SYSTEM:
1.
General: The engine starting system shall include dual 12 VDC starting
motor(s), starter relay, and automatic reset circuit breaker to protect against
butt engagement. Batteries shall be lead acid type mounted near the starting
motor. Required cables will be furnished and sized to satisfy circuit
requirements. The system shall be capable of starting a properly equipped
engine within 10 seconds at ambient temperatures greater than 30
degrees F.
2.
Batteries: Starting batteries shall be selected and supplied by the generator
set manufacturer. Batteries shall be a heavy duty SLI lead acid type with
thru-partition connectors, and housed in a hard rubber or polypropylene case
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-20
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
with provision for venting. Starting batteries shall be rated 12 VDC with an
ampere-hour and CCA rating as specified by the manufacturer. Sizing shall
consider specific application requirements of engine oil viscosity, ambient
starting temperature, overcharging, and vibration. Starting batteries shall be
close to the starting motor. Starting batteries shall be enclosed within battery
boxes that shall be provided with separate covers. The battery box covers
shall withstand a standing weight of 300 pounds. Battery boxes shall have
adequate volume to act as a secondary containment for the battery acid.
Battery boxes shall be vented and shall be made of nonconductive and acidresistant materials. Batteries and battery boxes shall be provided in
accordance with the seismic design requirements of Section 01900. Battery
cable size shall be selected by the engine-generator manufacturer and shall
be installed by the Contractor. Battery warranty shall be the responsibility of
the generator set manufacturer. Batteries shall be maintenance free.
3.
Battery Charging: Starting 12 VDC battery charger shall be selected and
supplied by the engine-generator set manufacturer. Battery chargers to be
provided as follows:
a.
b.
c.
d.
e.
Fully automatic with manually adjustable voltage and equalize timer
Phase: Single
Hz: 50/60
120//240 VAC, 13AAC
12 VDC, 35 ADC
G.
COOLING SYSTEM, SKID-MOUNTED RADIATOR: For locations requiring a skidmounted radiator as specified within this Section, the engine jacket water cooling
system shall be a closed-circuit design with provision for filling, expansion, and
deaeration and employing a close coupled radiator with a pusher type fan. The
radiator shall be sized to cool the engine continuously while operating at full rated
load, and test overload if applicable, and at site conditions. Fan shall be belt driven
from pulley or direct coupled on engine crankshaft. Poly-V-belt or a minimum of two
individual V-belts, each of which must be capable of driving the fan if one belt fails. A
flexible connection shall be provided for connection to the fixed air discharge plenum.
The flexible connection shall be provided with the necessary angle, straps, bolts,
clips, or other fasteners to secure the flexible material to the equipment and
ductwork plenum. Coolant shall be supplied and shall be fresh water with 50 percent
ethylene glycol antifreeze with corrosion inhibitors. Three piece radiator with a top
tank, bottom tank and center core assembly for ease of assembly.
H.
JACKET WATER HEATER: Engines shall be fitted with thermostatically controlled
jacket water heater(s) designed to maintain proper conditions for quick starting
regardless of ambient temperature. The jacket water heater(s) shall be provided to
maintain a coolant temperature of 90 degrees F while the engine is not operating.
Heaters shall include thermostatic controls and isolation valves. Heaters shall be
1000W maximum and shall be powered with 120 VAC current. Confirm circuitry
requirement in submittal documentation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-21
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
I.
EXHAUST SYSTEM:
1.
Exhaust piping shall be provided in accordance with Section 15050. Flexible
stainless steel expansion joint(s) shall be provided as shown between the
engine exhaust manifold(s) and the silencer. A combination "Y"/elbow shall
be provided at the exhaust manifold(s) to accommodate the low head
exhaust silencer mounting if required. Engine manufacturer shall size
expansion joints to allow for thermal growth of connected equipment and
piping.
2.
The exhaust silencer shall be a critical-grade type exhaust silencer meeting
the performance requirements specified within this Section. Silencer shall
have a 3/8-inch condensate drain connection. The silencer shall be
supported by preengineered spring hangers unless otherwise shown on the
Drawings. Seismic restraints and hangers shall be designed as specified in
Section 01900. The silencer shall be fabricated of heavy-gauge steel in allwelded construction with inspection ports and drain fittings in each chamber.
3.
The exhaust system shall include means with which to relieve, prevent, or
withstand the ignition of unburned fuel in the exhaust without damaging the
exhaust system, in accordance with NFPA 37. If relief valves or rupture discs
are used to meet this requirement, they shall be vented outdoors and away
from personnel.
4.
INSERTION LOSSES: Exhaust silencers shall meet or exceed the sound
attenuation criteria listed:
Silencer Name
Exhaust Silencer
63
25
Octave Band Center Frequencies (Hz)
125 250
500 1000 2000 4000
34
37
33
30
30
29
8000
27
J.
FINISH: Generator set, including base, shall be completely painted with two-part
polyurethane paint mixed prior to application in accordance with Section 09900.
One quart of touch-up paint shall be provided with generator set.
K.
PROTECTIVE DEVICES: The engine shall be provided with the following devices,
factory installed and adjusted. Protective devices shall include the following:
1.
An overspeed switch that shall be separate from the governor and shall close
at 10 percent above synchronous speed to actuate an alarm contact.
2.
A zero speed switch designed to open whenever the engine is rotating,
including cranking. The zero speed switch shall be employed for
authentication of no engine rotation in the engine starting controls. Less
than 2 rpm shall be acceptable as zero speed.
3.
An underspeed-normal speed, snap-action, single pole, double-throw
centrifugal switch. The underspeed switch shall be adjustable from 50 to
100 percent of normal operating speed.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-22
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
L.
4.
A low oil pressure switch that closes when the pressure in the lube oil system
is below permissible operating levels.
5.
A temperature switch, mounted in the lubricating oil system, designed to
close when the oil temperature downstream from the oil cooler reaches
unacceptable levels.
6.
A mushroom head Emergency Stop button located on the generator skid to
allow for immediate shutdown of the engine generator.
8.
All devices shall be specifically designed for engine service of a type suitable
for reliable operation in the presence of continuous vibration. All contacts
shall be electrically isolated and rated as required by NEC. Conduits shall be
routed to provide maximum access to all maintenance points.
MONITORING AND MEASURING CONNECTIONS: The engine shall be provided with
suitable taps or connections available for the measurement of the following:
1.
2.
3.
4.
5.
6.
7.
2.03
Lubricating oil inlet pressure.
Differential oil pressure across each filter.
Lubricating oil inlet temperature.
Engine speed.
Intake manifold vacuum.
Jacket water inlet temperature.
Jacket water outlet temperature.
GENERATOR COMPONENTS
A.
GENERAL:
1.
Single-bearing synchronous alternator directly connected to engine through
flexible coupling.
2.
Rotating field, brushless, three-phase, three-wire.
3.
Dripproof, guarded.
4.
Self-ventilated, air-cooled.
5.
Self-lubricated bearing.
6.
Generator rotor capable of operating at 15 percent over-speed. Balanced to
25 percent over-speed.
7.
Engine and generator torsionally compatible.
8.
Class H insulation with a Class F rise conforming to NEMA standard MG11.65.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-23
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
9.
B.
Equipment grounding shall exist
a.
Between generator and engine.
b.
Between generator frame and transfer scheme through cable
connections.
c.
Between battery charger, control cabinet(s), conduits, generator
enclosure, wire tray(s), fuel tank, light fixtures, and any other metal
conductive parts in accordance with NEC.
10.
Generator power connections shall be located in an enclosure that is readily
accessible for inspection.
11.
Full static-type three-phase sensing voltage regulator. Microprocessor
controlled, temperature compensated with under-frequency output reduction
in response to frequency reduction below 58 to 59 Hz.
12.
Voltage and engine speed adjusting rheostats.
13.
Two-thirds pitch stator winding.
14.
Permanent magnet generator pilot exciter capable of sustaining 300 percent
of rated alternator current output for approximately 10 seconds.
15.
Maximum subtransient reactance: 17.2 percent.
16.
All termination boxes shall be readily accessible and shall be located to
access conduits stubbing up from below.
17.
Generator wiring shall permit the installation of differential protection. Six
leads shall be available for installation of CTs.
18.
Provide mechanical lugs suitable for terminating cables at the generator
output circuit breaker.
VOLTAGE REGULATOR:
1.
The automatic voltage regulator shall incorporate PMG technology and shall
maintain generator output voltage by controlling the current applied to the
exciter field of the generator.
2.
The regulator shall be microprocessor controlled and shall be provided with
three-phase rms sensing circuits and temperature compensation.
3.
The regulator shall include electronic voltage buildup and overcurrent
protection. It shall incorporate 1:1 volts per Hz characteristics with the
regulated voltage a linear function proportional to frequency over a 30 to 70
Hz range.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-24
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
4.
The regulator shall be suitable for mounting within or external to the
generator assembly, and have provision for remote voltage level control,
using 16 gauge shielded wire.
5.
As installed, the voltage regulator shall meet the applicable sections of the
following standards:
a.
b.
c.
d.
C.
2.04
Canadian Standards Association (CSA).
International Electrotechnical Commission (IEC).
Institute of Electrical and Electronic Engineers (IEEE).
National Electrical Manufacturers Association (NEMA).
GENERATOR CIRCUIT BREAKER: Generator output breaker is located at the
generator.
1.
Circuit Breaker shall be UL Listed, 3 pole, 100% rated and include 90
degree C rated lugs
2.
See one-line drawing for circuit breaker size.
ENGINE-GENERATOR CONTROL PANEL
A.
PANEL: The engine-generator control panel shall include a voltmeter, ammeter,
wattmeter, frequency meter and a microprocessor-based controller for local starting,
monitoring, metering, and protective controls. It shall include a communications
interface module/modem for remote monitoring capabilities. The control panel shall
be provided in a NEMA 12 enclosure with a front hinged door. It shall be powered by
a 12 VDC battery charger and battery system. Readily accessible interfacing terminal
strips for all wires and cables leaving the panel shall be provided. All instruments,
gauges, meters shall be back lit or 12 VDC lighting shall be mounted to the control
panel to provide operational lighting. The control panel shall include the minimum
following features:
1.
Controls:
a.
b.
c.
d.
e.
2.
Manual-Off-Auto switch.
Mushroom head Emergency Stop pushbutton.
Alarms acknowledge/reset switch.
Remote Run Command.
Voltage regulator adjustment.
Displays:
a.
b.
c.
d.
e.
f.
g.
Oil pressure.
Coolant temperature.
Oil level.
Generator voltage.
Generator amperage.
Frequency.
Battery charging voltage.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-25
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
h.
i.
3.
Status Contacts: Status output contacts shall be form C, dry contacts rated
3A resistive at 120VAC and 28VDC. Where the status is from a solid-state
component the vendor shall provide interposing relays in their cabinet that
are controlled by the solid state components to provide the dry contacts. The
normally open contacts for trouble and failure shall be held closed and open
under fail conditions, otherwise normally open contacts shall close upon
activation. The following status output contacts shall be provided:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
B.
Engine run time.
Generator kilowatts.
Generator Running (4).
Generator Common Fault (2).
Generator Common Trouble (2).
Generator in Auto (2).
Generator Ready (2).
Loss of AC Power (2).
Charge Low/High (2).
Fuel in Rupture Basin (2).
Day Tank Pump Fail (2).
Pump
Pump 3 Running (2).
Pump 4 Running (2).
Day Tank Fuel High (2).
Day Tank Fuel Low (2).
Refer to Drawings for additional output contacts for the Generator
Control Panel.
Panel. The Generator Control Panel shall be interconnected
to the process control system
system through both hardwired contact circuits
and data network.
4.
Analog Signal Output:
Output: Provide a 22-wire, 44-20 mA analog output signal for
remote monitoring of day tank level.
5.
Terminal Strips for Interconnecting Wiring: All engine-generator associated
status, alarm, analog signal, and control points shall be collected on terminal
strips within the generator control panel before the signals leave the
generator skid and control panel. The installing contractor shall provide
terminal strips at the interface panel and shall terminate and label wires in
accordance with the identification paragraphs of Section 16000. The wires
shall also be tagged with the noun name of the statusday tank or alarm point
the signal wires are associated with.
6.
Network: Network
Network linking between engineengine-generator control panel and
proc
process control system shall be provided.
provided. The process control system shall
be provided with read only data exchange for equipment specified in this
Section and as specified on drawings.
MICROPROCESSOR ENGINE CONTROLLER:
1.
A microprocessor-based engine controller specifically designed for advanced
diesel engine management, monitoring, and emissions control shall monitor
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-26
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
all significant engine parameters, and adjust engine performance according
to speed, altitude, temperature, aftercooler temperature, and engine
condition. It shall incorporate revisable control software capable of
reconfiguring engine operation to desired performance levels. The controller
shall display a minimum of the following: volts, amps, watts, power factor,
generator running, generator ready, oil pressure and temperature, coolant
temperature, fuel level, hours, time and date of alarms, rpm, main fuel tank
level. The controller shall network to the plant process control system
system (PCS)
through Modbus/TCP or an approved substitute protocol. The PCS network
link shall only read data with ICP 800,101 as specified in Sections 17315
and 17500.
2.
The microprocessor based controller will annunciate the following trouble and
failure alarms:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
s.
t.
u.
Overcrank (failure).
Engine Temperature High (trouble and failure).
Oil Pressure Low (trouble and failure).
Generator Overcurrent (trouble and failure).
Oil Level Low (trouble).
Engine Oil Bearing Temperature High (failure).
Generator Bearing Temperature High (failure).
Generator Winding Temperature High (trouble and failure).
Oil Filter Differential High (trouble).
Underspeed (trouble).
Day Tank Leak into Containment Area (trouble).
Day Tank Low Level (two trouble levels and failure).
Day Tank High Level (trouble).
Day Tank Fuel Pump Failure (trouble).
Engine Exhaust Temperature Low (trouble).
Engine Fuel Pump Failure (failure).
Main Fuel Tank Level Low (trouble).
High DC (trouble).
Low DC (trouble).
Low Coolant Temperature (trouble).
Not in Automatic (trouble).
3.
All engine-mounted field switches and instruments shall have NEMA 4
enclosures which meet the specification requirements of Section 17110.
4.
The engine controller shall be configured to avoid interruption of power
whenever possible. In the event of system faults that do not require
immediate failure, the engine shall be programmed to continue operation at
power levels sufficient to remain within performance limits.
5.
The engine controller shall display real time and historical data to allow user
to optimize operation and provide accurate service information in the event
of a malfunction. Information shall be accessible through a data link for
remote monitoring. A data link failure shall not cause an interruption of
engine operation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-27
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
6.
2.05
The manufacturer’s microprocessor-based engine controller must be able to
comply with all of the items in this paragraph. If the manufacturer’s
controller can additionally perform the functions specified within this Section,
it is acceptable that those functions be performed by the controller and it is
not required to duplicate the function with separate hardware as specified
within this Section. The manufacturer, however, must identify and
demonstrate in the submittal process which of the controls and alarms are
proposed to be implemented through the controller instead of separate
control and alarm hardware. Total controls must provide all of the
functionality specified within this Section.
SPARE PARTS
A.
PROCEDURES: Section 01750.
B.
The following spare parts shall be provided:
1.
One complete replacement engine lubricating oil and fuel oil filter elements.
2.
One complete set of hoses (fuel, oil and radiator).
3.
One complete replacement engine air filter elements.
4.
One set any software programs applicable to the generator and all other
components that require software for troubleshooting, maintenance, and
adjustment.
5.
One set, if not already supplied, manufacturer's recommended specialized
tools or instruments to monitor/ troubleshoot engine or generator
components.
6.
One complete set, if not already supplied, of control fuses and replacement
lamps.
PART 3--EXECUTION
3.01
3.02
INSTALLATION
A.
Manufacturer's representative shall consult with Contractor during installation to
ensure proper installation and conformance with manufacturer's instructions. The
installation shall be certified on Form 11000-A specified in Section 01999.
B.
Seismic Anchorage and Bracing: Section 01900.
SHORT CIRCUIT / COORDINATION AND ARC FLASH WORK
A.
Provide
Provide submittals for Section 16431.
B.
Contractor shall assist the Power Systems Study contractor as specified in
Section
Section 16431.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-28
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
3.03
3.03
3.04
3.04
START-UP
A.
Start-up shall be performed by a manufacturer's service representative in the
presence of the Officer-in-Charge. In addition to the manufacturer’s standard startup check-out, it shall consist of a complete system check-out developed by an
electrical testing laboratory accredited by NETA to perform the tests. Every control
function including all failures, alarms, indicating lights, switches, horns, metering,
gauges and protective devices shall be demonstrated to work properly. Each
function will then be signed off individually by the Officer-in-Charge on a check list
developed by the qualified testing agency. If a particular function cannot be safely
demonstrated or if any adjustments are required, the Officer-in-Charge shall be
notified immediately. Allow 8 hours minimum for testing. Perform all tests in
accordance with Section 01660.
B.
Prior to acceptance, equipment shall be tested in accordance with Section 01660 to
show it will start and operate properly under all modes of operation. A minimum of 8
hours of manufacturer’s service representative time shall be allowed for operational
testing.
C.
Testing will include a 2-hour full load test at 1.0 power factor.
SYSTEM PERFORMANCE TEST
A.
The Contractor shall submit, 30 days prior to the test, the test procedure, developed
by an electrical testing agency accredited by NETA to perform the submitted tests, for
approval by the Officer-in-Charge, to demonstrate the correct function of the standby
power generation system.
B.
Removal of “Normal” power shall be simulated to prove proper operation of control
features, alarms, status, and the capability to cause the standby power generation
system to start, transfer power, and operate continuously without operator
assistance. It is recommended that testing procedures follow guidance in NFPA 110,
5-13. The field test shall be conducted by the Contractor and the manufacturer's
representative in the presence of the Officer-in-Charge. All costs of testing, including
fuel, a supplemental load bank or an outside testing agency, shall be borne by the
Contractor. Also at this time, the City’s load sequencing controls will be implemented
for operation in conjunction with the generator operation. The Contractor shall refer
to Section 01660 for additional details regarding these testing requirements.
C.
At the completion of testing, the bulk fuel storage tank shall be provided with a full
level of fuel.
D.
Provide manufacturer's service representative to assist
assist and supervise network
testing of ICP 800,101 with plant’s process control system in compliance with
Section 17030. Provide testing collaboration for data exchange through the plant’s
process control system with Section 17030 – Testing Manager.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-29
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
3.05
3.05
TRAINING
A.
3.06
3.06
The manufacturer's representative shall provide three days training for City
operations staff and additional three days to City maintenance staff. Training shall
be certified on Form 11000-B specified in Section 01999. The training shall include
the following:
1.
Operation of the generator sets including manual start-up and automatic
operation with the automatic transfer scheme.
2.
Routine maintenance.
3.
Troubleshooting.
4.
Instruction on generator control and monitoring equipment, specialized tools,
or instruments shall be provided.
5.
Technical review of the control logic using elementary diagrams.
MEASUREMENT AND PAYMENT
A.
The cost for Low Voltage Diesel Engine Standby Generator Set shall not be paid for
directly, but shall be considered incidental and included in the lump sum bids for the
respective line items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11081-30
ADDENDUM NO. 3
LOW VOLTAGE DIESEL ENGINE
STANDBY GENERATOR SET
SECTION 11083
LOW EMISSION DIESEL ENGINE STANDBY GENERATOR SET
PART 1--GENERAL
1.01
SUMMARY
A.
This Section specifies a diesel engine-generator set that will be operated to provide
standby power. The engine-generator set includes, but is not limited to, the following
components: Diesel engine; generator; grounding resistor, current and potential
transformers; electric starter, starting and control batteries and chargers; cooling
system equipment; day tank system with duplex transfer pumps and level controls;
super critical grade exhaust silencing system; operating and safety shutdown
controls; free-standing engine generator control panel; intake air cleaner; lubrication
system; engine block heater; and vibration isolation base and connectors.
B.
TYPE: The generation unit shall be driven by a heavy-duty, four-stroke, 1,800 rpm,
turbocharged, diesel-powered, internal combustion engine suitable for standby
operation at constant speed under the specified conditions. The unit may run
continuously for several days. The generator shall be a three-phase, three-wire, six
lead, wye-connected, resistive grounded, revolving field, brushless, permanent
magnet excited, synchronous type.
C.
EQUIPMENT LIST:
Item
Engine Generator
Resistor
Control Battery Charger
Starting Battery Charger
Control Power Battery
Starting Battery
Exhaust Silencer 1
Exhaust Silencer 2
Engine Block Heater
Control Panel
Day Tank
Day Tank Control Panel
Day Tank Fuel Transfer Pump
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Equipment Numbers
Generator Components
Generator 1
Generator 2
GEN 400,101
GEN 400,201
NGR 400,102
NGR 400,202
CHGR 400,115
CHGR 400,215
CHGR 400,116
CHGR 400,216
BAT 400,115
BAT 400,215
BAT 400,116
S 400,113
S 400,114
HTR 400,105
ICP 400,101A
Fuel System
T 400,121
ICP 400,121
P 400,122
P 400,123
11083-1
ADDENDUM NO. 3
Generator 3
GEN 400,301
NGR 400,302
CHGR 400,315
CHGR 400,316
BAT 400,315
BAT 400,216
S 400,213
S 400,214
HTR 400,205
ICP 400,201A
BAT 400,316
S 400,313
S 400,314
HTR 400,305
ICP 400,301A
T 400,221
ICP 400,221
P 400,222
P 400,223
T 400,321
ICP 400,321
P 400,322
P 400,323
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
Item
12.47KV Disconnect
Paralleling Switchgear
Switchgear Battery Charger
Switchgear Battery
Master Coordination Panel
Coordination Panel
LOAD CONNECTION BOX
12.47KV ATS 1
12.47KV ATS 2
D.
Equipment Numbers
Electrical System
SWGR 400,103
SWGR 400,203
SWGR 400,303
SWGR 400,821
SWGR 400,822
CHGR 400,317
BAT 400,317
ICP 400,100A
ICP 400,101B
ICP 400,201B
ICP 400,301B
MEE 400,861
ATS 400,801
ATS 400,802
GENERAL REQUIREMENTS:
Generator rating, kW
1,500
Day tank, gallons/location
275/remote
Fuel suction lift required, feet
Radiator mounting
1.02
17
Skid
QUALITY ASSURANCE
A.
REFERENCED STANDARDS: This Section incorporates by reference the latest
revisions of the following documents. In case of conflict between the requirements of
this Section and the listed documents, the requirements of the Contract
Specifications shall prevail.
Reference
Title
ANSI C57.13
Requirements for Instrument Transformers
ASME PTC 17
Performance Test Code - Reciprocating Internal Combustion
Engines
IBC
International Building Code
IFC
International Fire Code
NEMA MG1
National Electrical Manufacturers Association Standards
Publication MG-1
NFPA 37
Standard for the Installation and Use of Stationary Combustion
Engines and Gas Turbines
NFPA 30
Flammable and Combustible Liquids Code
NFPA 70
National Electrical Code (NEC)
NFPA 110
Emergency and Standby Power Systems
SAE J 1349
Society of Automotive Engineers Engine Power Test Code
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-2
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
B.
GENERAL REQUIREMENTS FOR MANUFACTURERS: Equipment shall be in current
production as a standard series. All material and parts in this unit shall be new and
unused, of current manufacture, of the highest grade, and free from all defects
affecting performance. The vendor shall have available 24-hour-per-day service by
factory-trained technicians and shall have a manufacturer's authorized dealer's parts
and service facility located within 50 miles of the job site.
C.
UNIT RESPONSIBILITY:
D.
1.
The provider of the diesel generators and paralleling switchgear shall be the
responsible distributor and have unit responsibility for the components
specified in this Section as well as in Sections 16911, 16281, 17621, and
13210. The responsible distributor shall select all components of the system
to assure compatibility, ease of construction and efficient maintenance. The
responsible distributor shall coordinate selection and design of all system
components such that all equipment furnished under the Specification for
the equipment system, including equipment specified elsewhere but
referenced in the Specification, is compatible and operates properly to
achieve the performance requirements specified. This requirement for unit
responsibility shall in no way relieve the Contractor of his responsibility to the
City for performance of all systems as provided in other parts of the contract
documents.
2.
A Certificate of Unit Responsibility, Form 11000-C, shall be provided. The
certificate shall be signed by an officer of the manufacturer's corporation and
shall be notarized. No other submittal material will be processed until a
Certificate of Unit Responsibility has been received and found to be
satisfactory. Failure to provide acceptable proof that the unit responsibility
requirement has been satisfied will result in withholding approval of progress
payments for the subject equipment even though the equipment may have
been installed in the Work.
FACTORY TEST:
1.
General: The factory tests shall be completed as part of this Contract. Each
engine-generator set shall be subject to both static and operating testing as
described below. In addition, the generator shall be factory tested as
described below. The Contractor shall submit copies of the results of the
factory test(s) to the Officer-in-Charge for approval. Shipment of the
generator set from the factory shall not be approved until factory test results
and certification documents are accepted and approved by the Officer-inCharge.
2.
Static Testing: The entire unit, including control panels and accessories, shall
be adequately tested on a major components basis, using static methods to
ensure that all safety devices and control circuits are properly installed,
aligned and connected. All trim piping shall be pressure tested, and all
regulators, solenoid valves, etc., tested for proper function.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-3
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
3.
Operating Tests:
a.
The engine-generator unit shall be set up in a test cell and operated
to determine its operating characteristics under various loads. The
tests shall be conducted in accordance with SAE J 1349 and NEMA
MG-1.
b.
Engine and generator monitoring systems shall be verified to be
operating accurately. Control panel instrumentation, gauges, back
lighting, switches, etc., shall be confirmed to be operating correctly.
c.
The paralleling Switchgear and the generators shall be wired together
and operated. All functions, interlocks, and software shall be tested.
d.
The engine generator test shall include full load steady-state and
transient response testing including engine and generator voltage dip
and load data via step loading. The engine generator shall be factory
tested under the following cumulative step loading conditions:
i.
ii.
iii.
iv.
v.
Step Load 1: Resistive load equivalent to 25 percent of
engine kW rating.
Step Load 2: Resistive load equivalent to 25 percent of
engine kW rating.
Step Load 3: Resistive load equivalent to 25 percent of
engine kW rating.
Step Load 4: Resistive load equivalent to 25 percent of
engine kW rating.
The maximum allowable voltage dip shall be 20 percent for
each loading step. The voltage dip shall recover to 2 percent
of rated voltage within 2 seconds.
e.
The complete unit shall be subjected to a continuous operating test of
at least 8 hours with 2 hours at half load, 2 hours at three quarters
load, and 4 hours at full load.
f.
Records, in addition to the information required by SAE J 1349, shall
be provided for all specified tests. In addition to the tests required by
SAE J 1349 and NEMA MG-1, testing shall minimally include the
following tests:
i.
ii.
iii.
iv.
v.
vi.
vii.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Average starting time for not less than five cold starts.
Records shall include test cell temperature and number of
cranking cycles before successful start.
Fuel consumption at 50, 75, and 100 percent rated load.
Voltage and frequency transients upon application and
removal of rated load. Values shall be recorded on high
speed charts to provide accurate definition of response.
Voltage regulation.
Rated power.
Maximum power.
Winding resistance.
11083-4
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
E.
Winding insulation resistance.
Open circuit saturation.
Current balance on windings.
Voltage balance on windings.
Regulator range test.
Phase sequence.
Mechanical balance.
Emissions conformance. Each engine will not be individually
emissions tested but will have a label affixed certifying EPA
emissions conformance.
All alarms, indicators, and protective functions specified in
this section.
g.
In addition to the specified testing, a torsiograph analysis shall be
performed to verify that the engine-generator set, as configured, is
free from harmful torsional stress.
h.
The results of the factory tests shall be certified by the quality control
department as overseen by factory-engineering group of the
manufacturer's.
i.
The Factory Testing shall be witnessed by two representatives of the
City. The Contractor shall pay air fare, rental car, hotel and meal
expenses for the representatives of the City to travel to and from the
test site and to witness the test, minimum of two days. A project test
schedule and copy of proposed test procedures shall be provided at
least 60 days in advance of test data. The Officer-in-Charge shall be
given 45 days notice and confirmation of actual test date(s).
PROFESSIONAL ENGINEER DESIGN REQUIREMENTS:
1.
Foundation: The engine-generator anchoring system and anchor bolt design
as specified within this Section shall be performed under the direct
supervision of a Hawaii registered professional engineer routinely engaged in
this type of work and shall follow the design guidelines in Section 01900.
2.
Mass Elastic System and Critical Speeds: The mass elastic system,
consisting of engine, flywheel, generator, intermediate couplings and
accessories attached to the power train, shall be designed to be free from
dangerous torsional vibratory criticals and critical speeds from 25 percent
below to the unit's operating synchronous speed. All necessary torsional
calculations and the evaluation of the mass elastic system shall be
performed under the direct supervision of a registered professional engineer
routinely engaged in this type of work. The registered professional engineer
shall produce a sealed and signed report setting forth the results of the
analysis and recommendations, if any, for controlling torsional vibration and
critical speeds. The report shall be submitted as part of the factory operating
tests as specified within this Section.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-5
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
1.03
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
GENERAL:
C.
1.
A Certificate of Unit Responsibility as specified within this Section.
2.
A copy of the factory test report as specified within this Section.
3.
Outline and installation drawings (plans and sections) for the complete
engine generator set, day tank system, exhaust system, and generator
control panel showing the location, size and other details for the mounting of
the set and electrical and monitoring connections.
4.
Wet weight of complete unit and of heaviest single component.
5.
Mass elastic system calculations.
6.
Foundation, mounting and isolation requirements and vibration isolation
system transmissibility calculations.
7.
Manufacturer template locations for stub-up of conduits at the engine
generator equipment pad, engine generator control panel, and automatic
transfer switch.
8.
Field test procedures for approval 14 days prior to testing.
9.
Seismic design drawings, calculations, and data as specified in Section
01900.
ENGINE:
1.
Torque, brake horsepower, and fuel consumption curves for the specified
conditions.
2.
Complete fuel piping schematics for day tank and engine-mounted auxiliaries
showing the relative position of all piping, filters, valving, and appurtenances
and including fuel regulatory data. Provide catalog information and operating
description of day tank fuel storage and transfer system. Provide day tank
control schematics.
3.
Details of governing system.
4.
Cooling system design data, including heat rejection to jacket water,
intercooler, lube oil, ambient air, and exhaust.
5.
Complete lube oil piping schematics showing the relative positions of all
valving, pumps, filters, temperature and pressure detectors.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-6
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
6.
Complete cooling water piping schematics, showing the relative position of all
pumps, temperature and level detectors, remote radiator, heat exchangers
and safety devices, and the rate of flow in all cooling water circuits.
7.
Complete details of all safety devices and pressure, temperature, and level
switches.
8.
Manufacturer’s model number and descriptive information.
9.
Sound pressure level data by octave band for engine casing plus radiator,
generator, and engine exhaust components at 50 feet distance.
10.
Engine starting:
a.
b.
c.
d.
e.
D.
Engine cranking voltage.
Number of batteries.
Battery rating of completed bank, amp-hour.
Battery dimensions.
Recommended size of battery cables, AWG.
11.
Radiator airflow and static pressure (external to radiator).
12.
Exhaust gas flow rate, in acfm, and temperature at rated condition.
13.
Exhaust silencer pressure drop versus air flow.
14.
Exhaust silencer sound insertion losses and selfself-generated noise per octave
band.
15.
Heat rejection to atmosphere from generator engine casing and generator.
16.
Circuit information for engine block heater.
GENERATOR:
1.
Weight.
2.
Stator and field ratings including temperature rise at full load and overload
conditions.
3.
Complete description of insulation system.
4.
Generator impedances: Xd, Xq, Xd', Xd", X2, Xo.
5.
Catalog data showing kVA, full load amperes, etc.
6.
Generator decrement curve.
7.
Available fault current.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-7
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
E.
F.
8.
Neutral grounding resistor.
9.
Generator nameplate data.
LOAD CONNECTION BOX
1.
Design with the outline and installation drawings (plans and sections),
2.
Nameplate Drawing / Schedule
3.
Electrical wiring diagrams
4.
Data showing electrical ratings specified.
5.
Catalog product data for components, cable, connectors, and terminations.
ENGINE GENERATOR CONTROLS AND POWER DISTRIBUTION:
1.
A copy of the complete wiring, panel, elementary and process/
instrumentation diagrams for the generator engine control, power
distribution, voltage regulation and excitation circuitry showing identified
terminals and identified conductors. The diagrams shall show any addenda
updates that apply to the equipment in this Section marked to show specific
changes necessary for the supplied equipment. If no changes are required,
the drawing shall be marked, "No Changes Required."
2.
Catalog information for all panel face instruments, meters, gauges, switches,
devices, skid mounted termination boxes, terminal strips, the control panel
lighting configuration and method.
3.
Complete step-by-step functional descriptions of the operation of each
control circuit.
4.
Conduit stub-out locations.
5.
Interconnection Diagrams for entire system including the generator,
generator control panel, paralleling switchgear, fuel system.
6.
Network configuration files (such as electronic data sheet, EDS) for data
exchange with the plant’s process control system or KAIKAI-PCS.
7.
Vendor--toNetwork diagrams detailing the network linking between Vendor
to-Vendor
KAI--PCS.
panels and the plant’s process control system or KAI
G.
Operation and maintenance information specified in Section 01730, including parts
list.
H.
Copies of all generator test documentation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-8
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
1.04
I.
Finalized, complete as-constructed, electrical wiring, panel, elementary and
process/instrument diagrams showing connection and interconnection of identified
terminals and identified conductors to components of the complete electrical system.
J.
Warranty as specified within this Section.
K.
Manufacturer’s certification of installation with Reference Form 11000-A.
L.
Manufacturer's instruction certification with Reference Form 11000-B.
M.
Each engine shall have a label affixed certifying EPA conformance.
SYSTEM DESCRIPTION
A.
GENERAL: The generator set shall include the capability of automatically controlling
generator set operation. After starting, the unit will attain rated speed and voltage,
and accept rated load. Generator set speed shall be controlled by the engine
governor, while generator output voltage regulation shall be a function of the
generator automatic voltage regulator. Manual adjustment of generator speed and
voltage at the generator control panel shall be provided. The generator set start,
stop, and cool-down sequences shall be initiated manually or automatically by the
closing or opening of a contact. The control system shall automatically engage the
cranking motor, sense engine starting speed, disengage the motor, and arm the
engine protection circuit.
B.
AUTOMATIC MODE: The engine-generator shall operate as follows in automatic AUTO
mode. Upon receipt of a start/run signal (closed dry contact) from the automatic
transfer scheme (initiating starting) as specified in Section 16281, the engine shall
immediately start. The engine controls shall bring the engine up to operating speed and
stabilize it at a generator frequency of 60 Hz. The generator controls shall excite the
generator field and stabilize the output at 12,470 V. The generator controls shall
interface with the paralleling switch gear generator coordination panels to enable
synchronization of generators to a common bus and to load share equally across the
running generators.
1.
The generator coordination panels shall automatically control the following
circuit breakers in the paralleling switchgear:
a.
b.
c.
d.
e.
f.
C.
CB 400,821 – Main 1
CB 400,822 – Main 2
CB 400,823 - Tie
CB 400,824 – Gen 2
CB 400,825 – Gen 1
CB 400,826 – Gen 3
RUN MODE: Operation of the engine-generator in the MANUAL mode shall be the
same as in the automatic mode except that the engine start/stop signals shall be
manually initiated from the engine control panel. When manual engine-generator
operations are no longer desired, the generator’s control panel selector switch shall
be placed in automatic and aligned for engine starting by automatic means from the
auto transfer scheme upon loss of normal power.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-9
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
D.
TEST MODE: The generators shall start and run in response to a “Test Run”
command. Test runs may be conducted with either no load or plant load.
E.
ENGINE DESIGN REQUIREMENTS:
1.
General: The engine shall be rated as follows:
a.
b.
c.
d.
e.
Maximum piston speed: 2,500 feet per minute
Rotational speed: 1,800 rpm, maximum
Fuel: Diesel No. 2, low sulfur
Minimum external fan backpressure: 0.5 in wc capability (after
radiator)
Fuel consumption, maximum gallons per hour: 110
2.
Exhaust Silencing: The engine-generator shall be provided with two Critical
Application Series exhaust silencers installed in series. The engine exhaust
silencers shall be supported above the engine as shown and shall be of the
horizontal, multi-chamber, tuned port type unless otherwise shown. The
combination of exhaust piping design and silencers shall provide a minimum
sound level attenuation per this section.
3.
Exhaust Emissions: The engine shall be specifically designed to minimize the
discharge of gaseous pollutants to the atmosphere. The engine shall be
certified EPA emissions conformance Tier 2.
4.
Fuel Control Systems: Fuel control systems shall be capable of continuously
monitoring engine operating performance and adjusting the operating
parameters to obtain optimum emissions and fuel consumption levels
without loss or dip in power. Such adjustments shall be accomplished in a
manner that will not reduce engine efficiency or result in greater pollutant
emissions. The engines shall operate efficiently from 50 to 100 percent of
the specified rated output; exhaust emission characteristics must be
maintained at all engine loading conditions without manual engine
adjustments. The use of a catalytic converter is not acceptable.
5.
Service Piping: The engine vendor shall be responsible for properly sizing the
service piping within the engine and cooling water systems. The engine
vendor shall also be responsible for all flexible connections between the
engine-driven pump set and field piping. All service piping to and from the
engines shall be routed along and anchored to the engine subbase. The
connection to field piping shall be made with flexible metal hoses at the
backs or sides of the engines. No valves or pressure regulators shall be
installed on the engine side of the flexible connections.
6.
Skid-Mounted Radiator Engine Cooling: Each engine cooling system specified
with a skid-mounted radiator in this Section shall be a closed-loop, air-cooled,
front-mounted radiator type. Engine jacket water and auxiliary water from the
closed-loop cooling system shall be circulated through the engine jacket, and
all auxiliary circuits, through a generator-set-mounted radiator by an enginedriven pump. Radiator size and water flow rate shall be calculated to limit
temperature rise in the room to 13 degrees Fahrenheit.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-10
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
F.
7.
Block Heater: The engine cooling water system shall include an electric
heater for the engine jacket coolant, which shall keep the engine block warm
to facilitate quick starts and immediate application of full load.
8.
Vibration Isolation: The engine/generator skid shall include vibration isolation
between the skid frame and the structure. Isolation shall be Type F per
Section 11021 with 22-inch static deflection.
GENERATOR DESIGN REQUIREMENTS:
1.
2.
3.
General: The generator shall be rated as follows:
a.
Rated kW: As specified within this Section at 1,800 rpm with 0.8
power factor.
b.
Output voltage: 12,470V, three-phase, three-wire, six lead, wye
connected, with center tap resistive grounded as shown in the
Drawings. The generator manufacturer shall size the grounding
resistor to allow a maximum fault current of 200A. The rating of the
resistor shall be 10 seconds or greater.
c.
Insulation: Class H, with Class F temperature rise.
d.
Lugs: The generator shall have bus bars for connection of medium
voltage cables and shall have space for terminating 2 sets of 500
kCM cables.
Voltage: The following voltage requirement shall be provided:
a.
Steady-state nominal voltage at rated kW: 12,470V, three-phase,
three-wire.
b.
Manual adjustment: ±5 percent of nominal.
c.
Regulation: Not to exceed 1 percent.
d.
Steady-load bandwidth: Not to exceed ±0.5 percent.
e.
Transient response: The transient voltage response shall not exceed
20 percent and the recovery shall not exceed 2 seconds
f.
Voltage waveform distortion from no load to full linear load shall not
exceed 5 percent total harmonic distortion. No single harmonic shall
exceed 3 percent.
Frequency: The following frequency requirements shall be provided:
a.
Steady-state nominal frequency at rated kW: 60 Hz.
b.
Manual adjustment: 56 to 64 Hz.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-11
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
c.
Synchronous operating speed at nominal frequency: 1,800 rpm.
d.
Regulation, no load to full load: Isochronous: ±0.25 percent.
e.
Steady-load bandwidth: Not to exceed ±0.5 percent.
f.
Transient response: Based upon 25 percent load steps.
1)
2)
G.
Dip, with step application of loads as indicated above, shall
not exceed 3 percent.
Recovery time: Not to exceed 2 seconds.
ENGINE-GENERATOR CONTROL PANEL DESIGN REQUIREMENTS:
1.
Electrical Diagrams: Furnish complete wiring, panel, elementary and
process/instrumentation diagrams shown in point-to-point fashion for the
engine-generator engine control, paralleling switchgear, power distribution,
voltage regulation, and excitation circuitry. Provide breaker status via a red
LED type light for breaker closed and a green LED type light for breaker open.
The vendor shall be responsible for determining conduit and conductor sizes
for all devices and controls furnished under this Section. Elementary
diagrams, schematics, and one-lines, shall show the scheme or sequence in
which the devices of the generator engine control system, generator
coordination panel, power distribution, voltage regulation, breaker control,
and excitation circuitry are connected in relation to each other. Panel
diagrams shall show the physical location of the parts of an electrical system.
In each case, every conductor and terminal shall be labeled and identified.
2.
Electrical Energy Source: Normal electric power for control shall be 24 VDC
from the control batteries. The engine vendor shall be responsible for
providing any voltage transformation equipment required.
3.
Engine Controls and Instrumentation: All engine control and instrumentation
systems shall be integrated into a free-standing engine generator control
panel which shall be bottom fed. All conductors and cables that interface
with devices mounted on the generator skid to devices mounted off the skid
shall leave the generator skid from grouped termination boxes. Provide
labeled terminal strips and conductors at the engine-generator control panel
and at the termination boxes for these circuits. Conductors entering the
control panel shall land on labeled terminal strips prior to final connections
on the discrete components. Operator control devices, gauges, meters,
machine monitoring, etc., associated with engine shall be face-mounted in
the control panel. Terminal boxes shall be provided on the engine generator
set for interfacing power, control, and monitoring circuits between the control
panel and the engine generator set. All terminal boxes shall utilize labeled
terminal strips and conductors.
4.
Provide relays as specified on the Drawings to control the motorized dampers
for the generator intake and exhaust louvers. Dry contacts from the relays shall
de-energize the motorized dampers when the engine receives a run signal. Dry
contacts rated 120VAC, 10 amp inductive minimum.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-12
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
5.
1.05
ENVIRONMENTAL CONDITIONS
A.
1.06
Equipment shall be installed in locations as shown on the Drawings. Refer to Section
01800 for environmental design conditions.
SHIPMENT, STORAGE, AND HANDLING
A.
1.07
The equipment to be furnished under this Section shall be shipped to the site with
weathertight covers on all piping and electrical connections. All shaft housing
penetrations shall be sealed in a manner that shall protect against damage from the
elements and deterioration of the equipment due to moisture, corrosive gases, dirt
and debris. Additionally, each individual shipment shall be packaged in a manner
designed to protect the equipment against damage caused by sudden acceleration
or deceleration, and shall have an accelerometer affixed to the unit prior to
shipment.
EXTENDED WARRANTY
A.
In addition to the warranty specified in Section 01730, the manufacturer's and
dealer's extended warranty shall in no event be for a period of less than five years
from date of initial start-up of the system. The warranty shall include sections
identified under Unit Responsibility (16281 and 16911). It shall include a local
cylinder head exchange program, repair parts, labor, reasonable travel expense
necessary for repairs at the job site, and expendables (lubricating oil, filters,
antifreeze, and other service items made unusable by the defect) used during the
course of repair. Applicable deductible costs shall be specified in the manufacturer's
warranty. Submittals received without written warranties as specified will be rejected
in their entirety. A warranty nameplate of not less than 152 mm x 203 mm (6 in x 8
in) must be affixed to the generator set with the following data:
1.
2.
3.
4.
5.
6.
7.
1.08
All indication, gauges, meters shall be 24 VDC back lighted devices or the
control panel shall be provided with 24 VDC control panel face lighting that
shall be mounted at the top of the panel and provide suitable lighting for
clear and easy viewing of the panel face mounted devices.
Warranty Period:
Start-up Date:
Termination Date:
Vendor Name:
Vendor Address:
24-Hour Emergency Number:
Preventive maintenance to be performed by:
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. Contractor shall design the structural
components, seismic attachment, braces, and anchors to the structure for all parts
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-13
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
or elements of the mechanical and electrical systems in accordance with Section
01900.
B.
Vibration Isolation: The engine/generator skid shall include vibration isolation
between the skid frame and the structure. Isolation shall be Type F per Section
11021.
PART 2--PRODUCTS
2.01
2.02
ACCEPTABLE PRODUCTS
A.
GENERAL: The following candidate manufacturers are capable of producing
equipment and/or products that will satisfy the requirements of this Section. This
statement, however, shall not be construed as an endorsement of a particular
manufacturer’s products, nor shall it be construed that named manufacturers’
standard equipment or products will comply with the requirements of this section.
B.
ENGINE: Candidate manufacturers include Caterpillar and Cummins.
C.
GENERATOR: Candidate manufacturers include Caterpillar and Cummins.
D.
SILENCER: Candidate manufacturers include Beaird, Maxim, Nelson, or approved
substitute.
E.
DAY TANKS: Candidate manufacturers include Simplex, Tramont, Pryco, or approved
substitute.
F.
JACKET WATER HEATER: Candidate manufacturers include Kim Hotstart, Chromalox,
or approved substitute.
G.
FUEL COMPUTER: Candidate manufactures include Flowscan series 8500/8600, or
approved substitute.
ENGINE COMPONENTS
A.
GENERAL:
1.
Each diesel engine-generator set shall consist of a skid-mounted engine
radiator system and heat exchanger(s), engine-mounted accessories, and
direct-connected generator, all mounted on a rigid base and frame. All
engine accessories shall be installed by the engine vendor. The frame shall
be supported by steel spring isolators rated for not less than 98 percent
isolation efficiency (2-inch static deflection). Anchor bolts shall be provided
and designed as specified in Section 01900.
2.
Flexible couplings for jacket water, lube oil, fuel, and exhaust piping shall be
provided. Water connectors braided, fiber jacketed rubber hoses. Oil and fuel
connectors shall be braided stainless steel jacketed rubber hoses. All hoses
shall be, at a minimum, 150 psig working pressure. Fuel connectors shall
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-14
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
bear the Underwriters Laboratories label. The exhaust connector shall be
unbraided, stainless steel, suitable for temperatures up to 1,300 degrees F.
3.
B.
Engine couplings shall be as follows:
a.
Exhaust flex will be stainless steel bellows with carbon steel turbo
and muffler connections. Exhaust flex shall be in alignment.
b.
Fuel flex connections will be rubber lined with stainless braiding on
the outside.
c.
Radiator hoses will be rubber with fiber braiding.
ENGINE:
1.
General: The engine shall be a four-stroke cycle, turbocharged, water-cooled,
diesel fuel unit capable of meeting the design and performance requirements
operating on No. 2 diesel fuel.
2.
Base and Frame:
a.
The engine base shall be of rigid construction with heavy transverse
girders formed to support the crankshaft main bearings.
b.
The engine frame shall be a suitable box shape to provide
longitudinal and transverse rigidity.
3.
Cylinders: Cylinders shall be cast with the engine block. Engine block shall
be cast iron with replaceable wet liners. All cylinder liners shall be finished to
give a straight bore, shall be machined and honed.
4.
Cylinder Heads: Cylinder heads shall be of the individual valve-in-head type
constructed of cast iron with valve guides and plug sockets fully jacketed for
efficient cooling. Renewable hardened steel inserts shall be provided for all
valve stem guides. Valve seats shall be made of hardened steel selected
specifically for high temperature service.
5.
Crankshaft: The crankshaft shall be made from a single forged steel billet
and heat treated. The crankshaft shall be sized to provide a liberal margin of
safety against abnormal strains. Journals shall be hardened and
micropolished. The shaft shall be finished all over, drilled and ported for
pressure lubrication of all bearings and statically and dynamically balanced
after fabrication. If of two-piece design, the crankshaft shall be machined
and balanced as a single unit.
6.
Main Crankshaft Bearings: The main crankshaft bearings shall be amply
sized and shall be arranged for replacement without removing the
crankshaft. To provide proper support for the flywheel, the bearing at the
flywheel end of the engine shall be of greater area than the intermediate
crankshaft bearings. Bearing caps shall be fitted into place and bolted to the
frame.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-15
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
7.
Connecting Rods and Crank Pin Bearings: The connecting rods shall be
made of heat-treated steel forgings. The crank end of the rod shall be of tee
foot design for use with two-piece babbitted or sleeved crank pin boxes.
Provision shall be made for the use of large through bolts to securely fasten
the crank pin boxes to the foot of the rod. The design shall permit removal of
the piston and connecting rod through the cylinder liner. Oil jets shall supply
piston cooling and lubricating oil; drilled connecting rod passages will not be
permitted.
8.
Flywheel: The flywheel shall be of heavy-duty design and one-piece
construction and shall be made of high-grade close-grained cast iron.
Torsional dampers, if required, shall be of the viscous type.
9.
Pistons: Pistons shall be of the oil-cooled made of close-grained cast iron or
aluminum alloy accurately machined to size. The piston shall be long in
proportion to the diameter and shall be fitted with not less than two
compression and one oil control rings. The oil control rings may be located in
the piston skirt or above the wrist pin.
10.
Piston Pins: Piston pins shall be made of high-grade steel, hardened and
ground to ensure a fine running fit. They shall be either of the type that are
fitted into the pistons so as to prevent rotation in the pistons but permitting
free expansion of both pistons and pins, or of the full floating type held
longitudinally by retaining rings fitted into the wrist pin bore of the piston.
11.
Valves and Valve Gear: Inlet and exhaust valves shall be precision machined
and shall be made of the highest grade heat-resisting material. Valve seats
shall be replaceable, of heat resistant high alloy steel. Valves shall be the
largest possible diameter so as to produce the greatest volumetric efficiency
and adequate scavenging of the cylinders in order to keep valve maintenance
to a minimum. All valve mechanisms shall be constructed so as to provide
positive action with utmost rigidity. Two intake and exhaust valves shall be
provided in each cylinder head.
12.
Camshaft: Camshafts shall be alloy steel forgings with integral cams,
machined, heat-treated and ground with polished bearing and contact
surfaces. The camshafts shall be chain driven or driven through gears front
and back.
13.
Gear Train: Gears shall be lapped and shaved for uniform loading and quiet
operation.
14.
Exhaust Manifold: Exhaust manifolds shall be single-outlet or, if in pairs,
shall be joined to provide a single exhaust outlet for the engine. A flexible
stainless steel expansion bellows shall be provided at the outlet whose style
shall be coordinated with the location of the silencer mounting as shown.
Exhaust manifolds shall be shielded or insulated to reduce surface
temperature to a level that would prevent injury.
15.
Engine/Crankcase Breather: The engine breather(s) shall be equipped with
crankcase ventilation filter(s) to remove oil mist coming from the crankcase
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-16
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
breather vent. Neither oil fumes nor condensed liquid oil shall be discharged
to the room. Return connection point from the filter shall be as directed by
the engine manufacturer. Connections of liquid or gas lines to the engine’s
exhaust air plenum, if any, shall be separated by flexible connectors. Product
shall be similar to Nelson Ecovent Recirculator.
C.
16.
Turbocharger and Aftercooler: The engine combustion air shall be
pressurized using exhaust gas driven centrifugal compressor(s). An
aftercooler, selected specifically for use with the closed loop engine cooling
system, shall be provided for cooling the combustion air.
17.
Air Filters: The engine shall obtain the necessary volume of combustion air
through inlet air filters of the dry panel type with replaceable filter cartridges
and service indicator. Separate filters shall be provided for each cylinder
bank. The filters shall be mounted on the engine or engine skid so that they
are easily maintained yet do not block maintenance of other engine parts.
FUEL OIL SYSTEM:
1.
General: The engine manufacturer shall be responsible for both design and
provision of a fuel oil delivery system meeting the functional requirements of
this paragraph. The system shall contain the features specified, and
additional components as necessary to provide a complete and operable
system. The fuel oil system shall provide for fuel return to the bulk tank from
the day tank, and fuel delivery from the day tank to the engine. Major
components include a double-walled day tank with duplex return pumps, level
and pump controls, engine driven injector pump, and fuel filtration. Fuel oil
piping is specified in Section 15050. Flexible connections shall be provided
at fuel piping connections to the engine.
2.
Remote Day Tank:
a.
Day Tank Fuel Transfer System: The day tank and fuel transfer
system shall be specifically designed for operation with above grade
bulk storage tanks. The system shall prevent siphoning or back
siphoning of fuel between the day tank and the bulk storage tank.
The system shall return any day tank overflow to the bulk storage
tank with the use of transfer pumps and without pressurizing the day
tank and supply feed to the engine greater than recommended by the
engine manufacturer. The system shall include a day tank; duplex
electric fuel transfer pumps; and a day tank control panel with all
controls and accessories to automatically operate the transfer pumps
(from day tank to storage tank and from storage tank to day tank)
pumps, indicate status conditions, and transmit information to the
engine generator control panel and meets the specification
requirements of Section 17110. The size of the day tank and
equipment numbers for the tank, control panel, suction lift, and
pumps shall be as specified within this Section. Accessories shall be
listed to provide for a complete and functional system.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-17
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
b.
Day Tank: Day tank shall have a capacity as specified within this
Section. Tank shall comply with NFPA 30, NFPA 37, and be UL 142
and UL 508 rated. It shall be an above-ground, double-wall steel tank
pressure tested to 5 psig. Tank shall be heavy gauge steel,
continuous seam welded with internal reinforcement, and suitable for
diesel fuel application, with welded pipe fittings of the sizes shown for
fuel supply and return, overflow, vent and drain, and machine formed
fuel supply suction tube. Tank shall be provided with heavy gauge
steel channel feet with mounting holes, all necessary mounting
attachments, and a removable steel top cover. The tank exterior shall
be shop primed and painted with epoxy enamel to match the
generator set. Tank elevation shall be as required by the engine
manufacturer to prevent flooding of the engine. Tank shall include
the following features:
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
Manual fill port with lockable cap and drop tube.
Manual hand pump inlet.
Day tank level indicator and control.
Day tank temperature indicator and control.
Leak detector switch between inner and outer walls.
Suction siphon prevention and prime retention solenoid
valves on each fill pump inlet.
Three-valve bypass on each solenoid and strainer.
Drain with hand valve.
Vent line.
Vent cap.
Atmospheric vent.
Emergency vent.
Secondary containment drain with valve.
Gravity drain for overflow basin.
Level control panel (UL 508).
Duplex fuel transfer pumps.
Check valve for each pump.
Fuel line isolation and automatic closing, fusible link (165
degrees F) valves.
One capped 2” diameter spare connection without dip tube.
c.
Fuel Transfer Pumps (from day tank to storage tank): Pumps shall be
pressure loaded, self-compensating, positive displacement gear
pumps. Pump motors shall be 480V TEFC, 1,200 or 1,725 rpm as
needed, continuous duty 40 degrees C ambient, Class B insulation
equipped with overload protection. Fuel transfer pumps (from
storage tank to day tank) are specified in Section 13210.
d.
Day Tank Control Panel: Day tank control panel shall be 480V with all
necessary transformers to reduce voltage as needed by other day
tank components. The day tank control panel shall automatically
maintain the proper fuel level in the day tank and prevent siphoning
or back siphoning of fuel between day and bulk storage tanks. It shall
automatically operate the transfer pumps (from day tank to storage
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-18
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
tank and from storage tank to day tank).For the transfer pumps from
the day tank to the storage tank the day tank panel shall alternate
their starting, indicate status conditions, and transmits information to
the engine generator control panel and KAI-PCS. The day tank control
panel shall include fuel transfer pump running indicators, pump fail
alarm output, high/low/leak alarm conditions, day tank level
indication, and shall allow for manual operation of fuel supply and
return pumps. All wiring for instrumentation, control, and power shall
be provided and terminated at termination strips. Provide control
power transformer. Controls shall be housed in a NEMA 12 enclosure
that can be field-mounted and meets the specification requirements
of Section 17110.
e.
Day Tank Sequence of Operation: The day tank panel transfers fuel
from the day tank to the storage tank, and signals the storage tank
panel to transfer fuel from the storage tank to the day tank. The
storage tank panel transfers fuel from the storage tank to the day
tank. Day tank control panel and the storage tank panel shall provide
the following control sequence.
Day Tank Level
(percent capacity)
Low Low (10%)
Low (70%)
High (100%)
Control Response
In the day tank panel: a) The trouble alarm
contact closes. b) The critical low fuel contact
closes. c) the critical low level indicator light
illuminate
The day tank panel signals the storage tank
panel to start a pump.
At the storage tank panel: a) The lead pump
starts. If lead pump does not start, start the
lag pump and open the trouble contact. b)
Pump running indicator light illuminates and
pump running contact closes.
The day tank panel signals the storage tank
panel to turn off the pump.
The storage tank panel turns the pump off,
the pump running contact opens, and the
pump running indicator light de-illuminate
High High (106%)
High (100%)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
The day tank panel starts a pump.
The pump running indicator light illuminate
High level trouble alarm
If lead return pump does not start, start lag
return pump
The day tank panel turns off the pump
The pump running indicator light de-illuminate
11083-19
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
f.
Day Tank Panel Alarms and Statuses: Day tank control panel shall
provide the following alarms and statuses.
Alarm
Location
Fuel in rupture basin
alarm
Local and Engine-generator control panel
Critical low level
trouble alarm
Local and Engine-generator control panel
High level trouble
alarm
Local and Engine-generator control panel
Pump failure alarm
Local and Engine-generator control panel
Control system trouble
alarm
Local
Status
g.
3.
4.
Location
Pump Running
Local and Engine-generator control panel
Pump Running
Local and Engine-generator control panel
Day tank level
(gallons)
Local and Engine-generator control panel
Day Tank Alarms and Statuses hardwired to the Master Coordination
Panel (ICP 400,100A).
Fuel Appurtenances:
a.
Pressure gauge: 4-1/2-inch premium grade, glycerin filled units with
Bourdon tube element, 270-degree milled stainless steel movement,
stainless steel case, stainless steel bourdon tube, and shatterproof
glass window. Range: 0-15 psi.
b.
Gauge Valves: Machined from ASTM A276 bar stock. Use with 1/2inch NPT connections and integral bleed valve.
Fuel Metering System:
a.
The fuel metering system shall be integral with the engine. It shall
include fuel filter, transfer pump, injection pumps, lines, and nozzles.
The transfer pump shall deliver fuel under low pressure to individual
injection pumps, one for each cylinder. The pumps shall be of a
variable displacement type to alter the volume of fuel delivered to the
spray nozzles according to load demand.
b.
Fuel filters shall be of the replaceable microglass element type
designed for long service life.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-20
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
5.
D.
E.
F.
Fuel Computer:
a.
Meet EPA reporting requirements fro tracking NOx emissions.
b.
Track operation time and fuel consumption.
c.
Digital LCD Engine Hour Meter, Tachometer, Fuel Flowmeter, and Fuel
Totalizer.
d.
Switch that resets totalizer reading.
LUBRICATION SYSTEM:
1.
The engine shall be of the wet sump type, provided with a full pressure
lubricating oil system arranged to distribute oil to all moving parts of the
engine. The lubrication oil pump shall be a positive displacement type that is
integral with the engine and gear driven from the engine gear train. The
system shall incorporate full flow filtration with bypass valve to continue
lubrication in the event of filter clogging. The bypass valve must be integral
with the engine filter base or receptacle. Systems where bypass valves are
located in the replaceable oil filter are not acceptable. The filter shall be
provided with inlet and discharge pressure taps. Pressure gauges shall be
oil-filled, suitable for engine service. The oil filter shall be provided with
differential pressure indicators and shall be mounted on the subbase.
2.
Engine shall be equipped with a lubricating oil cooler, sized to cool the oil as
recommended by the manufacturer. Jacket water shall be circulated through
the water side of the oil cooler.
SPEED GOVERNING SYSTEM:
1.
The engine governor shall control engine speed and transient load response
within commercial and ISO 8528 tolerances. It shall be selected, installed,
and tested by the generator set manufacturer. The engine governor shall be
a microprocessor based speed control fuel control governor. In the event of a
dc power loss, the forward acting actuator shall move to the minimum fuel
position.
2.
Engine governing shall maintain steady-state speed regulation of 0.25
percent. Speed drop shall be adjustable from 0 (isochronous) to 10 percent
from no load to full rated load. Ramping to rated speed during start-up shall
be delayed until engine oil pressure is assured, with rate of acceleration
controlled. Rate of acceleration during start-up shall be manually adjustable.
ELECTRIC STARTING SYSTEM:
1.
General: The engine starting system shall include dual 24 VDC starting
motor(s), starter relay, and automatic reset circuit breaker to protect against
butt engagement. Batteries shall be lead acid type mounted near the starting
motor. Required cables will be furnished and sized to satisfy circuit
requirements. The system shall be capable of starting a properly equipped
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-21
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
engine within 10 seconds at ambient temperatures greater than 30
degrees F.
2.
Batteries: Starting batteries shall be selected and supplied by the generator
set manufacturer. Batteries shall be a heavy duty SLI lead acid type with
thru-partition connectors, and housed in a hard rubber or polypropylene case
with provision for venting. Starting batteries shall be rated 24 VDC with an
ampere-hour and CCA rating as specified by the manufacturer. Sizing shall
consider specific application requirements of engine oil viscosity, ambient
starting temperature, overcharging, and vibration. Starting batteries shall be
close to the starting motor. Starting batteries shall be enclosed within battery
boxes that shall be provided with separate covers. The battery box covers
shall withstand a standing weight of 300 pounds. Battery boxes shall have
adequate volume to act as a secondary containment for the battery acid.
Battery boxes shall be vented and shall be made of nonconductive and acidresistant materials. Batteries and battery boxes shall be provided in
accordance with the seismic design requirements of Section 01900. Battery
cable size shall be selected by the engine-generator manufacturer and shall
be installed by the Contractor. Battery warranty shall be the responsibility of
the generator set manufacturer. Batteries shall be maintenance free.
3.
Battery Charging: Starting 24 VDC battery charger shall be selected and
supplied by the engine-generator set manufacturer. Battery chargers to be
provided as follows:
a.
b.
c.
d.
e.
Fully automatic with manually adjustable voltage and equalize timer
Phase: Single
Hz: 50/60
120//240 VAC, 13AAC
24 VDC, 25 ADC
G.
COOLING SYSTEM, SKID-MOUNTED RADIATOR: For locations requiring a skidmounted radiator as specified within this Section, the engine jacket water cooling
system shall be a closed-circuit design with provision for filling, expansion, and
deaeration and employing a close coupled radiator with a pusher type fan. The
radiator shall be sized to cool the engine continuously while operating at full rated
load, and test overload if applicable, and at site conditions. Fan shall be belt driven
from pulley or direct coupled on engine crankshaft. Poly-V-belt or a minimum of two
individual V-belts, each of which must be capable of driving the fan if one belt fails. A
flexible connection shall be provided for connection to the fixed air discharge plenum.
The flexible connection shall be provided with the necessary angle, straps, bolts,
clips, or other fasteners to secure the flexible material to the equipment and
ductwork plenum. Coolant shall be supplied and shall be fresh water with 50 percent
ethylene glycol antifreeze with corrosion inhibitors. Three piece radiator with a top
tank, bottom tank and center core assembly for ease of assembly.
H.
JACKET WATER HEATER: Engines shall be fitted with thermostatically controlled
jacket water heater(s) designed to maintain proper conditions for quick starting
regardless of ambient temperature. The jacket water heater(s) shall be provided to
maintain a coolant temperature of 90 degrees F while the engine is not operating.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-22
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
Heaters shall include thermostatic controls and isolation valves. Heaters shall be
9000W and shall be powered with 480 VAC current. Confirm circuitry requirement in
submittal documentation.
I.
EXHAUST SYSTEM:
1.
Exhaust piping shall be provided in accordance with Section 15050. Flexible
stainless steel expansion joint(s) shall be provided as shown between the
engine exhaust manifold(s) and the silencer. A combination "Y"/elbow shall
be provided at the exhaust manifold(s) to accommodate the low head
exhaust silencer mounting if required. Engine manufacturer shall size
expansion joints to allow for thermal growth of connected equipment and
piping.
2.
Two exhaust silencers shall be provided and mounted in series. A criticalgrade type exhaust silencer upstream and a residential-grade type exhaust
silencer downstream meeting the performance requirements specified within
this Section. Silencers shall have a 3/8-inch condensate drain connection.
The silencers shall be supported by pre-engineered spring hangers unless
otherwise shown on the Drawings. Seismic restraints and hangers shall be
designed as specified in Section 01900. The silencers shall be fabricated of
heavy-gauge steel in all-welded construction with inspection ports and drain
fittings in each chamber.
3.
The exhaust system shall include means with which to relieve, prevent, or
withstand the ignition of unburned fuel in the exhaust without damaging the
exhaust system, in accordance with NFPA 37. If relief valves or rupture discs
are used to meet this requirement, they shall be vented outdoors and away
from personnel.
4.
INSERTION LOSSES: Exhaust silencers shall meet or exceed the sound
attenuation criteria listed:
Silencer Name
Exhaust Silencer 1
Exhaust Silencer 2
63
25
23
125
34
26
Octave Band Center Frequencies (Hz)
250
500 1000 2000 4000
37
33
30
30
29
25
23
22
21
20
8000
27
17
J.
FINISH: Generator set, including base, shall be completely painted with two-part
polyurethane paint mixed prior to application in accordance with Section 09900.
One quart of touch-up paint shall be provided with generator set.
K.
PROTECTIVE DEVICES: The engine shall be provided with the following devices,
factory installed and adjusted. Protective device control, alarm, and status shall be
interfaced with medium voltage ATS Section 16281, controls Section 17500 and as
indicated on the Drawings. Each device shall be suitable for use with the engine's
control circuit and shall be complete with all necessary conduit and wiring. Leads
shall be brought to a common engine-mounted terminal box located on the subbase.
Protective devices shall include the following:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-23
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
L.
1.
An overspeed switch that shall be separate from the governor and shall close
at 10 percent above synchronous speed to actuate an alarm contact.
2.
A zero speed switch designed to open whenever the engine is rotating,
including cranking. The zero speed switch shall be employed for
authentication of no engine rotation in the engine starting controls. Less
than 2 rpm shall be acceptable as zero speed.
3.
An underspeed-normal speed, snap-action, single pole, double-throw
centrifugal switch. The underspeed switch shall be adjustable from 50 to
100 percent of normal operating speed.
4.
A low oil pressure switch that closes when the pressure in the lube oil system
is below permissible operating levels.
5.
A temperature switch, mounted in the lubricating oil system, designed to
close when the oil temperature downstream from the oil cooler reaches
unacceptable levels.
6.
A mushroom head Emergency Stop button located on the generator skid to
allow for immediate shutdown of the engine generator.
7.
Protective device with dual RTDs shall be included to monitor generator
winding temperature.
8.
All devices shall be specifically designed for engine service of a type suitable
for reliable operation in the presence of continuous vibration. All contacts
shall be electrically isolated and rated as required by NEC. Conduits shall be
routed to provide maximum access to all maintenance points.
MONITORING AND MEASURING CONNECTIONS: The engine shall be provided with
suitable taps or connections available for the measurement of the following:
1.
2.
3.
4.
5.
6.
7.
2.03
Lubricating oil inlet pressure.
Differential oil pressure across each filter.
Lubricating oil inlet temperature.
Engine speed.
Intake manifold vacuum.
Jacket water inlet temperature.
Jacket water outlet temperature.
GENERATOR COMPONENTS
A.
GENERAL:
1.
Single-bearing synchronous alternator directly connected to engine through
flexible coupling.
2.
Rotating field, brushless, three-phase, three-wire.
3.
Dripproof, guarded.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-24
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
4.
Self-ventilated, air-cooled.
5.
Self-lubricated bearing.
6.
Generator rotor capable of operating at 15 percent over-speed. Balanced to
25 percent over-speed.
7.
Engine and generator torsionally compatible.
8.
Class H insulation with a Class F rise conforming to NEMA standard MG11.65.
9.
Equipment grounding shall exist:
a.
Between generator and engine.
b.
Between generator frame and transfer scheme through cable
connections.
c.
Between battery charger, control cabinet(s), conduits, generator
enclosure, wire tray(s), fuel tank, light fixtures, and any other metal
conductive parts in accordance with NEC.
10.
Neutral grounding resistor shall be sized for 10 seconds or greater and a
maximum of 200A of fault current. Installation shall include current
transformers.
11.
Generator power connections shall be located in an enclosure that is readily
accessible for inspection.
12.
Full static-type three-phase sensing voltage regulator. Microprocessor
controlled, temperature compensated with under-frequency output reduction
in response to frequency reduction below 58 to 59 Hz.
13.
Voltage and engine speed adjusting rheostats.
14.
Two-thirds pitch stator winding.
15.
Permanent magnet generator pilot exciter capable of sustaining 300 percent
of rated alternator current output for approximately 10 seconds.
16.
Maximum subtransient reactance: 17.2 percent.
17.
All termination boxes shall be readily accessible and shall be located to
access conduits stubbing up from below.
18.
Generator wiring shall permit the installation of differential protection. Six
leads shall be available for installation of CTs.
19.
Generator protection shall be as indicated on the one-line diagram.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-25
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
20.
B.
Provide compression lugs suitable for terminating medium voltage cables at
the generator connection box.
VOLTAGE REGULATOR:
1.
The automatic voltage regulator shall incorporate PMG technology and shall
maintain generator output voltage by controlling the current applied to the
exciter field of the generator.
2.
The regulator shall be microprocessor controlled and shall be provided with
three-phase rms sensing circuits and temperature compensation.
3.
The regulator shall include electronic voltage buildup and overcurrent
protection. It shall incorporate 1:1 volts per Hz characteristics with the
regulated voltage a linear function proportional to frequency over a 30 to 70
Hz range.
4.
The regulator shall be suitable for mounting within or external to the
generator assembly, and have provision for remote voltage level control,
using 16 gauge shielded wire.
5.
As installed, the voltage regulator shall meet the applicable sections of the
following standards:
a.
b.
c.
d.
C.
GENERATOR CIRCUIT BREAKER: Generator output breaker is housed in the
paralleling switchgear located in the MV Electrical Distribution Room. This circuit
breaker is for protection of the generator and for connecting or disconnecting the
generator from the paralleling switchgear bus.
1.
2.04
Canadian Standards Association (CSA).
International Electrotechnical Commission (IEC).
Institute of Electrical and Electronic Engineers (IEEE).
National Electrical Manufacturers Association (NEMA).
In the generator room there is a generator disconnect switch for each
generator. This switch shall be used when maintenance is performed on the
generator. Generator disconnect switch is specified in Section 16753
ENGINE-GENERATOR CONTROL PANEL
A.
PANEL: The bottom-fed, free-standing engine-generator control panel shall include a
voltmeter, ammeter, wattmeter, frequency meter, and a microprocessor-based
controller for local starting, monitoring, metering, and protective controls. It shall
include a communications interface module/modem for remote monitoring
capabilities. Location for mounting the engine-generator control panel is as indicated
on the Drawings. The control panel shall be provided in a NEMA 12 enclosure with a
front hinged door, is installed to be free of vibration from the running enginegenerator and meets the specification requirements of Section 17110. It shall be
powered by a dedicated 24 VDC control power battery charger and battery system.
Readily accessible interfacing terminal strips for all wires and cables leaving the
panel shall be provided. All instruments, gauges, meters shall be back lit or 24 VDC
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-26
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
lighting shall be mounted to the control panel to provide operational lighting. The
control panel shall include the minimum following features:
1.
Controls:
a.
b.
c.
d.
e.
f.
2.
Displays:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
3.
Oil pressure.
Coolant temperature.
Oil level.
Generator voltage.
Generator amperage.
Frequency.
Battery charging voltage.
Engine run time.
Generator breaker open/closed status LED lights.
Generator kilowatts.
Generator Disconnect Switch open/close status LED lights.
Status Contacts: Status output contacts shall be form C, dry contacts rated
3A resistive at 120VAC and 28VDC. Where the status is from a solid-state
component the vendor shall provide interposing relays in their cabinet that
are controlled by the solid state components to provide the dry contacts. The
normally open contacts for trouble and failure shall be held closed and open
under fail conditions, otherwise normally open contacts shall close upon
activation. The following status output contacts shall be provided:
a.
b.
c.
d.
e.
f.
4.
Manual-Off-Auto switch.
Mushroom head Emergency Stop pushbutton.
Alarms acknowledge/reset switch.
Lockout/Failure Fault reset switch. (The control design shall be such
that the fault indication shall remain until reset. The fault reset
switch shall operate only when the Run-Off-Auto switch is in the OFF
position.)
Remote Run Command.
Voltage regulator adjustment.
Generator Running (4).
Generator Common Fault (2).
Generator Common Trouble (2).
Generator in Auto (2).
Generator Ready (2).
Refer to Drawings for additional output contacts for the Generator
Control Panel, for the Generator Coordination Panel
Panel and for the
Master Coordination Panel.
Panel. The Master Coordination Panel shall be
interconnected to the process control system through both hardwired
contacts and data network.
Terminal Strips for Interconnecting Wiring: All engine-generator associated
status, alarm, analog signal, and control points shall be collected on terminal
strips within the generator control panel before the signals leave the
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-27
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
generator skid and control panel. The installing contractor shall provide
terminal strips at the interface panel and shall terminate and label wires in
accordance with the identification paragraphs of Section 16000. The wires
shall also be tagged with the noun name of the status or alarm point the
signal wires are associated with.
5.
B.
Network: Network linking
linking between generator control panels, generator
coordination panels, master coordination panel and procress control system
shall be provided to allow crosscross-communications for equipment specified in
this Section and drawings.
drawings.
MICROPROCESSOR ENGINE CONTROLLER:
1.
A microprocessor-based engine controller specifically designed for advanced
diesel engine management, monitoring, and emissions control shall monitor
all significant engine parameters, and adjust engine performance according
to speed, altitude, temperature, aftercooler temperature, and engine
condition. It shall incorporate revisable control software capable of
reconfiguring engine operation to desired performance levels. The controller
shall display a minimum of the following: volts, amps, watts, power factor,
generator running, generator ready, oil pressure and temperature, coolant
temperature, fuel level, hours, time and date of alarms, rpm, main fuel tank
level. The master coordination panel’s controller shall network to the plant
process
process control system (PCS) through Modbus/TCP or an approved substitute
protocol. The PCS network link shall only read data with ICP 400,100A as
specified in Sections 17315 and 17500.
2.
The microprocessor based controller will annunciate the following trouble and
failure alarms:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
s.
t.
Overcrank (failure).
Overspeed (failure).
Engine Temperature High (trouble and failure).
Oil Pressure Low (trouble and failure).
Generator Overcurrent (trouble and failure).
Oil Level Low (trouble).
Engine Oil Bearing Temperature High (failure).
Generator Bearing Temperature High (failure).
Generator Winding Temperature High (trouble and failure).
Oil Filter Differential High (trouble).
Underspeed (trouble).
Day Tank Leak into Containment Area (trouble).
Day Tank Low Level (two trouble levels and failure).
Day Tank High Level (trouble).
Day Tank Fuel Pump Failure (trouble).
Engine Exhaust Temperature Low (trouble).
Engine Fuel Pump Failure (failure).
Main Fuel Tank Level Low (trouble).
High DC (trouble).
Low DC (trouble).
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-28
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
u.
v.
C.
3.
All engine-mounted field switches and instruments shall have NEMA 4
enclosures which meet the specification requirements of Section 17110.
4.
The engine controller shall be configured to avoid interruption of power
whenever possible. In the event of system faults that do not require
immediate failure, the engine shall be programmed to continue operation at
power levels sufficient to remain within performance limits.
5.
The engine controller shall display real time and historical data to allow user
to optimize operation and provide accurate service information in the event
of a malfunction. Information shall be accessible through a data link for
remote monitoring. A data link failure shall not cause an interruption of
engine operation.
6.
Adjustable engine cool down timer. Adjustable range 0 to 60 minutes. Set to
5 minutes.
7.
The manufacturer’s microprocessor-based engine controller must be able to
comply with all of the items in this paragraph. If the manufacturer’s
controller can additionally perform the functions specified within this Section,
it is acceptable that those functions be performed by the controller and it is
not required to duplicate the function with separate hardware as specified
within this Section. The manufacturer, however, must identify and
demonstrate in the submittal process which of the controls and alarms are
proposed to be implemented through the controller instead of separate
control and alarm hardware. Total controls must provide all of the
functionality specified within this Section.
NAMEPLATES/PLACARDS:
1.
Provide nameplates for the engine generator control panel and its
components.
2.
Provide placard on the engine generator control panel identifying the location
of the following:
a.
b.
c.
2.05
Low Coolant Temperature (trouble).
Not in Automatic (trouble).
The location of the generator output circuit breaker.
The location of the generator output disconnect switch.
The location of the fuel day tank.
TAP BOX
A.
General: The Tap Box allows a portable load bank to be connected to the generators.
The Tap Box shall be as follows:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-29
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
B.
C.
D.
E.
Generator Manufacturer Responsibility
1.
The generator manufacturer shall be responsible for both design and
provision of a Tap Box as described in this section.
2.
The Contractor shall be responsible for the installation and testing the Tap
Box.
The Tap Box shall be rated as following:
1.
Voltage: Nominal 12.47kV, Voltage Class 15kV.
2.
BIL: 95 (kV Peak) minimum.
3.
Continuous Current rating: 200 amps.
4.
Short-Time Short-Circuit Current withstand shall match the paralleling
switchgear.
The Tap Box structure and construction shall be as follows:
1.
Enclosure stainless steel type 316.
2.
Enclosure shall have a hasp to accept a padlock. Main access door on
enclosure shall be lockable when either in-use or not in-use.
3.
NEMA 3R.
4.
Conductive bus and connectors shall be tin plated copper.
5.
Tap Box shall be constructed to be anchored to a concrete equipment pad.
6.
Tap Box shall be bottom entry for the conduits connecting to the paralleling
switchgear as identified in the raceway schedule and the conduit for future
use
7.
Tap Box shall contain a thermostat controlled strip heater (120V power
source provided by Contractor).
8.
The Tap Box shall allow the main access door to be closed and locked while
the portable equipment cable is connected to the Tap Box. Note the portable
equipment cable is routed across the surface of the terrain.
Cable and Terminations:
1.
Provide medium voltage cable to connect the Tap Box to the paralleling
switchgear circuit breaker. The cable shall be as follows:
a.
15kV rated.
b.
200A (minimum) rated.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-30
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
2.
c.
Insulation Ethylene propylene rubber (EPR), Type MV-105, continuous
current at 105 degrees C, wall thickness 133% insulation level.
d.
Shielded.
e.
Jacket Polyvinyl chloride (PVC).
f.
The medium voltage cable shall be routed in an underground raceway
provided by the Contractor.
g.
Provide electrical connectors for terminating cables.
Provide portable equipment cable(s) as follows:
a.
50 feet length.
b.
15kV rated.
c.
200A (minimum) rated.
d.
Suitable for outdoor use and routed exposed across the ground.
e.
Connectors for portable equipment cable shall include mating
connector for the Tap Box and at the opposite end an irreversible
compression connector with medium voltage cable termination.
f.
The irreversible compression connector shall be:
1.
2.
3.
4.
5.
g.
h.
F.
Uninsulated Copper terminal.
15kV rated.
90 degree C rated.
One hole – 5/16 inch stud hole size.
Long barrel with no inspection window.
Termination shall be:
1.
Meets or exceeds IEEE 48 requirements.
2.
Termination shall be installed per the manufacturer’s
instructions for shielded cables.
Cable protection shall be provided to prevent dirt, dust, debris and
water from entering the connectors and cable when the cable is not
in use.
Nameplate / Placards
1.
Provide nameplates for the Tap Box in accordance with Section 16000.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-31
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
2.
Provide the following placards for the Tap Box:
a.
b.
c.
d.
e.
f.
2.06
Phases (i.e. Phase A, Phase B, Phase C)
Ground
Phase conductor connection locations.
Ground conductor connection location.
The location of the disconnect switch (circuit breaker number) and
the paralleling switchgear location.
Electrical safety warnings and / Authorize personnel only.
SPARE PARTS
A.
PROCEDURES: Section 01750.
B.
The following spare parts shall be provided:
1.
One complete replacement engine lubricating oil and fuel oil filter elements.
2.
One complete set of hoses (fuel, oil and radiator).
3.
One complete replacement engine air filter elements.
4.
One set any software programs applicable to the generator and all other
components that require software for troubleshooting, maintenance, and
adjustment.
5.
One set, if not already supplied, manufacturer's recommended specialized
tools or instruments to monitor/ troubleshoot engine or generator
components.
6.
One complete set, if not already supplied, of control fuses and replacement
lamps.
PART 3--EXECUTION
3.01
3.02
INSTALLATION
A.
Manufacturer's representative shall consult with Contractor during installation to
ensure proper installation and conformance with manufacturer's instructions. The
installation shall be certified on Form 11000-A specified in Section 01999.
B.
SEISMIC ANCHORAGE AND BRACING: Section 01900.
SHORT CIRCUIT / COORDINATION AND ARC FLASH WORK
A.
Provide submittals for Section 16431.
B.
Contractor shall assist the Power Systems Study contractor as specified in Section
16431.
16431.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-32
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
3.03
3.03
3.04
3.04
START-UP
A.
Start-up shall be performed by a manufacturer's service representative in the
presence of the Officer-in-Charge. In addition to the manufacturer’s standard startup check-out, it shall consist of a complete system check-out developed by an
electrical testing laboratory accredited by NETA to perform the tests. Every control
function including all failures, alarms, indicating lights, switches, horns, metering,
gauges and protective devices shall be demonstrated to work properly. Each
function will then be signed off individually by the Officer-in-Charge on a check list
developed by the qualified testing agency. If a particular function cannot be safely
demonstrated or if any adjustments are required, the Officer-in-Charge shall be
notified immediately. Allow 8 hours minimum for testing. Perform all tests in
accordance with Section 01660.
B.
Prior to acceptance, equipment shall be tested in accordance with Section 01660 to
show it will start and operate properly under all modes of operation. A minimum of 8
hours of manufacturer’s service representative time shall be allowed for operational
testing.
C.
Testing will include a 2-hour full load test at 1.0 power factor.
SYSTEM PERFORMANCE TEST
A.
The Contractor shall submit, 30 days prior to the test, the test procedure, developed
by an electrical testing agency accredited by NETA to perform the submitted tests, for
approval by the Officer-in-Charge, to demonstrate the correct function of the standby
power generation system.
B.
Removal of “Normal” power shall be simulated to prove proper operation of control
features, alarms, status, and the capability to cause the standby power generation
system to start, transfer power, and operate continuously without operator
assistance. It is recommended that testing procedures follow guidance in NFPA 110,
5-13. The field test shall be conducted by the Contractor and the manufacturer's
representative in the presence of the Officer-in-Charge. All costs of testing, including
fuel, a supplemental load bank or an outside testing agency, shall be borne by the
Contractor. Also at this time, the City’s load sequencing controls will be implemented
for operation in conjunction with the generator operation. As part of the system
performance test, the Contractor shall assist the City in the implementation and
testing of the load sequencing controls. The Contractor shall allow for up to 14 days
time in this phase of performance testing as contingency in the overall project
scheduling for the City to modify and/or correct load sequencing controls to optimize
performance as required. The Contractor shall refer to Section 01660 for additional
details regarding these testing requirements.
C.
At the completion of testing, the bulk fuel storage tank shall be provided with a full
level of fuel.
D.
Provide manufacturer's service representative to assist
assist and supervise network
testing of ICP 400,100A with plant’s process control system in compliance with
Section 17030. Provide testing collaboration for data exchange through
through the plant’s
process control system with Section 17030 – Testing Manager.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-33
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
3.05
3.05
TRAINING
A.
3.06
3.06
The manufacturer's representative shall provide three days training for City
operations staff and additional three days to City maintenance staff. Training shall
be certified on Form 11000-B. specified in Section 01999. The training shall include
the following:
1.
Operation of the generator sets including manual start-up and automatic
operation with the automatic transfer scheme.
2.
Routine maintenance.
3.
Troubleshooting.
4.
Instruction on generator control and monitoring equipment, specialized tools,
or instruments shall be provided.
5.
Technical review of the control logic using elementary diagrams.
6.
Operation of the Tap Box.
MEASUREMENT AND PAYMENT
A.
The cost for Low Emissions Diesel Engine Standby Generator Sets shall not be paid
for directly, but shall be considered incidental and included in the lump sum bids for
the respective line items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11083-34
ADDENDUM NO. 3
LOW EMISSION DIESEL ENGINE
STANDBY GENERATOR SET
SECTION 11109
FABRICATED SLIDE GATES
PART 1--GENERAL
1.01
1.02
SUMMARY
A.
This section specifies the minimum requirements for corrosion-resistant fabricated
slide gates (gates) for control of wastewater flow as shown on the Drawings and
specified herein. Gates shall be all 316L stainless steel construction. The scope of
supply shall include gate frames, slides, seals, stems, stem guides, operators, floor
stands, gate enclosures where specified, and all other appurtenances, in-place and
complete. Powered operators for gates are specified in Section 15185.
B.
EQUIPMENT LIST: Equipment provided under this section is listed in paragraph 1.04,
Service Requirements.
QUALITY ASSURANCE
A.
REFERENCED STANDARDS: This Section incorporates by reference the latest
revisions of the following documents. In case of conflict between the requirements
of this Section and the listed documents, the requirements of the Contract
Specifications shall prevail.
Reference
B.
Title
ASTM A240
Standard Specification for Chromium and ChromiumNickel Stainless Steel Plate, Sheet, and Strip for
Pressure Vessels and for General Applications
ASTM A276
Standard Specification for Stainless Steel Bars and
Shapes
ASTM D2000
Standard Classification System for Rubber Products in
Automotive Applications
AWWA C561--12
Fabricated Stainless Steel Slide Gates
ASTM A380
Standard Practice for Cleaning, Descaling, and
Passivation of Stainless Steel Parts, Equipment, and
Systems
UNIT RESPONSIBILITY: Unit responsibility, as specified in Section 11000, is assigned
to the gate manufacturer (Manufacturer) for the gates and appurtenances specified
in this Section and for the powered operators specified in Section 15185.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-1
ADDENDUM NO. 3
FABRICATED SLIDE GATES
C.
1.03
1.04
All gates for this project shall be supplied by the same Manufacturer, who shall be
fully experienced, reputable and qualified in the manufacturing of the equipment
furnished and who has been fabricating gates and appurtenances for a minimum
period of 10 years.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
Product information, calculations, charts and graphs demonstrating compliance with
the requirements of this Section and the Drawings.
C.
Plans, elevations, sections, and details showing dimensions and mounting
requirements for each gate specified.
D.
Manufacturer’s data including materials of construction, construction details of
equipment, and weight of equipment.
E.
Manufacturer’s product literature.
F.
Electric motor operator data, where applicable, including manufacturer's catalog
information, complete dimensional data, drive unit size, calculations substantiating
selection and wiring diagrams.
G.
Certificate of unit responsibility attesting that unit responsibility has been assigned
as specified in this Section and Section 11000. No other submittal material will be
reviewed until the certificate has been received and found to be in conformance with
these requirements.
H.
Results of factory testing including leak testing per AWWA C-561, Section 5.22.
I.
Name, location and qualifications of the passivation shop.
J.
Certification attesting that all gate components have been cleaned, passivated and
tested in accordance with the procedures described in this section
K.
Manufacturer’s operation and maintenance manual defining maintenance
requirements.
SERVICE REQUIREMENTS
A.
PERFORMANCE REQUIREMENTS
1.
Gates are intended to isolate channels and pipes or to control water surface
elevations.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-2
ADDENDUM NO. 3
FABRICATED SLIDE GATES
B.
2.
Gates shall be designed for the Design Head specified. The Design Head is
defined as the maximum head that will be applied to the gate. The Design
Head is measured from the maximum water surface elevation to the bottom
of the gate.
3.
Slides and frames shall have a safety factor of 5 with regard to ultimate
tensile, compressive and shear strength; calculations shall be submitted to
show conformance.
4.
Gates shall comply with field leakage tests as defined in AWWA C561.
5.
Gates shall not require exercise at a frequency of more than once per year to
meet the extended warranty requirements described in this section.
6.
Gates shall be passivated prior to shipping in accordance with the
requirements of this section.
See the Gate Schedule for specific dimensional and design requirements.
Gate Schedule
Equipment
Number
Gate
Type a
SG 100,001
SG 100, 002
SG 100, 101
SG 100, 109
WG 100, 111
SG 100, 182
SG 200, 101
SG 200, 201
SG 300, 113
SG 300, 123
SG 300, 133
SG 300, 111
SG 300, 121
SG 300, 131
SG 300, 114
SG 300, 124
SG 300, 134
SG 300, 112
SG 300, 122
SG 300, 132
SG 300, 211
SG 300, 311
SG 300,161
SG 300, 182
SG 300, 171
SG 300, 172
SG 600, 001
S
S
C
C
W
S
S
S
S
S
S
C
C
C
S
S
S
C
C
C
C
C
S
C
C
C
S
Size
WXHb
(inches)
48 x 48
48 x 48
42 x 80
42 x 60
96 x 24
48 x 48
55 x 55
55 x 55
30 x 30
20 x 20
30 x 30
36 x 98
36 x 98
36 x 98
6x6
6x6
6x6
36 x 72
36 x 72
36 x 72
60 x 72
60 x 72
48 X 48
48 X 48
11.75 X 12
11.75 X 12
36 x 36
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Design Head e, feet
Frame
Type c
Frame
Mounting d
Seating
Unseating
Operator
Type f
NSC
NSC
SC
SC
SC
SC
NSC
NSC
SC
SC
SC
SC
SC
SC
NSC
NSC
NSC
SC
SC
SC
SC
SC
SC
NSC
SC
SC
NSC
3
3
1
1
2
1
3
3
2
2
2
1
1
1
2
2
2
1
1
1
1
1
2
3
e
e
3
4
4
6.0
6.0
2.5
NA
66
66
10
10
10
7
7
7
7
7
7
5
5
5
5
5
6
6
1
1
20
NA
NA
NA
NA
NA
3
NA
NA
70 i
55 i
70 i
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
6
0
0
NA
E
E
E
E
MH
E
E
E
E
E
E
E
E
E
MFN
MFN
MFN
E
E
E
E
E
E
E
E
E
E
11109-3
ADDENDUM NO. 3
Operator
Mount g
Special
Feature h
SP
SP
YTT
YTT
YA
YTT
SP
SP
YA
YA
YA
YA
YA
YA
WB
WB
WB
YA
YA
YA
YA
YA
YA
YTT
YTT
YTT
YTT
RB
RB
DS
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
EN
RB, *
RB, *
RB
FABRICATED SLIDE GATES
Equipment
Number
Gate
Type a
SG 600, 002
SG 600, 003
SG 700, 101
SG 700, 201
SG 700, 103
SG 700, 203
S
S
C
C
S
S
Size
WXHb
(inches)
36 x 36
48 x 48
42 x 84
42 x 84
6x6
6x6
Design Head e, feet
Frame
Type c
Frame
Mounting d
Seating
Unseating
Operator
Type f
NSC
NSC
SC
SC
NSC
NSC
3
3
1
1
2
2
20
20
7
7
12
12
NA
NA
NA
NA
NA
NA
E
E
E
E
MFN
MFN
Operator
Mount g
Special
Feature h
YTT
YTT
YTT
YTT
WB
WB
RB
RB
a. C = channel, S = Sluice, W = weir
b. Nominal size of opening (aperture style gates) or channel width x slide height (channel and weir gates). See Drawings
for additional dimensional requirements.
c. SC = self contained, NSC = non self contained
d. 1 = embedded frame/sill, 2 = wall mounted with embedded sill, 3 = upper section of frame wall mounted with sill and
lower portion of frame embedded (e.g., sluice style gate mounted in channelized structure), e = flange mounted
e. Design Head is the maximum water surface elevation minus the invert elevation of the gate.
f. MH = manual hand wheel, MFN = manual 2” floor nut, E = electric motor
g. YTT = yoke-mounted torque tube, SP = structure-mounted pedestal, YA = yoke-mounted actuator, WB = wall bracket
h. RB = radius bottom, DS = dual stem, EN = stainless steel enclosure, *coordinate requirements
requirements with sluiceway mfg.
(Section 11129)
i. The unseating head indicated would be an unusual condition resulting from a closed gate on a pressurized forcemain.
For this condition, the gate would not need to seal the pipe to AWWA standards but the gate would need to withstand
the resulting force without damage to the gate or seals.
1.05
1.06
COMPONENT SIZING
A.
Operating forces used for determining the strength of gate components (yokes,
frames, slides, stems, slide nut pockets, and other load-bearing members) shall be
based on the sum of the guide friction force (computed using an opening breakaway
friction factor of 0.2)
0.2 and the weight of slide and stem.
B.
When the gate is in motion, the operating forces shall be based on the sum of the
frictional force (using a guide friction factor of 0.25) and the weight of slide and
stem.
EXTENDED WARRANTY
A.
In addition to the warranty specified in Section 01740, the Manufacturer must
provide a special extended warranty for gates and appurtenances (excluding electric
operators) with all of the conditions listed below:
1.
The Manufacturer shall guarantee the gates, when installed and operated as
recommended by the Manufacturer, trouble-free operation for a period of 10years starting at the date of delivery of equipment
equipment to the project site.
site
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-4
ADDENDUM NO. 3
FABRICATED SLIDE GATES
1.07
2.
If, during the warranty period, the the gate fails to meet the specified
requirements,
requirements the Manufacturer shall remedy the problem at no cost or
refund the material and installation cost for a replacement gate.
3.
Leakage during the warranty period shall be within the limits defined in
AWWA C561. The manufacturer shall provide labor cost and materials
required for seal replacement to remedy excess leakage.
4.
Gate slides shall be free of sticking or binding and move freely via operator
input without damaging equipment when exercise of the gate slides is limited
to once per year. Exercising is defined as fully opening and closing the gate
once.
5.
Any gate component with evidence of corrosion affecting the function or
service life of the
the component shall be replaced free of charge during the
warranty period.
6.
Electric operators associated with gates will be covered under the normal
warranty requirements defined in Section 01740.
PICKLING AND PASSIVATION OF STAINLESS STEEL
A.
GENERAL:
1.
Equipment specified under this section shall be cleaned, descaled and
passivated in accordance with methods defined in ASTM A380 – Standard
Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts,
and the specific requirements of this section.
2.
For purposes of this section, passivation is defined as the removal of
exogenous iron or iron compounds from the surface of stainless steel by
means of treatment with an acid solution that will remove the surface
contamination but will not significantly affect the stainless steel itself.
3.
The processes specified in this section shall be performed in an
environmentally controlled shop with at least 5-years experience performing
nitric-hydrofluoric acid solution pickling in compliance with all state and
federal laws. The equipment manufacturer shall submit the name and
qualifications of the passivation shop in accordance with the submittal
requirements of Section 01300 prior to shipping parts for passivation.
4.
Equipment components that bolt together shall be disassembled prior to
passivation treatment to allow for effective circulation and removal of
cleaning solutions.
5.
All fasteners and anchor bolts required for assembly and mounting of
equipment shall be batch processed at the passivation shop, then dried and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-5
ADDENDUM NO. 3
FABRICATED SLIDE GATES
sealed in plastic bags and labeled. Fasteners shall conform to the
requirements of Section 11000.
6.
B.
The use of “fabricator’s crayons” shall be prohibited during fabrication of
equipment as these marks may prevent proper passivation.
PASSIVATION PROCESS REQUIREMENTS:
1.
The processes required for proper passivation shall include precleaning,
chemical descaling, neutralization, post-cleaning inspection, testing,
certification, and protection as defined below.
a.
Precleaning – Precleaning required for the removal of all grease, oil,
paint, soil, grit and other gross contaminants preparatory to the
fabrication process shall be accomplished by vapor degreasing,
immersion or spray application of alkaline or emulsion cleaners,
steam, or high pressure water jetting.
b.
Chemical Descaling –Chemical descaling (pickling) shall be
accomplished by immersion bath or spray application of a nitrichydrofluoric acid solution to produce a matt white, pristine
appearance. The acid solution and process used shall conform to
Code B, Table A1.1, ASTM A380.
c.
Neutralization – The chemical reactions of the pickling media shall
be stopped by rinsing of the part with a 10 percent soda ash solution
for a minimum of 30-minutes followed by a water bath using high
pressure water jetting. The pH of the wetted part surface shall be
same as the water used for rinsing.
d.
Post Cleaning Inspection – Post treatment inspection of the
chemically pickled and neutralized part shall exhibit a clean surface
with no signs of etching, pitting, or frosting resulting from the pickling
procedure.
e.
Testing – The passivated part shall be tested for the presence or
absence of free iron with a solution of potassium ferricyanide as
defined in Verification Test Practice E, ASTM A967. The test solution
shall be mixed and used within 24-hours or less and applied with
sterile cotton swabs. The test result shall indicate an absence of free
iron on the surface of the part.
f.
Certification – All parts passivated shall be certified by an officer of
both the manufacturer and the passivating shop as having been
cleaned and passivated and tested in accordance with the
procedures described in this section. Test results shall indicate an
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-6
ADDENDUM NO. 3
FABRICATED SLIDE GATES
absence of free iron on all passivated surfaces. The Certification
shall be submitted to the City prior to shipping the equipment to the
project site. Equipment that is not certified will not be accepted.
g.
Protection – Protection shall be provided by applying shrink wrap to
all parts of the equipment sufficient to prevent exposure of
passivated surfaces to contaminants during handling, shipping and
installation. Protected equipment shall be tagged with highly visible
warning signs stating the equipment has been passivated and shall
only be opened by authorized personnel. Equipment arriving at the
project site without proper protection will require retesting for the
presence of free iron and re-passivation if free iron is detected.
C.
Assembly of equipment following passivation – If assembly of bolted parts is
required following passivation, it shall be done at the manufacturing facility under
clean conditions such that the parts will not be contaminated with exogenous iron or
iron compounds. Following assembly, retest
retest for the presence of free iron per ASTM
A967 and treat any contaminated areas with
with citric acid solution.
solution. Equipment
requiring assembly shall be re-shrink wrapped sufficient to prevent exposure of
passivated surfaces to contaminants during handling, shipping and installation.
D.
WITNESS OF PASSIVATION PROCESS:
1.
The City retains the right to witness the stainless steel passivation process.
Provide at least 30-days notice to the Officer-in-Charge prior to start of
passivation process.
PART 2--PRODUCTS
2.01
ACCEPTABLE MANUFACTURERS
A.
Gates shall be all stainless steel construction. Acceptable manufacturers include
the following:
1.
Stainless steel slide gate manufacturers:
a.
b.
d.
B.
Whipps, Inc. Athol, Massachusetts
Fontaine International Corporation, Orange Massachusetts
Waterman Industries, Exeter California
The manufacturer’s standard models or products may require modifications to
conform to specified requirements.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-7
ADDENDUM NO. 3
FABRICATED SLIDE GATES
2.02
MATERIALS
A.
Materials of construction shall be as follows:
Component
2.03
Material
Slide
ASTM A240 Type 316L stainless steel
Frame
ASTM A276 Type 316L stainless steel
Slide Seats
ASTM D4020 UHMW Polyethylene
Seating faces or seals
ASTM D4020 UHMW PE
Stem and supports
ASTM A276 Type 316 stainless steel
Fasteners, adjusting
hardware, and anchors
ASTM A276 Type 316 stainless steel
Yoke
ASTM A276 Type 316L stainless steel
Flush bottom seal
Resilient synthetic rubber bonded to frame or ASTM
D2000 neoprene
Pedestal/Torque Tube
ASTM A276 Type 316L stainless steel
Enclosure
ASTM A276 Type 316L stainless steel
FEATURES
A.
B.
GENERAL:
1.
Mounting requirements as shown on the Drawings and specified in this
section.
2.
Unless otherwise indicated, provide gates with rising stems with clear,
graduated plastic covers in accordance with AWWA C561.
3.
Weir gates having a width greater than 60 inches shall have dual stems
mechanically linked to a common operator.
4.
Stainless Steel Passivation: All stainless steel components to be cleaned,
descaled, and passivated after fabrication in accordance with ASTM A380
and the specific requirements of this section. .
SLIDE:
1.
Slides shall consist of steel plate reinforced with steel members welded to
the plate. Minimum thickness of the steel plate shall be ¼”.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-8
ADDENDUM NO. 3
FABRICATED SLIDE GATES
C.
2.
Slides shall be reinforced with horizontal stiffeners welded to vertical
stiffeners. Slides shall not deflect more than 1/1000 of the span of the gate
under the design head.
3.
Gates with an opening width x design head of 80’ or greater shall
incorporate a 3”minimum structural edge extended into the guide grove or
design equivalent.
4.
The slide manufacturer shall submit drawings and comprehensive design
criteria to substantiate that the maximum deflection for each slide has not
exceeded 1/1000 of the span regardless of the type used. Comprehensive
safety factor calculations shall include bending moments, buckling stress,
and bonding stress with thermal expansion factors. Safety factors shall be
calculated for the slide under the maximum head indicated in this section,
and for shear at the slide/seal interface.
FRAME:
1.
Guide frames extending above operating floors or slabs shall be selfcontained and sufficiently strong so that no further support or reinforcement
is required. Frames for self-contained gates shall be designed for maximum
loads imposed by gate operators in the stalled condition plus the weight of
the slide, stem, torque tube or pedestal, and operator.
2.
The yoke shall be formed by two structural members welded at the top of the
guides to provide a one-piece rigid frame and configured to enable slide
removal without removing the yoke. The yoke shall be designed to support
the maximum stall force applied by the operator in addition to the weight of
the stem, torque tube or pedestal, and operator where this equipment is
being supported at the yoke.
3.
The frame shall be designed with a minimum factor of safety of 4 with regard
to ultimate tensile, compressive, and shear strength.
4.
Wall-mounted frames shall be the flanged type. Guides for wall mounted
frames shall be formed from one plate with wrap around gussets. Bolted
together guides are not accepted.
5.
Embedded frame gates shall be installed in block-out recesses formed in the
channel walls and floor.
6.
Thimble-mounted gates shall be drilled to match the wall thimble. Wall
thimbles shall conform to AWWA C561.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-9
ADDENDUM NO. 3
FABRICATED SLIDE GATES
D.
E.
SEALS:
1.
Gates shall incorporate factory-set self-adjusting seals utilizing a sealing
surface of UHMW PE to achieve the leakage rates specified. Self adjusting
seals shall not require adjustment and shall be replaceable without removing
the guide frame.
2.
All moving contact surfaces shall be incompatible to each other thereby
minimizing sticking or jamming.
3.
Seals sandwiched between bolted together guide members are not
acceptable.
STEMS:
1.
All stems shall be of the rising type unless otherwise specified.
2.
Provide stem diameter to withstand at least twice the rated output of the
electric operator or the manual operator at 40-pounds pull. Stems shall be
minimum 1-1/21/2-inch diameter.
3.
Stem guides shall be provided at intervals necessary to maintain a
slenderness ratio (L/R) of the unsupported stem length of less than 200,
where R is the radius of gyration of the stem.
4.
Stems shall be designed to withstand tensile and compressive loads that
occur under maximum operating conditions. Design for compressive loading
shall meet AISC code where K=1 with a minimum safety Factor of 2 to 1.
5.
Stem sections shall be joined together by solid couplings, threaded and
keyed to the stems. All couplings of the same size shall be interchangeable.
6.
The threaded portion of the stem shall have dual lead, machine rolled, full
depth ACME type threading with a 16 micromicro-inch finish
finish or better. Stub
threads are not acceptable.
7.
Stems shall be fixed to the slide by a threaded and keyed assembly into a
lifting nut attached to the disc in a lifting bracket, which is bolted to the disc.
The bolts securing the bracket shall be in tension and not shear.
8.
Yoke-supported stems shall be provided with a torque between the top of the
yoke and the operator constructed of 316L SS. The torque tube shall have
appropriate flanges at the top and bottom for mounting to the operator and
yoke, and be sized and constructed to provide lateral support to the stem
between the yoke and the operator. Torque tubes shall be provided with
UHMW stem guides at appropriate intervals to provide lateral support to the
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-10
ADDENDUM NO. 3
FABRICATED SLIDE GATES
stem. Torque tubes shall be equipped with tabs for bolting lateral supports;
the dimensions and location of the tabs shall be determined by the
manufacturer and coordinated during the submittal review process.
F.
G.
2.04
OPERATORS:
1.
See Gate Schedule for operator requirements.
2.
Unless otherwise indicated, manual operators shall meet requirements of
AWWA C561 as appropriate.
3.
Yoke-supported operators shall be provided with 316 SS pedestals between
the top of the yoke and the operator. See drawings for length requirements.
4.
Unless otherwise indicated and whenever possible, operator base shall be
set 42” above the walking surface.
5.
Electric operators are specified in Section 15185.
ENCLOSURES:
1.
Gates isolating pipes and channels within the headworks structure shall be
equipped with all stainless steel enclosures for odor control purposes.
2.
Enclosures shall be designed and fabricated by the gate manufacturer.
Submit drawings prior to fabrication.
3.
Enclosures shall be essentially air tight and designed to withstand negative
pressure of 0.3” WC imposed by the odor control system drawing air from
below the channel covers.
4.
Enclosures shall be compatible with specified electric actuators and shall be
removable without removing the actuator.
5.
Enclosure face panels shall be removable from one side. Removable
panels shall be provided in sections weighing no more than 3030-pounds
each. Provide handles for lifting the removable face panels.
FACTORY TESTING
A.
Conduct shop performance test per AWWA C563 or AWWA C561 as applicable.
Gates SG 200, 101 and SG 200, 201 shall be factory
factory leak tested, all other gates
to be field leak tested following installation. Submit written report of results to
Officer-in-Charge.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-11
ADDENDUM NO. 3
FABRICATED SLIDE GATES
B.
The City retains the right to witness the stainless steel preparation and passivation
process. Provide at least 30-days notice to Officer-in-Charge prior to start of
passivation process for gates and appurtenances.
PART 3--EXECUTION
3.01
3.02
INSTALLATION
A.
Install gates and appurtenances in accordance with manufacturer’s instruction and
as shown on the Drawings.
B.
For embedded gates, fill blockouts along guide frames and gate sill with grout
following installation.
C.
Provide all 316 SS anchors; size anchors in accordance with the design
requirements specified in this section and in accordance with Sections 01900,
05501, and 11000.
D.
Proper handling shall incorporate all practices described in Section 8.5 – Protection
of Cleaned Surfaces, ASTM A380. Passivated parts contaminated due to improper
handling and installation will require retesting for the presence of free iron and repassivation if free iron is detected.
FIELD TESTING
A.
3.03
TRAINING
A.
3.04
Operation and Leakage Tests: In accordance with AWWA C563 or AWWA C 561 as
appropriate.
Provide four hours of training as specified in Section 01660. Training shall be
certified on Form 11000-B specified in Section 01999.
MEASUREMENT AND PAYMENT
A.
Fabricated slide gates shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11109-12
ADDENDUM NO. 3
FABRICATED SLIDE GATES
SECTION 11116
IN-CHANNEL GRINDERS
PART 1--GENERAL
1.01
DESCRIPTION
A.
SCOPE: This section specifies in-channel grinders complete with electric motors and
all appurtenances. The grinder units for this project shall incorporate dual rotating
helical drum screens on motor-driven shafts that direct solids toward counterrotating, intermeshing cutter stacks located between the helical drums. The
assembly shall be housed in a cast metal frame and provided with immersible
motors. Motor starters for the channel grinder shall be installed in a plant MCC and
all logic shall be integrated into the plant control system.
B.
EQUIPMENT LIST:
Item
Equipment No.
Junction Structure
Channel Grinder 1
GDR 700, 111
Channel Grinder 1 Screen 1
SN 700, 112
Channel Grinder 1 Screen 2
SN 700, 113
113
Channel Grinder 2
GDR 700, 211
Channel Grinder 2 Screen 1
SN 700, 212
Channel Grinder 2 Screen 2
SN 700, 213
Mokapu Diversion Structure
Channel Grinder
1.02
GDR 100, 106
Channel Grinder Screen 1
SN 100,107
100,107
Channel Grinder Screen 2
SN 100,108
QUALITY ASSURANCE
A.
REFERENCES:
1.
This section contains references to the latest revision of the following
documents. They are a part of this section as specified and modified. Where
a referenced document contains references to other standards, those
documents are included as references under this section as if referenced
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-1
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
directly. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect at the time of Advertisement for Bids or Invitation to Bid
(or on the effective date of the Agreement if there were no Bids). If
referenced documents have been discontinued by the issuing organization,
references to those documents shall mean the replacement documents
issued or otherwise identified by that organization or, if there are no
replacement documents, the last version of the document before it was
discontinued. Where document dates are given in the following listing,
references to those documents shall mean the specific document version
associated with that date, regardless of whether the document has been
superseded by a version with a later date, discontinued or replaced.
Reference
Title
AGMA 6010-E-88
Spur, Helical, Herringbone, and Bevel Enclosed Drives
ASTM A36/A36M-94
Carbon Structural Steel
ASTM A48-83
Grey Iron Casting
ASTM A536-84
Ferritic Ductile Iron Castings
ASTM A743
Stainless Steel Casting
AISI 316
316 Stainless Steel
AISI 4130
Heat Treated Alloy Steel
AISI 4140
Heat Treated Alloy Steel
AISI 8620
Heat Treated Alloy Steel
AISI 17-4
17-4 Stainless Steel
SAE 660
660 Bronze Steel
NEMA 250-91
Enclosures for Electrical Equipment (1000 Volts Max)
3.
Controllers and electrical components shall, as applicable, meet the
requirements of the following agencies:
a.
b.
c.
B.
National Electrical Manufacturer’s Association (NEMA) Standards
National Electric Code (NEC)
Underwriters Laboratory (UL and cUL)
UNIT RESPONSIBILITY: The Contractor shall assign unit responsibility as specified in
Section 11000, to the channel grinder manufacturer, for the channel grinder,
associated hardware, and wiring.. A completed Certificate of Unit Responsibility (Form
11000-C, Section 01999) shall be provided.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-2
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
1.03
C.
FACTORY TESTS: Factory testing of this this equipment is not required.
D.
WARRANTY AND PERFORMANCE AFFIDAVIT: Provide a Standard Product Warranty in
accordance with Section 01740.
SUBMITTALS
A.
The following information shall be provided in accordance with Section 01300.
1.
A copy of this specification section, with addendum updates included, and all
referenced and applicable sections, with addendum updates included, with
each paragraph check-marked to indicate specification compliance or
marked to indicate requested deviations from specification requirements or
those parts which are to be provided by the Contractor or others. Check
marks ( ) shall denote full compliance with a paragraph as a whole. If
deviations from the specifications are indicated, and therefore requested by
the Contractor, each deviation shall be underlined and denoted by a number
in the margin to the right of the identified paragraph, referenced to a detailed
written explanation of the reasons for requesting the deviation. The Engineer
shall be the final authority for determining acceptability of requested
deviations. The remaining portions of the paragraph not underlined will
signify compliance on the part of the Contractor with the specifications.
Failure to include a copy of the marked-up specification sections, along with
justification(s) for any requested deviations to the specification requirements
shall be cause for rejection of the entire submittal and no further submittal
material will be reviewed.
2.
A copy of the contract document control diagrams, process and
instrumentation diagrams and mechanical layout drawings relating to the
submitted equipment, with addendum updates that apply to the equipment
in this section, marked to show specific changes necessary for the
equipment proposed in the submittal. If no changes are required, the
drawing or drawings shall be marked "no changes required". Failure to
include copies of the relevant drawings with the submittal shall be cause for
rejection of the entire submittal with no further review.
3.
Certificate of Unit Responsibility attesting that the Contractor has assigned
unit responsibility in accordance with the requirements of this section and
paragraph 11000-1.02 C. No other submittal material will be reviewed until
the certificate has been received and found to be in conformance with these
requirements.
4.
Shop drawings for the grinder. This includes but is not limited to motor
elementaries, loop drawings, PLC I/O card drawings, P&IDs, and network
drawings.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-3
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
1.04
5.
Motor Data Form 11060-A.
6.
Manufacturer’s operation and maintenance information in accordance with
Section 01730.
7.
Testing forms in accordance with Section 01660.
8.
Motor submittal information specified in paragraph 11060-1.03.
9.
Seismic calculations in accordance with Section 01900.
10.
Channel Grinder Vendor Coordination: Contractor shall obtain approval of the
selected channel grinder vendor (in addition to the client) for all drawings
associated with the installation and commissioning the vendor equipment.
This includes the control strategies given to the system integrator for
programming and development the plant control system PLCs and HMIs.
This shall be done before installation and programming of the plant control
system occur. Submittal to the vendor shall meet the same requirements of
this contract. Vendor representative shall approve commissioning of vendor
equipment. Vendor coordination is a requirement for the vendor unit
responsibility. Vendor representative shall coordinate with Section 16920
and provide current transformer (CT) settings required to detect a grinder jam
condition.
PERFORMANCE REQUIREMENTS
A.
DESIGN REQUIREMENTS: The manufacturer shall review the drawings to familiarize
themselves with the location and the set-up of the equipment specified and shall
assure themselves that the equipment specified is appropriate for and coordinated
with what is shown on the contract drawings. The manufacturer shall also review the
relevant electrical plan and one-line diagram and the relevant process and
instrumentation diagram drawings to ensure that the contract drawings are
appropriate and coordinated with the equipment and controls specified.
B.
SERVICE CONDITIONS: Equipment provided under this specification will be used to
reduce or shred influent solids found in typical domestic wastewater including fecal
material, vegetables, rubber goods, plastics, paper products, bones, wood, semi-solid
grease particles, rocks, sand, and metal pieces of various size and composition. The
liquid component of the wastewater stream will primarily consist of water but could
also contain vegetable and animal fats, petroleum products, and various solvents.
The grinding equipment will be located within a corrosive environment typical of
covered wastewater conveyance channels. Specific environmental conditions for the
project area are listed in Section 01800.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-4
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
C.
OPERATING REQUIREMENTS: The equipment specified in this section will be
operated continuously and shall be capable of running dry without harming the
cutters. The equipment shall be designed to operate without an external source of
water for the flushing seals or cutter faces. The entire grinder assembly, including
the motors, shall be rated for periodic submergence for up to seven consecutive
days at a maximum depth of 30 feet.
D.
PERFORMANCE REQUIREMENTS AND CHARACTERISTICS: The grinders specified in
this section (GDR 700, 111, GDR 700, 211, and GDR 100, 106) shall conform to the
following criteria and performance requirements:
Criteria, unit
Value
Number of drum screens/unit
Drum screen diameter, inches
Drum screen spacing, inches
Cutting stack height, inches
Peak capacity, MGD
Maximum head loss
at peak flow, inches*
2
20
0.5
66
34
24
Motors
Grinder motor:
Horsepower, maximum
Revolutions per minute
Type (reference Section 11060)
Reduction ratio
Screen drum motors:
Horsepower, maximum
Revolutions per minute
Type (reference Section 11060)
Reduction ratio
10
1760
Immersible
29:1
1
1740
Immersible
377:1
* Based on downstream water depth of 40-inches.
PART 2--PRODUCTS
2.01
PRODUCTS
A.
The in-channel grinder shall be Channel Monster Model CDD 6020-XDM2.5 as
manufactured by JWC Environmental, configured to meet the requirements specified
in this section, or pre-approved substitute. Any approved manufacturer shall be able
to demonstrate experience with a minimum of 200 units of the same size.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-5
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
2.02
MATERIALS
A.
Materials of construction shall comply with the following table.
Component
2.03
Material
Grinder plate and frame
Carbon steel, ASTM A36 or stainless steel
Shafts
AISI 4140 alloy steel, tensile strength, 170,000 psi
minimum, 2.5” thickness minimum measured
between flats with minimum hardness of 38-42
Rockwell C.
Shaft collars
ASTM A743 stainless steel, AISI 17-4 stainless steel
and SAE 660 bearing bronze
Cutters
AISI 8620 alloy steel, through hardened to a minimum
60-65 Rockwell C
Spacers
AISI 8620 alloy steel, through hardened to a minimum
34-38 Rockwell C
Fasteners, including bolts,
nuts, washers and keys
AISI 316 stainless steel
Grinder housings
Ductile iron, ASTM A 536-84
Grinder support frame
assemblies
Type 316L
L stainless steel
EQUIPMENT
A.
SCREENS: Two rotating helical drum screens shall direct solids incapable of passing
through the screens toward and into the dual, counter-rotating cutter stacks. The
rotating coil screen drums shall be self-cleaning and driven by motors and reducers
independent of the cutter stack drive mechanism. Each drum screen shall be
independently driven.
1.
SCREENS: Electro-polished coil screen drums shall be constructed of helical
wound, ½-inch (13 mm) diameter AISI 304 stainless steel with ½-inch (13
mm) spacing between coils The screens shall have end flanges and stub
shafts to support and rotate the screen. The shaft shall not run through the
center of the screen.
2.
SCREEN SHAFT BEARINGS AND SEALS: The radial and axial loads of the
screen shafts shall be borne by two sealed and oversized Conrad-type ball
bearings. The bearings shall be protected by buna-N double lip seals. The lip
seal shall be rated at 10 psi continuous duty by the seal manufacturer.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-6
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
3.
B.
MOTORS:
a.
Motors shall be TENVTENV-XP, immersible, 1,740 rpm,
rpm, 460 volt, 3
phase, 60 Hz, service factor 1.15, efficiency not less than 85% at
full load, and power factor not less than 70% at full load. Motor
shall be U.L. rated NEMA 6P, Class I, Div. I Groups C&D, Class II,
Div. II, Groups F&G, Class II, Div.I
b.
Motor
Motor shall have an insulation class H Capable of delivering rated
horsepower under voltage and frequency variations specified in
NEMA MGMG-1.
c.
Over temperature switch.
d.
Motors shall be rated for submergence of 7 consecutive days at a
maximum depth of 30 feet.
CUTTER STACK: The cutter stack shall be a twin-shaft design capable of continuous
operation. Bar screens or single shaft devices utilizing stationary cutters, will not be
acceptable. Two-shaft design shall consist of two parallel shafts alternately stacked
with individual intermeshing cutters and spacers positioned on the shaft to form a
helical pattern. Cutter cartridges consisting of multiple cast cutters and spacers will
not be acceptable. The two shafts shall counter- rotate with the driven shaft
operating at approximately 2/3 the speed of the drive shaft. Each in-channel
grinding system shall include guide plate, frame, end housings, covers, shafts, side
rail, reducer, motor, cutters, spacers, bearings, and seals.
1.
GUIDE PLATE AND FRAME: The grinder’s guide plate and frame shall be
made of ASTM A36 merchant quality steel. Frame shall be designed for
channel installation and shall house both the screen and grinder assembly.
2.
GRINDER END HOUSINGS, COVERS, AND SHAFTS: Grinder end housings
shall be cast of ASTM A536 ductile iron and designed to protect the bushings
while guiding particles directly into the cutting chamber. Top covers shall be
ductile iron and bottom covers shall be hot rolled plates. Grinder drive and
driven shafts shall be made of AISI 4140 heat treated hexagon steel with a
tensile-strength rating of not less than 149,000 psi. Shaft diameter shall be
a minimum of 2.5 inches as measured between the flats.
3.
SIDE RAILS: Side rails shall be designed to mate with the cutting teeth and
shall be bolted to the body.
4.
GEAR: The speed reduction gear shall be designed for continuous duty heavy
shock loads in accordance with AGMA 6010-E and shall be a concentric
shaft, planetary design, sealed in grease.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-7
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
5.
MOTOR:
a.
Motors shall be TENV-XP, immersible, 1,760 rpm, 460 volt, 3 phase,
60 Hz, service factor 1.15, efficiency not less than 91% at full load,
and power factor not less than 80% at full load. Motor shall be U.L.
rated NEMA 6P, Class I, Div. I Groups C&D, Class II, Div. II, Groups
F&G, Class II, Div.I
b.
Motor shall have an insulation class H Capable of delivering rated
horsepower under voltage and frequency variations specified in
NEMA MG-1.
c.
Grinder shall provide a minimum peak shaft torque of 3,700 lb-in/hp
and provide and provide a minimum peak force at cutter tip of 993
lbf/hp (5,923 N/ kW).
d.
Over temperature switch.
e.
Motors shall be rated for submergence of 7 consecutive days at a
maximum depth of 30 feet.
.
6.
CUTTERS AND SPACERS: Shafts shall mate with the individual cutters and
spacers with no more than 0.040-inch clearance. Each cutter shall be an
individual disk. Spacer shall be an individual disk constructed of AISI 8620
alloy steel. The driven shaft shall rotate at approximately 2/3 the speed of
the drive shaft, driven through gears mounted above the upper bearings.
7.
BEARINGS AND SEALS: The bearing/seal design shall be either of the
following two types:
a.
Type 1: Shaft radial and axial loads shall be borne by four sealed
oversize Conrad-type ball bearings, which will be rated by the bearing
manufacturer with a minimum basic dynamic load rating of 7,050
pounds. The bearings will be protected against the intrusion of any
foreign particles by a combination of a tortuous path device and endface mechanical seals. Face materials must be a minimum of
tungsten carbide to tungsten carbide with 6% nickel binder, not
requiring an external flush. The mechanical seal will be rated at 90
psi continuous duty by the manufacturer. The bearings and seals will
be housed in replaceable wear sleeves that support and align the
bearings and seals.
b.
Type 2: The grinder shall have a bearing/seal configuration designed
to resist the intrusion of wastewater, sludge, and grit into the bearing
system. The bearing shall be sleeve type manufactured from nylon
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-8
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
acetal suitable for grease lubrication. The seal assembly shall
consist of a neoprene V-ring seal with stainless steel grit check. The
seal shall require no external water source for sealing. The bearings
shall be grease lubricated for a grit purge.
8.
BAR RACK FOR MOTOR SHAFT PROTECTION: The grinder shall be equipped
with a Type 304 stainless steel removable overflow bar rack that extends
between the top of the grinder and bottom of the channel covers. This
overflow bar rack will capture debris during high flow periods when the
grinder is flooded.
C.
DRIVE SHAFTS FOR DRUMS AND GRINDER: Drive shafts and housings for the drums
and grinders will be extended such that the motors extend above the channel covers
as shown on the Drawings. Provide shafts and housings such that there are no
flange connections between the bottom of the channel covers and the top of the
channel covers to facilitate effective sealing for odor control.
D.
POWER CORDS:
1.
Power cords for the grinder and screen motors shall be sized by the
manufacturer for the length and duty required. The power cords shall be
potted into the motor frame. Power cord length assumptions for bidding
purposes are shown in the table below. Final determination of power cord
length shall be made by the Contractor and submitted to the Officer-inCharge for approval.
Equipment No.
Power Cord Length (ft)
Junction Structure
GDR 700, 111
200
SN 700, 112
200
SN 700, 113
200
GDR 700, 211
200
SN 700, 212
200
SN 700, 213
200
Mokapu Diversion Structure
GDR 100, 106
200
SN 100, 107
200
SN 100, 108
200
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-9
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
E.
RECEPTACLE / PLUG:
1.
The motor cords shall have plugs at opposite end away from motor to
support easy in-channel grinder removal for maintenance and servicing. The
terminal box shall have mating receptacle.
2.
Receptacle / Plug shall be as follows:
a.
b.
c.
d.
F.
Receptacle / plug shell shall have a corrosion resistant shell. Shell
shall be stainless steel type 316 or fiberglass reinforced
thermoplastic polyester.
Receptacle / plug shall be suitable and sized for the motor power
conductors and thermostat sensor conductors.
Receptacle and plug shall be pad-lockable.
Acceptable manufacturers:
i.
Meltric Corporation
ii.
Or approved substitute.
PLANT CONTROL SYSTEM INTEGRATION:
1.
All control and I/O shall be interfaced with the plant control system (PCS) as
shown in the contract documentation.
2.
Both local and automatic control shall be provided for the equipment
specified in this Section. The PCS shall be responsible for the automatic
operation of the grinder and associated screens.
screens Field located control
stations shall provide independent operation of grinder and associated
screens from the PCS. Operation of the equipment includes the following
functions (see CS-102 and CS-701):
a.
Operate in a “Hand,” “Off,” or “Auto
Auto”
Auto mode using a three-position
selector switch and “Forward”, “Off”, or “Reverse”.
“Reverse” In the “Off”
mode, the grinder shall not run. In the “Hand” mode, the grinder
shall run in “Forward” or “Reverse”.
Auto”
“Reverse” In the “Auto
Auto mode, the grinder
shall start and stop as controlled by the plant control system. Screen
motors have a “Hand,” “Off” or Auto” mode using a three position
selector switch and “Forward”, “Off”, or “Reverse” mode using a
three position switch which work the same as the grinders but in
Auto the screens only run when the grinder is running.
b.
The grinder shall only be reset through a reset pushbutton located at
the motor control center (MCC).
c.
Sense an overload (jam) condition of the cutter shaft,
shaft momentarily
reverse the cutter shaft direction to clear the condition and return to
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-10
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
a forward direction. If the overload has cleared, return to normal
operation. This operation shall only be available when grinder is set
to “Auto” mode (jam condition interlock for reverse control is
through PCS).
2.04
d.
If a second overload (jam) occurs, the same schedule shall apply as
for one overload condition. This operation shall only be available
when grinder is set to “Auto” mode (jam condition interlock for
reverse control is through PCS).
PCS).
e.
If a third overload (jam) occurs within 30 seconds, the cutter shaft
shall reverse the shaft direction, shutdown, and an alarm circuit will
be energized. This operation shall only be available when grinder is
set to “Auto” mode (jam condition interlock
interlock for reverse control is
through PCS).
f.
Sense an overload condition of one drum screen, momentarily
reverse the drum screen direction to clear the condition and return
to a forward direction. If the overload has cleared, return to normal
operation.
operation. This operation shall only be available when screen is set
to “Auto” mode (jam condition interlock for reverse control is
through PCS).
g.
If two reverses occur within 30 seconds, the drum screen will
shutdown and an alarm circuit will be energized. The
The other drum
screen and grinder will continue to operate. This operation shall
only be available when screen is set to “Auto” mode (jam condition
interlock for reverse control is through PCS).
4.
The face of the MCC buckets shall be provided with status lights for Power
On, Run, and Fail. Relay contacts shall be included for Run and Fail signal
outputs.
5.
Motor starter shall be a full-voltage reversing type with 120 volt operating
coils. Forward and reverse contactors on the starter shall have both
mechanical and electrical interlocks. Overload relays shall be adjustable so
that the range selected includes the full load ampere ranting and service
factor. Starter and overload relay shall also meet contract specifications, see
sections 16920 and 16155.
SPARE PARTS
A.
The following spare parts shall be provided:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-11
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
2 sets—seal assemblies
4 sets—gaskets
1 cutter cartridge
B.
2.05
Spare parts shall be tagged and stored in accordance with Section 11000.
PRODUCT DATA
A.
The following product data shall be provided in accordance with Section 01300:
1.
Applicable operating and maintenance information specified in Section
01730.
2.
Motor product data specified in Section 11060.
3.
Completed Installation Certification Form 11000-A (Section 01999) specified
in paragraph 11116-3.02
2.
4.
Completed Training Certification Form 11000-B (Section 01999) specified in
paragraph 11116-3.03.
PART 3--EXECUTION
3.01
SHIPMENT AND STORAGE
A.
3.02
INSTALLATION
A.
3.03
The equipment shall be installed as specified and in accordance with the
manufacturer’s written recommendations. The equipment shall be installed and
tested under the direction of factory-trained personnel. The installation shall be
certified on Form 11000-A specified in Section 01999.
TESTING
A.
3.04
Equipment shall be shipped and stored in accordance with Section 01605.
Testing of equipment and systems shall be conducted in accordance with the
requirements of Section 01660.
TRAINING
A.
A minimum of 4 hours of training, as specified in Section 01664, shall be provided.
Training shall be certified on Form 11000-B specified in Section 01999.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-12
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
3.05
FIELD SERVICES
A.
3.06
Field start-up services and equipment inspection shall consist of two trips for a
minimum of 2 days for each site.
MEASUREMENT AND PAYMENT
A.
In-channel grinders shall not be paid for directly, but shall be considered incidental and
included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11116-13
ADDENDUM NO. 3
IN-CHANNEL GRINDERS
SECTION 11149
GRIT PROCESSING UNITS
PART 1--GENERAL
1.01
DESCRIPTION
A.
SCOPE:
1.
This section specifies grit concentrating and classifying equipment. The
equipment shall be suitable for cleaning organic material from grit laden
slurries and for separating and dewatering grit to the specified total solids
content prior to discharging to a roll-off container.
2.
Each system includes the vendor control panel, vendor-provided devices, and
the monitoring devices as shown and specified herein.
B.
TYPE: Grit concentrating (washing) equipment shall employ a strong free vortex
which utilizes centrifugal and gravitation forces and secondary boundary layer
velocities to effect the separation, collection, and classification of the grit. Grit
classifying (dewatering) equipment shall employ an inclined belt with a tailroll
mechanism. The tailroll mechanism shall be self-cleaning and shall be installed with
a scraper. The equipment shall be specifically designed for conditions described in
this specification and shown on the drawings.
C.
EQUIPMENT LIST:
Item
1.02
Equipment number
Grit Concentrator 1
MME300,230
Grit Classifier 1
MME300,240
Grit Concentrator 2
MME300,330
Grit Classifier 2
MME300,340
Control Panel 1
ICP300,240 NEMA 7
Control Panel 2
ICP300,340 NEMA 7
DESIGN REQUIREMENTS
A.
The grit concentrator shall receive the underflow from the grit settler. The unit shall
be mounted above and discharge the concentrated and washed grit slurry to the grit
classifier. The de-gritted overflow shall be discharged upstream of the grit settler.
B.
The grit classifier shall receive the underflow from the grit concentrator and allow the
washed grit to settle in its integral clarifier. A slow moving belt shall carry the grit to
the point of discharge allowing it to dewater during transport. The washed and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-1
ADDENDUM NO. 3
GRIT PROCESSING UNITS
dewatered grit shall be discharged to a dewatered grit receptacle supplied by others.
The de-gritted overflow shall be discharged upstream of the primary grit removal
equipment. The grit removal system and all appurtenances shall be supplied by a
single vendor.
1.03
C.
The system to be furnished hereunder shall be made by a manufacturer regularly
engaged in such work and who has furnished similar installations and had them in
successful and continuous operation for a minimum period of ten years.
D.
Data on performance testing, service history and operation of existing installations
using the submitted equipment shall be made available to the Officer-in-Charge,
upon request, for use in determining that the grit removal system offered meets the
intent of the contract, performance requirements and criteria stated in these
specifications. Grit screw classifiers, grasshoppers, reciprocating rakes and similar
type of units shall not be accepted. Units using apex valves shall not be accepted.
Equipment using paddles or air to supplement or induce a vortex shall not be
accepted.
E.
CONTROL PANEL: Control panels shall be provided as part of this Section’s
requirement. Control panels shall allow manual operation and enable automatic
operation through the plant control system (PCS). Vendor shall coordinate automatic
operation requirements necessary for specified equipment in this Section with
Section 17500’s CS 302.
PERFORMANCE REQUIREMENTS:
A.
The performance requirements shall be as follows:
Item
1.04
Value
Rated continuous duty hydraulic slurry application rate, gpm
350
Maximum hydraulic slurry application rate, gpm
550
Grit processing capacity, ton per hour
1
Grit removal efficiency for grain size greater than 75 microns and
specific gravity greater than 2.65 at rated continuous flow, percent
95
Solids concentration of final dewatered product, percent
90
Proportion of total solids lost by ignition, percent
5
Maximum influent solids concentration, percent
1
OPERATING CONDITIONS
A.
The grit slurry will be comprise of sand, snails, sticks, gravel, petroleum products,
industrial solvents, detergents, and organic solids. The grit slurry is expected to
range between 70 degrees F and 90 degrees F, the pH may vary between 6 and 9,
and the solids concentration is expected to be about 1 percent.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-2
ADDENDUM NO. 3
GRIT PROCESSING UNITS
1.05
QUALITY ASSURANCE
A.
REFERENCES:
1.
This section contains references to the documents listed below. They are a
part of this section as specified and modified. Where a referenced document
cites other standards, such standards are included as references under this
section as if referenced directly. In case of conflict between the requirements
of this section and those of the listed documents, the requirements of this
section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect at the time of Advertisement for Bids or Invitation to Bid
(or on the effective date of the Agreement if there were no Bids). If
referenced documents have been discontinued by the issuing organization,
references to those documents shall mean the replacement documents
issued or otherwise identified by that organization or, if there are no
replacement documents, the last version of the document before it was
discontinued. Where document dates are given in the following listing,
references to those documents shall mean the specific document version
associated with that date, whether or not the document has been
superseded by a version with a later date, has been discontinued or has been
replaced.
Reference
Title
ASTM A240/A240M
Chromium and Chromium-Nickel Stainless Steel Plate, Sheet,
and Strip for Pressure Vessels and for General Applications
ASTM A276
Stainless Steel Bars and Shapes
ASTM A312/A312M
Seamless and Welded Austenitic Stainless Steel Pipes
ASTM A320/A320M
Alloy-Steel and Stainless Steel Bolting Materials for LowTemperature Service
ASTM A480/A480M
Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet,
and Strip
ASTM A484/A484M
Stainless Steel Bars, Billets, and Forgings
AWS D1.1
Structural Welding Code—Steel
NEMA ICS 2
Industrial Control and Systems Controllers, Contactors, and
Overload Relays Rated 600 Volts
ASTM A380
Standard Practice for Cleaning, Descaling, and Passivation of
Stainless Steel Parts, Equipment, and Systems
B.
UNIT RESPONSIBILITY:
1.
The Contractor shall assign unit responsibility, as specified in Section 11000,
to the manufacturer of the grit concentrator provided under this section. All
mechanical equipment components, at least, of this entire equipment
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-3
ADDENDUM NO. 3
GRIT PROCESSING UNITS
assembly shall be furnished by the grit concentrator manufacturer. All grit
classifying equipment will also be provided by the same manufacturer to
ensure that the process runs correctly.
2.
1.06
This manufacturer is the unit responsibility manufacturer and has unit
responsibility, as described in Section 11000 for the equipment assembly
specified in this section. A completed, signed, and notarized Certificate of
Unit Responsibility (Form 11000-C, Section 01999) shall be provided.
C.
Warranty: any product that proves defective in material, workmanship or design
within twelve (12) months after acceptance shall be, at the discretion of the
manufacturer, modified, repaired or replaced, or buyer’s payment for the products
shall be refunded. This shall be buyer’s sole remedy.
D.
Certificate of compliance: the manufacturer shall warrant that the grit removal
system to be supplied shall be manufactured in strict compliance with the contract
specifications.
E.
The system manufacturer shall be ISO 9001:2008 and 14001 certified.
F.
Manufacturer shall be successful in the experience of manufacture, operation, and
servicing of grit removal systems of type, size, quality, performance, and reliability
equal to that specified for a period of not less than ten (10) years. The manufacturer
shall submit evidence of experience having supplied a minimum of ten (10)
installations in North America of similar size to the proposed system and with a
maximum surface loading of 24 gpm/square foot or less at the specified peak design
flow.
SUBMITTALS AND OPERATION AND MAINTENANCE MANUALS
A.
Submittals shall be provided in accordance with the general conditions and shall
include the following:
1.
Completed Certificate of Unit Responsibility attesting that the Contractor has
assigned, and that the manufacturer accepts unit responsibility in
accordance with the requirements of this section and paragraph 11000-1.02
C. No other submittal material will be reviewed until the certificate has been
received and found to be in conformance with these requirements.
2.
A copy of this specification section, with addendum updates included, and all
referenced and applicable sections, with addendum updates included, with
each paragraph check-marked to indicate specification compliance or
marked to indicate requested deviations from specification requirements. A
check mark shall denote full compliance with a paragraph as a whole. If
deviations from the specifications are indicated, and therefore requested by
the Contractor, each deviation shall be underlined and denoted by a number
in the margin to the right of the identified paragraph, referenced to a detailed
written explanation of the reasons for requesting the deviation.
3.
The Officer-in-Charge shall be the final authority for determining acceptability
of requested deviations. The remaining portions of the paragraph not
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-4
ADDENDUM NO. 3
GRIT PROCESSING UNITS
underlined will signify compliance on the part of the Contractor with the
specifications. Failure to include a copy of the marked-up specification
sections, along with justification(s) for any requested deviations to the
specification requirements, with the submittal shall be sufficient cause for
rejection of the entire submittal with no further consideration.
4.
A copy of motor elementary diagrams and process and instrumentation
diagrams (P&IDs) relating to the submitted equipment, with addendum
updates that apply to the equipment in this section, marked to show specific
changes necessary for the equipment proposed in the submittal. If no
changes are required, the drawings shall be marked "no changes required".
Failure to include copies of the relevant drawings with the submittal shall be
cause for rejection of the entire submittal with no further review.
5.
Listing of equipment components and materials including required calibration
ranges for instruments.
6.
Detailed installation drawings showing equipment layout, and the size and
location of all piping, electrical, instrumentation and structural connections.
7.
Proof of Manufacturer’s ISO 9001 certification.
8.
Gear drive data including service factor, efficiency, torque rating and
materials.
9.
List of recommended spare parts in addition to those specified.
10.
Lifting point and equipment weight.
11.
Manufacturer's data confirming conformance to the specified conditions.
Include, as a minimum, equipment rated hydraulic capacity, head loss,
overflow rate, horsepower, electrical requirements, and efficiencies.
12.
Certification attesting that all stainless steel components have been cleaned,
passivated and tested in accordance with the procedures described in this
section
13.
Motor submittal information as specified in Section 11060.
14.
A list of required utility service (i.e., flushing water) including flow rates and
pressure.
15.
Control sequence descriptions for equipment control and external interface
requirements.
16.
Electrical elementary diagrams, internal connection diagrams, and external
interconnection diagrams, drawn in accordance with JIC and/or ICS
standards.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-5
ADDENDUM NO. 3
GRIT PROCESSING UNITS
B.
17.
Connection diagrams shall be the conventional type with lines showing pointto-point wiring and must show terminals and devices as viewed by the
electrician; wireless or wire schedule types are not acceptable.
18.
A copy of Section 17500’s CS 302, with addendum updates included, with
each paragraph check-marked to indicate operation compliance or marked to
indicate requested deviations from operation requirements. Check marks
shall denote full compliance with a paragraph as a whole. If deviations from
the operations are indicated and, therefore requested by the Contractor, each
deviation shall be underlined and denoted by a number in the margin to the
right of the identified paragraph. The remaining portions of the paragraph
not underlined will signify compliance on the part of the Contractor with the
specifications. The submittal shall be accompanied by a detailed, written
justification for each deviation. Failure to include a copy of the marked-up
section, along with justification(s) for any requested deviations to the
operation requirements, with the submittal shall be sufficient cause for
rejection of the entire submittal with no further consideration.
Operation and maintenance manuals shall be provided at the completion of the job
and in accordance with the general conditions. The manuals shall include the
following data:
1.
2.
3.
4.
5.
6.
Alignment, adjustment, and repair instructions.
Manufacturer’s installation instructions.
Assembly diagrams.
Troubleshooting guide.
Lubrication instructions.
Spare parts lists and predicted life of parts subjected to wear.
PART 2--PRODUCTS
2.01
MANUFACTURER
A.
Candidate manufacturers and models are listed below. To conform to specified
requirements, the manufacturer’s standard product may require modification.
1.
2.
2.02
Hydro International
Approved substitute.
MATERIALS
A.
Materials of construction shall be as follows:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-6
ADDENDUM NO. 3
GRIT PROCESSING UNITS
Reference
Title
Washer and screw housing,
plates and sheets
ASTM A240/A240M, Type 316L SS ASTM A480/A480M, No. 1
finish for sheets and “Hotrolled or Cold-rolled, and Annealed or
Heat Treated, and Blast Cleaned or Pickled” finish for plates
Support bars, angles, and
shapes
ASTM A276, Type 316L SS ASTM A484/A484M, Class A finish for
shapes
Support tubes and process
tubes
ASTM A312/A312M, Grade TP316SS
Classifying belt
ASTM A240/A240M, Type 316L SS
Bolts, washers, nuts
ASTM A320/A320M, Class 1
Discharge hose
Abrasion resistant SBR or EPDM
2.03
B.
Where not inferred from the table above, all stainless steel components shall be
treated in a fully immersed pickling bath, to protect the stainless steel against
corrosion.
C.
Materials specified are considered the minimum acceptable for the purposes of
durability, strength, and resistance to erosion and corrosion. The contractor may
propose alternative materials for the purpose of providing greater strength or to meet
required stress limitations. Alternative materials, however, must provide at least the
same qualities as those specified for the Purpose.
EQUIPMENT
A.
GENERAL
1.
Each grit concentrating/classifying mounting system shall be designed as
specified in Section 05501 and Section 01900. Equipment manufacturer
shall furnish all anchor bolts of sufficient size and strength.
2.
Grit concentrating/classifying unit shall be manufacturer’s standard
cataloged product modified to provide compliance with the Drawings,
specifications and the service conditions as specified and indicated. Welding
shall be in accordance with AWS D1.1. Shop tests shall be provided as
specified or required to ensure proper operation.
3.
Grit concentrating/classifying manufacturer shall provide grit concentrator
unit, motors, gear reducers, and lifting attachments as a complete integrated
package to ensure proper coordination, compatibility, and operation of the
systems.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-7
ADDENDUM NO. 3
GRIT PROCESSING UNITS
B.
GRIT CONCENTRATOR UNIT:
1.
Design Data:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
2.
Number of units:
Size:
Performance:
2
42" diameter
95% removal of all grit (specific gravity
2.65) ≥ 75 microns in the flow range
Influent solids concentration: ≤ 1.0%
Design flow/unit:
450 gpm with 202“ of headloss
Minimum flow/unit:
350 gpm with 120“ of headloss
Maximum flow/unit:
550 gpm with 296“ of headloss
Influent connection:
6” flanged pipe
Effluent connection:
8” flanged pipe
Underflow connection:
3” NPT pipe
NPW connection:
1.5” NPT
Material of construction:
316L SS
Operation:
Continuous / intermittent minimum
10-15 minutes
Operation:
a.
Defining characteristics of the dominant free vortex / secondary
boundary layer velocity type units are as follows:
1)
2)
3)
4)
5)
3.
Dominating increasing tangential velocity profile toward the
center of the unit.
The ability to handle increasing flows with no loss of the
specified grit removal efficiency and with no increase in
headloss.
The ability to concentrate (wash) the grit from lighter organic
material to meet the specified organic solids content.
No requirements for electrical or mechanical components,
flow deflecting / guiding weirs or baffles, or compressed air
lines within the unit to meet the specified performance.
Continuous removal of washed, clean grit.
b.
The grit concentrating / classification unit shall be all-hydraulic with
no moving parts within the unit.
c.
The grit underflow from the grit concentrating unit shall be
transported by gravity to the grit classifying unit.
d.
Fluidizing water shall be continuously supplied to the grit
concentrating / classification unit.
Construction:
a.
The grit concentrating / classification unit shall be fabricated from
type 316L stainless steel. The dished and flanged heads shall be a
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-8
ADDENDUM NO. 3
GRIT PROCESSING UNITS
minimum 1/4 inch thick. The vessel walls shall be a minimum 3/16
inch thick.
4.
b.
The grit concentrating / classification unit shall be designed to
withstand a maximum working pressure of 14.7 psig. The actual
maximum pressure at the inlet shall be no more than 14.7 psig.
c.
A minimum 18 inch diameter access shall be provided in the top of
the grit concentrating / classification unit. All internal elements shall
be removable from outside the unit.
d.
The grit concentrating / classification unit shall be free standing on
three legs and mounted above the grit classifying unit. Clearance
shall be provided between the bottom of the grit underflow pipe and
the classifying unit clarifier surface.
e.
The grit concentrating / classification unit shall include a hydraulic
valve (HV) to deliver a continuous flow of “washed” grit slurry to the
classifying unit.
f.
The grit concentrating / classification unit shall have a single 1-1/2
inch NPT pipe stub for connection of the system water.
g.
The unit shall have one (1) 1.5" grit underflow connection, one (1) 3"
threaded drain connection and one (1) 1.5" NPT fluidizing water
connection for the hydraulic valve supply and hydraulic valve
backwash.
Valves and Accessories: Each grit concentrating / classification unit shall be
supplied with the following equipment to regulate and automate the system
water supply:
a.
One (1) 1.5” bronze ball valve for utility water supply shut off.
b.
One (1) 1.5” bronze globe valve to regulate water flow to the HV
c.
One (1) 1.5” NEMA 7 brass solenoid valve to automate system water
to the HV
d.
One (1) 1.5” NEMA 7 brass solenoid valve to automate system
backwash water
e.
One (1) 0-100 psig pressure gauge to monitor the utility water
delivery pressure.
f.
One (1) 0-30 psig pressure gauge to monitor the pressure in the grit
slurry discharge (underflow) line.
g.
One (1) 0-30 psig pressure gauge to measure the inlet pressure to
the grit concentrating / classification unit.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-9
ADDENDUM NO. 3
GRIT PROCESSING UNITS
2.04
h.
Three (3) ¼” bronze ball valves to isolate the pressure gauges
i.
One (1) 0-35 gpm flow meter
GRIT CLASSIFIER
A.
Design Data:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
B.
C.
Number of units:
Maximum grit load:
Performance:
2
3 cy/hr
95% removal of all grit (specific gravity 2.65)
≥ 75 microns with less than 15% volatile
solids and greater than 60% total solids
Belt width:
18"
Clarifier size:
60" square
Min. Free water surface area: 17.3 ft3
Motor:
0.33 hp, TENV
Overflow connection:
6" flanged pipe
Drain connection:
3" flanged pipe
NPW connection:
1.5" NPT
Body material:
316L SS
Belt material:
Neoprene rubber, re-enforced with
polyester and aluminum
Operation:
1.
The grit classifying unit shall be designed to capture and dewater
concentrated, washed grit slurry from the grit concentrating unit.
2.
The grit classifying unit clarifier shall be designed based on a settling rate not
to exceed 3.2 gpm/ft2.
3.
The tailroll mechanism shall be self-cleaning. As the belt rotates with the
tailroll at the bottom of the unit the belt cleats shall lift from the belt to
provide a gap of at least 1-inch. The grit classifying unit belt shall be provided
with 2” openings to allow transfer of fine solids internal to the belt to the
underside of each cleat. The tailroll shall be fitted with a scraper, which shall
function as an internal belt scraper.
Construction:
1.
The grit classifying escalator shall be provided with an integral square clarifier
with at least 3 inches of freeboard.
2.
The housing for the grit classifying escalator belt shall be fitted under the
clarifier. The housing for the grit classifying escalator belt shall be type 316L
stainless steel bonded to the internal surfaces. The belt housing shall be
inclined at 30 degrees.
3.
The belt housing shall be provided with clean out plates and one (1) flanged
drain.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-10
ADDENDUM NO. 3
GRIT PROCESSING UNITS
D.
4.
The grit classifying escalator unit belt shall be made of 1/8 inch x 1/32 inch
two-ply polyester reinforced continuous conductor belting. The belt cleats
shall be 3-3/8” x 4-9/16” of molded 60 durometer neoprene and aluminum
reinforced and shall be vulcanized on the belt. The cleats shall attach to the
belt with minimum 5/32 inch thick neoprene hinges.
5.
The grit classifying escalator unit shall be provided with a 9-3/4 inch
diameter lagged headroll. The headroll shall be adjustable to allow take-up
of slack in the grit classifying escalator belt. Adjustment of the headroll shall
not affect the headroll retainer plate, scraper, or drive unit.
6.
The grit classifying escalator unit shall be provided with a headroll scraper
having 1/4 inch thick high density polyethylene (HDPE) contact surfaces with
a 1/4 inch thick HDPE retainer plate. Both retainer plate and scraper shall be
loaded to keep belt cleats closed tightly around the headroll during operation.
7.
The grit classifying escalator unit shall be provided with a tailroll designed to
mount internally to the unit belt housing with external sealed bearings.
8.
The grit classifying escalator unit support structure shall be as shown on the
general arrangement drawing and anchored to a stable base.
9.
The grit classifying escalator unit shall be supplied with a factory installed
rinse bar system. The system shall include:
a.
Two spray bars located above the belt and below the clarifier liquid
level to enhance grit classifying.
b.
One spray bar located at the bottom of the clarifier as a tailroll area
rinse.
Drive Unit:
1.
The grit classifying escalator shall be provided with a drive unit consisting of
the motor and the helical gear reducer, mounted as a single integrated unit.
All bearings shall be anti-friction, ball, or roller type bearings.
2.
The motor shall be 3 phase, 460 VAC, 60 Hz, NEMA design B, TENV enclosure
suitable for a Class I Division 1 environment.
3.
The helical gear reducer shall have hardened alloy steel gears accurately cut
to shape.
4.
A mechanical torque-limiting clutch shall be mounted on the headroll gear
assembly to prevent an accidental overload of the drive unit and belt.
5.
The drive speed shall be adjusted by a variable frequency drive (VFD)
specified in Section 16158. The belt speed shall be adjustable from
1-5 ft/min.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-11
ADDENDUM NO. 3
GRIT PROCESSING UNITS
E.
VALVES AND ACCESSORIES:
1.
2.
2.05
Each grit classifying escalator unit shall be supplied with the following valves:
a.
One (1) 3” eccentric cast iron plug valve located on the unit drain.
b.
One (1) 1” NEMA 7 brass solenoid valve to automate the water to the
rinse bar system.
c.
Two (2) 1” bronze ball valves to manually shut off flow to the rinse bar
system.
d.
One (1) 1” bronze globe valve to manually regulate flow to the tailroll
spray bar.
e.
One (1) 3/4” bronze ball valve to manually shut off the top rinse bars.
f.
One (1) 2-20 gpm acrylic flow meter
Provide the grit classifying escalator unit with one (1) motion detection
system (consisting of a controller with the probe. Install probe on the side of
the grit classifying escalator unit to detect movement of the headroll scraper
arm. Install the controller in non classified area. Meet the requirements of
Section 17216 for motion detection system.
CONTROLS AND INSTRUMENTATION
A.
CONTROL PANEL
1.
Two (2) control panels shall be furnished, completely pre-wired for local
control and tested.
2.
Each control panel shall adhere to the following specifications:
a.
b.
c.
d.
e.
f.
3.
The control panel shall contain push buttons, switches, indicator lights, and
other components necessary to operate locally and automatic through the
PCS the following equipment:
a.
b.
4.
Enclosure rating: NEMA 7
Voltage: 120 volt
Phase: 1 phase
Frequency: 60 Hz
Load: 15 amps
Logic: Hardwire relay with automatic control interlocked to the PCS
One (1) grit concentrator
One (1) grit classifier (also identified as grit classifying escalator)
Provide each control panel with applicable control relays and time delay
relays with a minimum one extra normally closed and one extra normally
opened contact is provided for each relay.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-12
ADDENDUM NO. 3
GRIT PROCESSING UNITS
5.
Provide relays with dry contacts rated for 24 V dc sensing voltage when
remote monitoring by the PCS is specified. Refer to drawings for signal
interconnection requirements between control panel, VFD, and PCS.
6.
Include the following items on the face of the control panel door:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
2.06
SEQUENCE OF OPERATION
A.
2.07
Combination main disconnect switch and circuit breaker
Back lit, push-to-test power on indicating light
Grit classifier emergency stop push button
Grit concentrator supply or utility water three position OCA switch.
Grit concentrator backwash water valve three position OCA switch
Grit concentrator auxiliary backwash pushbutton
Grit concentrator supply valve open light
Grit concentrator backwash valve open light
Grit concentrator backwash/blowdown
light (light flashes in Blow backwash/
down)
Grit concentrator wet/dry/auto
auto three position switch
Grit classifier running light
Grit classifier three position HOA switch
Grit classifier fail indicating light
Grit classifier supply or rinse water valve three position OCA switch
Grit classifier supply or rinse water valve open indicating light
Grit classifier speed indication meter
The system shall be controlled to provide automatic operation through the PCS logic
and manual operation through the control panel hardwired relay logic. Operation of
the equipment shall be as specified in Section 17500 CS 302.
UTILITY REQUIREMENTS
A.
WATER
1.
B.
Each grit concentrating / classification unit shall require clarified non-potable
water supplied at a regulated 50 psig ± 5 psi. The water requirements are as
follows:
a.
A maximum continuous supply of 35 gpm is required for normal
operation of each grit separation / classification unit.
b.
A maximum intermittent supply of 47 gpm is required for a periodic
short duration during backwash cycle for the grit separation /
classification unit.
c.
A continuous supply of 15 gpm for normal operation of each grit
classifying escalator unit.
ELECTRICAL: Each control panel require one (1) 120 VAC, single phase electrical
service connection to operate with foreign voltage for external interconnections as
specified.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-13
ADDENDUM NO. 3
GRIT PROCESSING UNITS
2.08
MATERIALS AND FINISHES
A.
MATERIALS
1.
All stainless steel used for the fabrication of the equipment shall conform to
the following standards:
Plate and sheet
Bar
Tube
B.
2.09
ASTM A 167
ASTM A 240
ASTM A 276
ASTM A 479
ASTM A 312
EXTERIOR SURFACES FINISHES
1.
All surfaces shall be free of sharp edges, weld spatter and residue. All welds
shall be ground smooth.
2.
All stainless steel surfaces shall be acid washed.
3.
All non-submerged exterior surfaces shall be glass bead blasted to a uniform
finish.
PASSIVATION OF STAINLESS STEEL
A.
GENERAL
1.
Equipment specified under this section shall be cleaned and passivated in
accordance with methods defined in ASTM A380 – Standard Practice for
Cleaning, Descaling, and Passivation of Stainless Steel Parts, and the
specific requirements of this section.
2.
For purposes of this section, cleaning and passivation is defined as the
removal of surface contaminants including exogenous iron or iron
compounds and the removal of oxide films from the surface of stainless steel
by means of mechanical cleaning and mechanical descaling.
3.
The processes specified in this section shall be performed in the
manufacturer’s facility or in a shop specializing in post fabrication treatment
of stainless steel.
4.
Equipment components that bolt together shall be disassembled prior to
passivation to provide access to all surfaces of the equipment.
5.
All fasteners and anchor bolts required for assembly and mounting of
equipment shall conform to the requirements of Section 11000.
6.
The use of “fabricator’s crayons” shall be prohibited during fabrication of
equipment as these marks may prevent proper passivation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-14
ADDENDUM NO. 3
GRIT PROCESSING UNITS
B.
PASSIVATION PROCESS REQUIREMENTS
1.
The processes required for proper passivation shall include precleaning,
mechanical descaling, post-treatment inspection, testing, certification, and
protection as defined below.
a.
Precleaning – Precleaning required for the removal of all grease, oil,
paint, soil, grit and other gross contaminants preparatory to the
fabrication process shall be accomplished by vapor degreasing,
immersion or spray application of alkaline or emulsion cleaners,
steam, or high pressure water jetting.
b.
Mechanical Cleaning and Descaling – Mechanical cleaning is the
removal of surface contamination, exogenous iron and rust.
Mechanical descaling is the removal of oxide films resulting from high
temperature processes such as heat treatment and welding from the
surface of stainless steel. Mechanical cleaning and descaling shall
be accomplished by abrasive bead blasting but may also include a
combination of sanding, grinding, and power brushing to provide a
surface that is smooth, uniform and free from all foreign matter, weld
slag, corrosion, coatings, heat tint, discoloration, and mill scale.
Grinding wheels and sanding tools should not contain iron, iron
oxides, zinc or other materials that could contaminate the stainless
steel surface. Abrasive blasting materials shall be unused glass
beads or iron-free silica or alumina sand. Blasting equipment should
not have been previously used for cleaning carbon steel or other
materials containing free iron. All surfaces shall be wiped clean
following mechanical cleaning.
c.
Post Cleaning Inspection – Post treatment inspection of the part shall
exhibit a clean, bright and uniform surface with no signs of etching or
pitting from the abrasive blasting procedure. All traces of oxide films
from high temperature processes shall have been removed.
d.
Testing – The passivated part shall be tested for the presence or
absence of free iron with a solution of potassium ferricyanide as
defined in Verification Test Practice E, ASTM A967. The test solution
shall be mixed and used within 24-hours or less and applied with
sterile cotton swabs.
e.
Certification – All parts passivated shall be certified by an officer of
both the manufacturer and the passivating shop (if applicable) as
having been cleaned and passivated and tested in accordance with
the procedures described in this section. The Certification shall be
submitted to the Owner prior to shipping the equipment to the project
site. Equipment that is not certified will not be accepted.
f.
Protection – Protection shall be provided by applying shrink wrap to
all parts of the equipment sufficient to prevent exposure of
passivated surfaces to contaminants during handling, shipping and
installation. Protected equipment shall be tagged with highly visible
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-15
ADDENDUM NO. 3
GRIT PROCESSING UNITS
warning signs stating the equipment has been passivated and shall
only be opened by authorized personnel. Equipment arriving at the
project site without proper protection will require retesting for the
presence of free iron and re-passivation if free iron is detected.
2.
Assembly of equipment following passivation – If assembly of bolted parts is
required following passivation, it shall be done at the manufacturing facility
under clean conditions such that the parts will not be contaminated with
exogenous iron or iron compounds. Equipment requiring assembly shall be
re-wrapped sufficient to prevent exposure of passivated surfaces to
contaminants during handling, shipping and installation and tagged with
warning signs.
3.
WITNESS OF PASSIVATION PROCESS: Owner retains the right to witness the
stainless steel passivation process. Provide at least 30-days notice to Officerin-Charge prior to start of passivation process.
PART 3--EXECUTION
3.01
DELIVERY AND INSTALLATION
A.
EQUIPMENT MOUNTING:
1.
PROCEDURES: Section 11002.
2.
Install a Group C Equipment Mounting System in accordance with the
Equipment Mounting Schedule specified in Section 11002.
B.
The equipment and material shall be shipped complete except where partial
disassembly is required by transportation regulations or for protection of
components.
C.
Proper handling shall incorporate all practices described in Section 8.5 – Protection
of Cleaned Surfaces, ASTM A380. Passivated parts contaminated due to improper
handling and installation will require retesting for the presence of free iron and repassivation if free iron is detected.
D.
The equipment specified in this section shall be aligned, connected, and installed at
the locations specified and in accordance with the manufacturer’s written
recommendations. Upon arrival of the equipment at the project site, an authorized
manufacturer’s representative and the Contractor shall make a joint inspection of the
condition of each piece of equipment, in the presence of the Officer-in-Charge.
E.
Spare parts shall be packed in containers bearing packing lists clearly designating
contents and pieces of equipment for which they are intended.
F.
The contractor shall inspect equipment prior to unloading and notify the
manufacturer of any damage to equipment to effect proper remedial action. Failure
to notify the manufacturer of damage to equipment prior to unloading shall void all
warranties pertaining to subject equipment.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-16
ADDENDUM NO. 3
GRIT PROCESSING UNITS
3.02
3.03
G.
Damage or defects shall be noted in writing. Damaged items shall not be accepted.
The equipment shall be unloaded and installed by the Contractor under the
supervision of the manufacturer’s field representatives. The manufacturer shall
provide the services of an on-site field representative for a minimum of one full day
during installation.
H.
The contractor shall unload, store and safeguard equipment, materials, and spare
parts in accordance with manufacturer’s recommendations.
I.
Upon completion of installation, and prior to start-up and testing, the manufacturer
shall submit a written certification that the installation has been completed in
accordance with the manufacturer’s recommendations. Form 11000-A specified in
Section 01999 shall be completed and provided to the Officer-in-Charge.
START-UP, TRAINING AND MANUFACTURER’S SERVICES
A.
A factory trained representative for the equipment specified herein shall be present
at the jobsite and/or classroom designated by the City for a maximum of four (4) 8hour man-days (two (2) visits) for installation inspection, plant startup, functional
testing, and operator instructions; travel time excluded.
B.
The Vendor shall provide a factory trained controls technician who shall work with the
Division 17 PCS programmer to ensure safety and optimal performance for this
Section’s equipment during the Section 17030 functional and operational testing of
the two concentrator/classifier units. A minimum of two 8-hour man-days for
functional testing and a minimum of two 8-hour man-days for operational testing
(travel time excluded) shall be scheduled and coordinated with Division 17 PCS
programmer.
FUNCTIONAL TESTING
A.
Prior to plant startup, all equipment shall be inspected for proper alignment,
operation, connection, and satisfactory operation by means of a functional test. The
manufacturer will be notified of any inabilities to perform functional testing prior to
operator training. Manufacturer will inspect all equipment prior to operation to
ensure proper installation.
B.
Testing and commissioning shall be performed in accordance with Section 01660.
Following completion of the Contractor pressure and leakage tests, electrical testing,
and ringout of circuits, the vendor shall provide an authorized manufacturer’s
representative to perform a pre-operational checkout of instrumentation and
equipment furnished under this contract. Preoperational checkout procedures
include those required prior to operation. Pre-operational checkout prior to operation
of equipment shall include the following:
1.
Verification of equipment alignment.
2.
Pre-operation lubrication
3.
Manufacturer’s recommendations for pre-start preparation and
preoperational checkout procedures.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-17
ADDENDUM NO. 3
GRIT PROCESSING UNITS
4.
C.
3.04
Manufacturer shall perform testing to demonstrate washed grit quality
specified in paragraph 11149-1.03A
3A.
3A. Testing shall include a minimum of 3
grab samples
samples of the dewatered grit product on different days during the
commissioning period. Samples shall be taken at least one week after the
commissioning period has started. Samples shall be lab tested for total
solids concentration.
Testing shall demonstrate accurate measurement of sensors and function of run
sequences, and verify compliance with this Section and Section 17500’s CS 302.
The test shall include Section 17030 functional and operational testing of the two
concentrator/classifier units.
MEASUREMENT AND PAYMENT
A.
Equipment specified in this section shall not be paid for directly, but shall be
considered incidental and included in the lump sum bids for the respective items in
the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11149-18
ADDENDUM NO. 3
GRIT PROCESSING UNITS
SECTION 11345
SUBMERSIBLE CLEAN WATER SUMP PUMPS
PART 1--GENERAL
1.01
SUMMARY
A.
SCOPE: This Section specifies sump pumps complete with motor, discharge flange,
control panel, level instruments, cables, and lifting chain. Pumps shall be of the
submersible, centrifugal type for use in pumping ground water and wash-down water.
B.
EQUIPMENT LIST:
Item
1.02
Equipment No.
TIPS West Elevator Sump Pump
P 200, 141
TIPS West Elevator Sump Pump Control Panel
ICP 200,140
TIPS West Elevator Sump LOW LEVEL float
LSL 200,140
TIPS West Elevator Sump HIGH LEVEL float
LSH 200,140
TIPS West Elevator Sump HIGH HIGH LEVEL float
LSHH 200,140
TIPS East Elevator Sump Pump
P 200, 241
TIPS East Elevator Sump Pump Control Panel
ICP 200,240
TIPS East Elevator Sump LOW LEVEL float
float
LSL 200,240
200,240
TIPS East Elevator Sump HIGH LEVEL float
LSH 200,240
200,240
TIPS East Elevator Sump HIGH HIGH LEVEL float
LSHH 200,240
200,240
QUALITY ASSURANCE
A.
REFERENCE STANDARDS:
1.
This Section incorporates by reference the latest revisions of the following
documents. They are part of this Section insofar as specified and modified
herein. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect on the effective date of the Agreement. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or
otherwise identified by that organization or, if there are no replacement
documents, the last version of the document before it was discontinued.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-1
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
Reference
ASTM A48
Gray Iron Castings
ANSI/HI 1.1 – 1.6
Centrifugal Pumps
ANSI/HI 9.1 – 9.5
Pumps – General Guidelines
ANSI/HI 9.6.3
Centrifugal and Vertical Pumps Allowable Operating
Region
ASTM A276
Stainless and Heat-Resisting Steel Bars and Shapes
UL 674
Motors and Generators, Electric, for Use in Hazardous
Locations, Class I, Groups C and D, Class II, Groups E, F,
and G
B.
1.03
Title
UNIT RESPONSIBILITY: Assign unit responsibility, as specified in Section 11000, to the
pump manufacturer for the pumps, appurtenances, drives, and motors, specified in this
Section. This manufacturer is the unit responsibility manufacturer and has unit
responsibility, as defined in Section 11000, for both the equipment specified in this
Section, and Section 11060. Provide completed and signed Unit Responsibility
Certification Form (Form 11000-C, Section 01999).
SUBMITTALS
A.
PROCEDURES: Section 01300
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
Certificate of Unit Responsibility (Form 11000-C) attesting that unit
responsibility has been assigned in accordance with the requirements of this
Section and Section 11000. No other submittal material will be reviewed until
the certificate has been found in conformance with this requirement.
3.
Predicted pump performance curves for each condition point specified showing
head, power, efficiency, and NPSH3 on the ordinate plotted against capacity on
the abscissa.
4.
Drawings showing general dimensions and confirming the size of pumps,
motors, drives and specified appurtenances; piping connections; construction
details of equipment (including bearings and bearing isolators); wiring
diagrams; and weight of equipment.
5.
Control panel wiring diagrams
6.
Motor Data Form 11060-A.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-2
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
7.
1.04
Manufacturer’s operation and maintenance information in accordance with
Section 01730.
PERFORMANCE REQUIREMENTS
A.
Equipment shall be suitable for installation and service at a wastewater treatment plant,
under the environmental conditions specified in Section 01800.
B.
SERVICE CONDITIONS:
Description
C.
Equipment Number
P 200, 141, P 200, 241
Area Exposure
See Section 01800
Fluid Type
Groundwater and wash-down water.
Fluid Temperature
30 to 70 degrees F
OPERATING CONDITIONS:
Description
Equipment Number
P 200, 141, P 200, 241
Condition A a,c
Capacity, gpm
50
Total head, feet
Condition B b,c
Capacity, gpm
Total head, feet
15
H/Q Curve
10
Notes:
a.
Condition A is taken as the rated operating condition. Performance at the rated
condition is guaranteed. Pumps furnished are selected within the AOR to
achieve Condition A performance, but also operate continuously without
objectionable vibration or cavitation at the head specified under Condition B.
b.
Condition B is presented to indicate operating conditions within the AOR when
the pump is operating at maximum speed against minimum anticipated system
head, assuming a hypothetical head-capacity curve.
c.
Total head in the above table is the algebraic difference between the discharge
head and suction head as defined in ANSI/HI 1.1 through 1.6.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-3
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
D.
DESIGN REQUIREMENTS:
Equipment Number
Item
P 200, 141, P 200, 241
Pump
Rigid sphere, inches diameter (min.), capable of
passing through the pump from inlet to discharge
Discharge piping connection size, inches, minimum
Operating speed, rpm, maximum
Operating speed
Electric Motor (see Section 11060)
Motor type
3/4
1.5
1,800
Constant
Constant Speed
Motor horsepower, maximum
Motor speed, rpm
Motor enclosure, type
Power supply
1/2
1,800
Submersible
480VAC/3-phase/60Hz
Motor space heaters
Moisture detection
Over-temperature Protection
No
Yes
Yes
PART 2--PRODUCTS
2.01
CANDIDATE MANUFACTURERS/PRODUCTS
A.
Candidate manufacturers and models are listed below. To conform with specified
requirements, the manufacturer’s standard product may require modification.
1.
2.
2.02
Tsunumi Pump
Approved substitute.
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
Material
Pump volute, discharge elbow
Cast iron, ASTM A48, Class 30 or 35B
Motor casing
Cast iron, ASTM A48, Class 30 or 35B
Impeller
Hardened Cast iron, ASTM A48
Power cord
14/4 SOOW cord of sufficient length to
reach control panel.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-4
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
Component
2.03
Material
Control cord
18/5 SOOW cord of sufficient length to
reach control panel
Motor and pump shaft
Stainless steel, ASTM A276, Series 416
Mechanical seal
Tandem, carbon/ceramic upper faces,
silicon carbide lower faces
All exposed nuts and bolts
Stainless steel, ASTM A276, Type 316.
Lifting chain
30 feet; Stainless steel ASTM A276, Type
304 or 316
FEATURES:
A.
PUMP AND MOTOR CASING: Casings shall be constructed of corrosion resistant cast
iron and shall be designed to allow removal of all rotating parts from the motor end of
the pumps. All mating surfaces where watertight sealing is required shall be machined
and fitted with nitrile O-rings. Casing shall be fitted with moisture sensor specifically
designed to detect the presence of water in the seal chamber.
B.
IMPELLERS: Impellers shall be statically and dynamically balanced.
C.
BEARINGS: Bearings shall be heavy-duty permanently lubricated ball type. Bearings
shall be designed for an L-10 life of 50,000 hours heavy-duty service without requiring
additional lubrication.
D.
MOTOR: The motor shall be designed to be non-overloading over the entire pump curve.
The motor housing shall be of submersible construction with the windings operating in a
sealed environment. Motors shall be either air or dielectric oil filled with built-in
automatic reset overload protection. The motor shall be provided with motor windings
thermostats, one in each winding, to protect the motor from overheating.
E.
LEVEL FLOAT SWITCHES: Provide level float switches for pump START/STOP control
(LSH and LSL) and for high high level alarm (LSHH).
(LSHH) Level float switches shall meet the
requirements of Section 17216 – INSTRUSPEC LFS.
LFS Provide float cord of sufficient
length to reach the control panel from the sump.
F.
CONTROL PANELS: The control panel for the sump pumps shall be designed in
accordance with Section 17110 and in conformance with the P&ID.
1.
Panels shall be provided with instruments used for control, monitoring, and
alarming.
2.
Control shall include HAND/OFF/AUTO mode selection and motor protection.
Alarms shall include HIGHHIGH-HIGH LEVEL, FAULT, HIGH MOTOR TEMPERATURE
and MOISTURE LEAK.
LEAK Include RESET push buttons
buttons to clear motor protection
alarms.
alarms. Status shall include pump running.
3.
Panels shall be NEMA 4X rated.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-5
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
2.04
4.
Panels shall contain distribution components, power supplies, and
transformers, as required, to derive power for all instruments and equipment
provided as part of the pump package.
5.
Separate pump and control circuit breaker with intrinsically safe module for
floats.
6.
Dry contact and panel lights for pump running, pump fail, moisture sensor,
motor over temperature, and high level alarm.
7.
Suitable for service from a single 480V ac, three-phase service.
8.
Internal enclosure heater.
9.
Terminal strip for connection of external devices.
10.
Motor starter per Division 16.
PUMP CONTROL SYSTEM:
A.
Controls shall be provided as specified in Section 17500_CS 210, in accordance with
Divisions 16 and 17.
B.
Pump Protection Controller:
C.
1.
Moisture sensor shall be wired to activate an indicator in the local control panel
and to send an alarm to the Plant Control System. Upon detection of moisture
the alarm shall be activated, but the pump shall be allowed to run.
2.
Temperature switch shall be wire to disable the pump if excessive heat is
detected and send an alarm to the Plant Control System. The thermostats shall
reset automatically after the motor windings have cooled down. Provide
provision for manual reset of the motor.
External Signal Interface: Provide dry contact closures for connection to the Plant
Control System rated 0.5 amps at 12 or 24 Vdc for the following conditions:
1.
2.
3.
2.05
Pump running status.
HIGH HIGH level alarm.
Ready status. Ready status is pump set to AUTO mode with no active alarms
present.
SPARE PARTS
A.
Each pump shall be provided with the following spare parts:
1 set - all gaskets
1 set - all bearings
1 set - mechanical seals
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-6
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
B.
Spare parts shall be packed and boxed as specified in Section 11000.
PART 3--EXECUTION
3.01
INSTALLATION
A.
3.02
3.03
EQUIPMENT MOUNTING: Install per manufacturer’s recommendation.
COATINGS
A.
PRIMER: per manufacturer’s recommendation.
B.
COATING: per manufacturer’s recommendation.
COMPONENT TEST PHASE
A.
PROCEDURES: Section 01660 and Section 01662.
B.
Perform the following tests:
1.
3.04
PERFORMANCE TEST
a.
Using clean water, measure pump flow and discharge pressure. Verify
pump flow and discharge pressure is within the range of specified
operating conditions.
b.
Temporary flow meters and pressure gauges will be required.
c.
Throttle valve on pump discharge as necessary to achieve specified
pump pressure within specified operating range.
d.
Test float switches to verify pump control system operates as specified
in this Section.
MANUFACTURER’S SERVICES
A.
ON-SITE INSPECTIONS AND TRAINING: Provide a factory-trained manufacturer’s
representative at the Site for the following activities. Specified durations do not
include travel time to or from the Site.
1.
INSTALLATION INSPECTIONS: Assist, supervise, and inspect the Contractor’s
activities during installation of submersible sump pumps. Provide 2 hours of
installation inspection during installation of each submersible sump pumps.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-7
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
3.05
MEASUREMENT AND PAYMENT
A.
Submersible clean water sump pumps shall not be paid for directly, but shall be
considered incidental and included in the lump sum bids for the respective items in
the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11345-8
ADDENDUM NO. 3
SUBMERSIBLE CLEAN WATER
SUMP PUMPS
SECTION 11346
SUBMERSIBLE SUMP PUMPS
PART 1--GENERAL
1.01
SUMMARY
A.
SCOPE: This Section specifies sump pumps complete with motor, discharge flange,
level instruments, control panel cable, guide rails, and lifting chain. Pumps shall be of
the submersible, centrifugal nonclog type for use in pumping floor drainage.
B.
EQUIPMENT LIST:
Item
Equipment No.
TIPS West Sump Pump 1
P 200, 151
TIPS West Sump Pump 2
P 200, 152
TIPS West Sump Pumps Control Panel
ICP 200, 150
TIPS West Sump LOW LOW LEVEL float
LSLL
LSLL 200,150
200,150
TIPS West Sump LOW LEVEL float
LSL 200, 150
TIPS West Sump HIGH LEVEL float
LSH 200,150
200,150
TIPS West Sump HIGH HIGH LEVEL float
LSHH 200,150
200,150
TIPS East Sump Pump 1
P 200, 251
TIPS East Sump Pump 2
P 200, 252
TIPS East Sump Pumps Control Panel
ICP 200, 250
TIPS East Sump LOW LOW LEVEL float
LSLL 200,250
TIPS East Sump LOW LEVEL float
LSL 200,250
TIPS East Sump HIGH LEVEL float
LSH 200,250
TIPS East Sump HIGH HIGH LEVEL float
LSHH 200,250
Headworks Sump Pump 1
P 300, 401
Headworks Sump Pump 2
P 300, 402
Headworks Sump Pumps Control Panel
ICP 300, 400
Headworks Sump LOW LOW LEVEL float
LSLL 300,400
Headworks Sump LOW LEVEL float
LSL 300,400
Headworks Sump HIGH LEVEL float
LSH 300,400
Headworks Sump HIGH HIGH LEVEL float
LSHH 300,400
300,400
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-1
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
1.02
QUALITY ASSURANCE
A.
REFERENCE STANDARDS:
1.
This Section incorporates by reference the latest revisions of the following
documents. They are part of this Section insofar as specified and modified
herein. In the event of conflict between the requirements of this Section and
those of the listed documents, the requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect on the effective date of the Agreement. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or
otherwise identified by that organization or, if there are no replacement
documents, the last version of the document before it was discontinued.
Reference
ASTM A48
Gray Iron Castings
ASTM A276
Stainless and Heat-Resisting Steel Bars and Shapes
UL 674
Motors and Generators, Electric, for Use in Hazardous Locations,
Class I, Groups C and D, Class II, Groups E, F, and G
B.
1.03
Title
UNIT RESPONSIBILITY: Assign unit responsibility, as specified in Section 11000, to the
pump manufacturer for the pumps, appurtenances, drives, and motors, specified in this
Section. This manufacturer is the unit responsibility manufacturer and has unit
responsibility, as defined in Section 11000, for both the equipment specified in this
Section, and Section 11060. Provide completed and signed Unit Responsibility
Certification Form (Form 11000-C, Section 01999).
SUBMITTALS
A.
PROCEDURES: Section 01300
B.
ACTION SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
Certificate of Unit Responsibility (Form 11000-C) attesting that unit
responsibility has been assigned in accordance with the requirements of this
Section and Section 11000. No other submittal material will be reviewed until
the certificate has been found in conformance with this requirement.
3.
Guaranteed pump performance curves for each condition point specified
showing head, power, efficiency, and NPSH3 on the ordinate plotted against
capacity on the abscissa.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-2
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
1.04
4.
Drawings showing general dimensions and confirming the size of pumps,
motors, drives and specified appurtenances; piping connections; construction
details of equipment (including bearings and bearing isolators); weight of
equipment
5.
Control panel wiring diagrams
6.
Motor Data Form 11060-A.
7.
Manufacturer’s operation and maintenance information in accordance with
Section 01730.
PERFORMANCE REQUIREMENTS
A.
SERVICE CONDITIONS:
Equipment Number
P 200, 151, P 200, 152
P 300, 401
P 200, 251, P 200, 252
P 300, 402
Description
B.
Area Exposure
See Section 01800
See Section 01800,
Class I, Div 1.
Fluid Type
Process drainage containing
washdown water and
wastewater sludge.
Process drainage containing
washdown water and
wastewater sludge.
Fluid Temperature
50 to 105 degrees F
50 to 105 degrees F
OPERATING CONDITIONS:
Description
Equipment Number
P 200, 151, P 200, 152
P 300, 401
P 200, 251, P 200, 252
P 300, 402
Condition A a,c
Capacity, gpm
250
250
Total head, feet
78
24
Minimum efficiency, percent
50
45
H/Q capacity curve
H/Q capacity curve
Total head, feet
70
18
Minimum efficiency, percent
50
45
Condition B b,c
Capacity, gpm
a. Condition A is taken as the rated operating condition. Performance at the rated
condition is guaranteed. Pumps furnished under this Section are selected to
achieve Condition A performance within its PACL, as defined in Section 11050,
but also operate continuously without objectionable vibration or cavitation at the
head specified under Condition B.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-3
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
b. Condition B is presented to indicate operating conditions when the pump is
operating at maximum speed against minimum anticipated system head,
assuming a hypothetical head-capacity curve. Condition B shall be located
within the PACL as defined in Section 11050.
c. Total head in the above table is the algebraic difference between the discharge
head and suction head as defined in ANSI/HI 1.1 through 1.6.
C.
DESIGN REQUIREMENTS:
Equipment Number
P 200, 151
P 200, 152
P 300, 401
P 200, 251
P 300, 402
P 200, 252
Item
Pump
Rigid sphere, inches diameter (min.), capable of
passing through the pump from inlet to discharge
2
2
Discharge piping connection size, inches,
minimum
3
3
1,800
1,800
Constant
Constant
Constant
Constant
Submersible
Submersible
20
3
1,800
1,800
90
90
480VAC/3phase/60Hz
480VAC/3phase/60Hz
Motor space heaters
No
No
Moisture Detection
Yes
Yes
Over-Temperature Protection
Yes
Yes
Operating speed, rpm, maximum
Operating speed
Electric Motor (see Section 11060)
Motor type
Motor enclosure
Motor horsepower, maximum
Motor speed, rpm
Motor efficiency, minimum
Power supply
PART 2--PRODUCTS
2.01
CANDIDATE MANUFACTURERS/PRODUCTS
A.
Candidate manufacturers and models are listed below. To conform with specified
requirements, the manufacturer’s standard product may require modification.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-4
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
1.
2.
3.
2.02
Wilo
Flygt
Or approved substitute
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
2.03
Material
Pump volute, discharge elbow
Cast iron, ASTM A48, Class 30 or 35B
Motor casing
Cast iron, ASTM A48, Class 30 or 35B
Impeller
Hardened Cast iron, ASTM A48
Wear rings and wear plates
Nitrile or stainless steel, ASTM A276,
Series 400 heat treated
Motor and pump shaft
Stainless steel, ASTM A276 Type 329,
403, 420 or ASTM A479 Type 403, 431
Mechanical seal
Tandem, carbon/ceramic upper faces,
silicon carbide lower faces
All exposed nuts and bolts
Stainless steel ASTM A276, Type 316
Guide bar brackets, guide rails,
and lifting chain or cable
Stainless steel ASTM A276 Type 316
FEATURES
A.
PUMPS AND MOTOR CASING: Casings shall be constructed of corrosion resistant cast
iron and shall be designed to allow removal of all rotating parts from the motor end of
the pumps. All mating surfaces where watertight sealing is required shall be
machined and fitted with nitrile O-rings. Casing shall be fitted with moisture sensor
specifically designed to detect the presence of water in the seal chamber.
B.
IMPELLERS:
1.
Alternate 1: The impeller shall be dynamically balanced with a non-clogging
design capable of passing solids, fibrous materials, heavy sludge, and other
matter found in normal sewage applications through to the discharge nozzle.
Impellers for pumps with discharge nozzles 4 inches in diameter and greater
shall be not less than two-vane design. Fit between the impeller and the
shaft shall be a sliding fit with a taper-lock bushing pressed by a screw that is
threaded into the end of the shaft, or a slip fit onto the shaft and drive key
and fastened to the shaft by an impeller nut having cover for protection from
pumped fluid. A wearing ring system designed for abrasion resistance shall
provide efficient sealing between the volute and impeller.
2.
Alternate 2: The impeller shall be dynamically balanced, semi-open, multivane, back-swept, non-clog design. The impeller vane leading edges shall be
mechanically self-cleaned upon each rotation as they pass across a spiral
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-5
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
groove located on the volute suction which shall keep them clear of debris,
maintaining an unobstructed leading edge. The impeller(s) vanes shall have
screw-shaped leading edges that are hardened to Rc 45 and shall be capable
of handling solids, fibrous materials, heavy sludge and other matter found in
waste water. The screw shape of the impeller inlet shall provide an inducing
effect for the handling of sludge and rag-laden wastewater. Impellers shall
be locked to the shaft and shall be coated with alkyd resin primer.
C.
BEARINGS: Bearings shall be heavy-duty permanently lubricated ball type. Bearings
shall be designed for an L-10 life of 50,000 hours heavy-duty service without
requiring additional lubrication.
D.
MECHANICAL SEALS. Provide tandem mechanical seals per the following requirements:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Dual cartridge
High capacity barrier fluid ports
Self-centering, non-fretting
Springs isolated from the both process and barrier fluids
Pressure Rating: 250 psig
Stationary Face: silicon carbide
Rotary Face: silicon carbide
Metal Parts: Type 316 stainless steel
Springs: Hastelloy C
O-Rings: fluorocarbon
Candidate Product: Chesterton 255 or approved substitute
E.
MOTOR: The motor shall be designed to be non-overloading over the entire pump
curve. The motor housing shall be of submersible construction with the windings
operating in a sealed environment. Motors shall be either air or dielectric oil filled
with built-in automatic reset overload protection. Motors shall be UL listed in
accordance with UL 674 for Class I, Group D hazardous atmosphere. Refer to Section
11060. The motor shall be provided with motor windings thermostats, one in each
winding, to protect the motor from overheating.
F.
CABLE: Pump motor and detector cables shall be suitable for submersible pump
applications. Power for the motor shall be carried by a heavy-duty, flexible, waterresistant portable, UL listed cable, sealed at the motor bell and of sufficient length to
connect to the junction box or the plug outlet. The cable entry shall be comprised of
a singles cylinder elastomer grommet and shall prevent water from leaking into the
motor due to capillary action even if cable is cut or damaged. Cables shall be water
tight to a minimum depth of 65 feet.
G.
GUIDE RAIL LIFTING SYSTEM AND DISCHARGE ELBOW:
1.
The pump shall be provided with a dual guide rail system to allow easy
removal of the pump without entering the wet well. The discharge connection
shall be bolted to the structure as required by the pump manufacturer and
shall serve as a lower attachment for the guide rails. The discharge
connection shall be an elbow discharge type.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-6
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
H.
2.04
2.
The pump and guide rail system shall be designed to automatically connect
the pump to the discharge piping when lowered into place on the discharge
connection. The design shall be non-sparking and shall conform to UL
requirements for installation in a location classified in accordance with NFPA
70, Article 500 for Class 1, Group D, Division 1 locations. When in place, the
connection shall form a watertight seal with the discharge fitting. The pump
shall be easily removable for inspection or service, requiring no bolts, nuts, or
other fastenings to be removed for this purpose. Sealing of the pumping unit
to the discharge connection shall be accomplished by a simple linear
downward motion of the pump with the entire weight of the pumping unit
guided to and pressing tightly against the discharge connections. No portion
of the pump shall bear directly on the floor of the sump and no rotary motion
of the pump shall be required for sealing. Once the pump has been
positioned on its support fitting at the discharge fitting, the guide bar system
shall not be required for pump support.
3.
The pump shall be provided with a lifting chain, guide bars, upper guide bar
brackets, intermediate guide bar brackets, cable holder assemblies, safety
chain hook assemblies, discharge elbow connections, anchor bolts, and all
other accessories necessary to complete the installation as specified. The
lifting chain length shall equal the depth of the sump.
LEVEL FLOAT SWITCHES: Provide level float switches for pump START/STOP, LEAD/LAG
control (LSLL, LSL, and LSH) and for high high level alarm (LSHH).
(LSHH) Level float switches
shall meet the requirements of Section 17216 – INSTRUSPEC LFS.
LFS Provide float cord of
sufficient length to reach the control panel from the sump.
CONTROL PANEL
A.
GENERAL: Panels shall be provided with instruments used for control, monitoring, and
alarming. The control panel for the sump pumps shall be designed in accordance with
Section 17110 and in conformance with the P&ID.
B.
The Headworks Sump Pumps Control Panel - ICP 300, 400 - shall be NEMA 7 rated for a
Class I, Division 1 installation. The TIPS West and TIPS East Sump Pumps Control
Panels - ICP 200, 150 and ICP 200, 250, shall be NEMA 4X rated.
C.
FEATURES:
1.
Panels shall be provided with instruments used for control, monitoring, and
alarming.
2.
Control shall include HAND/OFF/AUTO mode selection, pump LEAD/LAG,
LEAD/LAG and
motor protection. Alarms shall include HIGHHIGH-HIGH LEVEL, FAULT, HIGH MOTOR
TEMPERATURE and MOISTURE LEAK.
LEAK Include RESET push buttons to clear
motor protection alarms. Status shall include pump running.
3.
Panels shall contain distribution components, power supplies, and
transformers, as required, to derive power for all instruments and equipment
provided as part of the pump package.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-7
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
2.05
4.
Separate pump and control circuit breaker with intrinsically safe module for
floats.
5.
Dry contact and panel lights for pump running, pump fail, moisture sensor,
motor over temperature, and high level alarm.
6.
Suitable for service from a single 480V ac, three-phase service.
7.
Internal enclosure heater.
8.
Terminal strip for connection of external devices.
9.
Motor starter per Division 16.
PUMP CONTROL SYSTEM:
A.
Controls shall be provided as specified in Section 17500_CS 210 and CS 307,
307 in
accordance with Divisions 16 and 17.
B.
Pump Protection Controller:
C.
1.
Moisture sensor shall be wired to activate an indicator in the local control panel
and to send an alarm to the Plant Control System. Upon detection of moisture
the alarm shall be activated, but the pump shall be allowed to run.
2.
Temperature switch shall be wire to disable the pump if excessive heat is
detected and send an alarm to the Plant Control System. The thermostats shall
reset automatically after the motor windings have cooled down. Provide
provision for manual reset of the motor.
External Signal Interface: Provide dry contact closures for connection to the Plant
Control System rated 0.5 amps at 12 or 24 Vdc for the following conditions:
1.
2.
3.
2.06
Pump running status.
HIGH HIGH level alarm.
Ready status. Ready status is pump set to AUTO mode with no active alarms
present.
SPARE PARTS
A.
PROCEDURES: Section 11000.
B.
Provide the following spare parts for each model and size of pump furnished for this
Section:
1.
2.
3.
4.
5.
One complete set of all gaskets and seals
Two complete sets of all bearings
Two complete sets of mechanical seals
Two complete sets of discharge connection sealing devices
One removable cable seal chamber cap with 15 feet of cable
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-8
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
6.
7.
8.
Two terminal blocks
One complete spare TIPS sump pump
One complete spare Headworks sump pump
PART 3--EXECUTION
3.01
INSTALLATION
A.
3.02
3.03
EQUIPMENT MOUNTING:
1.
PROCEDURES: Section 11002.
2.
Install on a Group E Equipment Mounting System in accordance with the
Equipment Mounting Schedule specified in Section 11002.
COATINGS
A.
PROCEDURES: Section 09900.
B.
PRIMER COATING: Shop apply in accordance with Section 09900.
C.
FINISH COATING: Field apply in accordance with Section 09900.
COMPONENT TEST PHASE
A.
PROCEDURES: Section 01660 and Section 01662.
B.
Perform the following tests:
1.
3.04
PERFORMANCE TEST
a.
Using clean water, measure pump flow and discharge pressure. Verify
pump flow and discharge pressure is within the range of specified
operating conditions.
b.
Temporary flow meters and pressure gauges will be required.
c.
Throttle valve on pump discharge as necessary to achieve specified
pump pressure within specified operating range.
d.
Test float switches to verify pump control system operates as specified
in this Section.
MANUFACTURER’S SERVICES
A.
ON-SITE INSPECTIONS AND TRAINING: Provide a factory-trained manufacturer’s
representative at the Site for the following activities. Specified durations do not
include travel time to or from the Site.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-9
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
3.05
1.
INSTALLATION INSPECTIONS: Assist, supervise, and inspect the Contractor’s
activities during installation of submersible sump pumps. Provide 4 hours of
installation inspection during installation of each submersible sump pumps.
2.
TRAINING SESSIONS: Procedures Section 01664. Provide 2 hours of
classroom training. Complete Form 11000-B, Section 01999.
MEASUREMENT AND PAYMENT
A.
Submersible sump pumps shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
11346-10
ADDENDUM NO. 3
SUBMERSIBLE SUMP PUMPS
SECTION 12705
FURNITURE SYSTEMS
PART 1 - GENERAL
1.01
SUMMARY
A.
Workstations
1.
This specification establishes the minimum requirements for the acquisition and
installation of a complete and usable system of workstations composed of
freestanding work surfaces or base units, supporting components, and accessories.
Workstation requirements and configurations shall be in accordance with the
furniture layout shown in drawings and specified herein. Provide components and
hardware from a single manufacturer; they shall be standard products as shown in
the most recent published price lists or amendments; submit complete listing of
part/model numbers for all components to be provided, including names and codes
of components referenced on updated drawings. Coordinate the work of this section
with that to be performed under other sections. This specification may include items
which are not manufactured by the furniture manufacturer; provide any such items
under this section.
B.
Samples
1.
Submit samples as required to obtain final approval. The City reserves the right to
reject any finish samples that do not satisfy the construction or color requirements.
Work shall not proceed without sample approval in writing from the Officer-in-Charge.
Submit four sets of the finish samples listed below:
a.
.Work surface, and component finish. Minimum 2-1/2 by 3 inches with label
designating the manufacturer, material composition, thickness, color, and
finish.
C.
Alternate Design
1.
Manufacturers who are unable to provide workstations that conform exactly to the
furniture layouts and typical workstation types shown in the contract drawings and
described in the specifications, may submit alternate designs for consideration by
the Officer-in-Charge. Alternate designs shall meet or exceed the following criteria.
Alternate designs that are submitted but do not meet these criteria will be rejected.
The alternate design shall provide workstations and components of the same basic
size and configuration shown, with only the sizes of the individual components within
the workstation changed to meet the standard product of the manufacturer or site
conditions.
2.
Component Requirements
a.
The types of components or elements utilized shall be as as specified in PART
2 PRODUCTS of this specification.
The storage capacity, number of
workstations accommodated, width of aisles, or workstation configuration shall
not be reduced.
D.
Performance Requirements
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
12705 - 1
ADDENDUM NO. 3
FURNITURE SYSTEMS
1.
2.
1.02
Work surfaces, pedestals, shelf units, overhead door cabinets, lateral files, locks,
accessories, and miscellaneous hardware shall meet testing as specified. ISO 9001
certified manufacturers may perform in-house testing. Manufacturers not ISO 9001
qualified will be required to produce testing by an independent testing laboratory.
Component specific requirements are listed in appropriate paragraphs.
Selected Components
a.
Workstations shall conform to the requirements of ANSI/BIFMA X5.5.
SUBMITTALS
A.
Product Data: Manufacturer's data sheets on each product to be used, including:
1.
Preparation instructions and recommendations.
2.
Storage and handling requirements and recommendations.
3.
Installation methods.
B.
Shop Drawings: Submit as required by the Detail Drawings paragraph in this section.
C.
Selection Samples: For each finish product specified, two complete sets of color chips
representing manufacturer's full range of available colors and patterns.
D.
Verification Samples: For each finish product specified, two samples, minimum size 6
inches (150 mm) square, representing the actual product, color, and patterns.
E.
1.03
Manufacturer's Certificates: Certify products meet or exceed specified requirements.
QUALITY ASSURANCE
A.
General Safety
1.
Provide workstation products free of rough or sharp edges. Desk-based workstation
components shall have the option for a positive, integral locking device that secures
components to the base units.
B.
Fire Safety
1.
Components shall meet requirements for flame spread and smoke development as
specified by the IBC 2009 except as follows.
a.
Testing shall have been conducted in accordance with either ASTM E84 or UL
723 on the entire assembled panel and each different combination of fabric
and interior construction.
b.
Fabric shall meet the requirements of NFPA 265.
C.
Detail Drawings
1.
Drawing requirements, which are the furniture manufacturer's responsibility, shall be
provided as a single submittal. Provide electronic drawings to the user for future reconfiguration in the software package requested by the user. The electronic
drawings shall include all modifications made during installation. As a minimum,
submit the following:
a.
Overall reference drawings: Drawings showing workstation locations and
overall plan view within each floor. The scale shall be 1/8 inch = 1 foot.
Layouts shall reflect field verified conditions.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
12705 - 2
ADDENDUM NO. 3
FURNITURE SYSTEMS
b.
c.
1.04
A.
1.05
Installation drawings: Drawings showing workstations, panels, spine walls,
components, and plan view within each floor. Workstations shall be identified
by workstation type; submit drawings showing the proposed workstation
installation at a scale of 1/4 inch = 1 foot, unless otherwise specified. Scale of
other drawings shall be identical to Architectural plans. Installation drawings
shall reflect field verified conditions.
Workstation elevations: Dimensioned workstation elevations showing each
type of workstation with panel frame [and spine wall frame] configurations and
all components identified with manufacturer's catalog numbers. Elevations
shall be drawn at 1/2 inch = 1 foot scale.
DELIVERY, STORAGE, AND HANDLING
Deliver components to the jobsite in the manufacturer's original packaging with the brand,
item identification, and project reference clearly marked thereon. Remove furniture system
components from packaging and store in an unoccupied, dry location that is ventilated.
Storage shall be free from dirt and dust, water, and other contaminants, and in a manner
that permits easy access for inspection and handling.
SEQUENCING AND COORDINATION
A.
Ensure that products of this section are supplied to affected trades in time to prevent
interruption of construction progress.
B.
Coordinate casework installation with size, location and installation of service utilities.
1.06
A.
1.07
PROJECT CONDITIONS
Maintain environmental conditions (temperature, humidity, and ventilation) within limits
recommended by manufacturer for optimum results. Do not install products under
environmental conditions outside manufacturer's absolute limits.
WARRANTY
A.
Warrant the furniture systems for a period of 10 years with the following exceptions:
1.
Fabrics and other covering materials, and paper handling products shall be
guaranteed for 3 years.
B.
Warranties shall be signed by the authorized representative of the manufacturer. Present
warranties, accompanied by document authenticating the signer as an authorized
representative of the guarantor, to the Officer-in-Charge upon the completion of the project.
Guarantee that the workstation products and installation are free from any defects in
material and workmanship from the date of delivery. Submit two copies of the warranty.
PART 2 - PRODUCTS
2.01
A.
PANELS
D-1 Freestanding Single Pedestal Desk
Quantity: 4 ea.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
12705 - 3
ADDENDUM NO. 3
FURNITURE SYSTEMS
Herman Miller Inc. 5000 Series desk and
Herman Miller Meridian pedestal (or approved equivalent)
Desk:
Pedestal:
Desk:
5
72
30
LL
TS
MT
TL
7X
MT
NTG
freestanding metal desk shell with 2 panel end supports with adjustable
glides;
open back panel (face against architectural wall to be partial height modesty
panel to gain access to power and telcom outlets mounted on architectural
wall);
72” width;
30” depth;
full end panel left, full end panel right;
smooth paint on textured steel;
understructure finish Medium Tone
laminate top with thermoplastic edge;
top finish: laminate top – fiber laminate: Cardamom Fiber;
thermoplastic edge color Medium Tone;
no grommets;
Pedestal:
S16
18
22
BF
XS
TS
KD
B1
C
Standard-Pull Suspended Pedestal;
18” width;
22” depth;
Configuration: Box/ File
textured paint on smooth steel;
smooth paint on textured steel;
lock: keyed differently, black;
base height: 1” high base;
Compressor: standard compressor;
PO
B.
30” deep, 72” wide, 29” high;
22” deep, 15” wide, 19-5/8” high (includes base);
D-2 Freestanding Single Pedestal Desk with Flipper Door Unit
Quantity: 1 ea.
Same as D-1 above, except include flipper door unit (an independent storage hutch unit
which sits and connects onto desk top; include attachment hardware; flipper door unit
doors to flip above unit when opened) with closed back of unit (vertical surface between
flipper door unit and top of desk) to include an integral tackboard
Flipper door unit: 14-1/2” deep, 72” wide, 39-3/8” high
Flipper door unit shall consist of 2 (two) 36” wide units to equal 72” width;
Desk: see D-1
Pedestal: see D-1
Flipper Door Unit:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
12705 - 4
ADDENDUM NO. 3
FURNITURE SYSTEMS
5
7239-OD
T
TS
MT
8T18
KD
C.
flipper door unit;
door material: painted door;
painted door 72” width;
tackboard;
smooth paint on textured steel;
case/ end panel/door Medium Tone; Tackboard fabric: price category 1
Crossing, color Indigo;
lock: keyed differently, black;
F-1 Lateral File Cabinet
Quantity: 4 ea.
Herman Miller Meridian (or approved equivalent) freestanding, standard configuration lateral file
42” width x 20” depth x 61-1/2” high
26
42
20
5N
XS
MT
T2
KD
B2
CB
9R
D.
Standard pull freestanding lateral file;
unit width 42”;
unit depth 20”;
configuration: 5 drawer units, 11-3/4” high drawer;
textured paint on smooth steel;
surface finish: Medium Tone
top 1-1/4” high painted metal top with square edge;
lock: keyed differently, black;
base height: 1-1/2” high base;
include counterweight
drawer interior: side-to-side filing rail
C-1 Ergonomic Task Chair
Quantity: 5 ea.
Herman Miller Aeron Work (task) Chair (or approved equivalent)
Seat depth: (based on B size): 17”
Seat height range: (based on B size): 15”-20-7/8”
Overall chair width outer arms (based on B size): 27”
Overall seat width (based on B size): 20-1/4”
Overall chair height (based on B size): 42” max
AE11
1
A
W
C
AJ
G1
C9
work chair;
tilt: standard tilt;
arms: fully adjustable arms;
non-upholstered arm pads;
size: B size;
back support option: adjustable lumbar support;
base/ frame finish: Graphite;
casters: 2-1/2” braking caster, black yoke, hard floor or carpet;
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
12705 - 5
ADDENDUM NO. 3
FURNITURE SYSTEMS
BK
3D01
armpad finish: Black;
Pellicle material: price category 1: Pellicle Classic, color Carbon; armpad
leather: price category 7 Black
PART 3 - EXECUTION
3.01
INSTALLATION
A.
Examine substrates, areas, and conditions, with Installer present, for compliance with
requirements for installation tolerances, operational clearances, and other conditions
affecting performance.
1.
Proceed with installation only after unsatisfactory conditions have been corrected.
B.
Install the workstations using certified installers in accordance with manufacturer's
recommended installation instructions. Workstation components shall be installed level,
plumb, square, and with proper alignment with adjoining furniture. The components shall
be securely interconnected and securely attached to the building where required. Provide
three sets of special tools and equipment necessary for the relocation of panels and other
components. Verify that equipment is properly installed, connected, and adjusted.
3.02
A.
3.03
A.
CLEANING
Upon completion of installation, all products shall be cleaned and polished and the area
shall be left in a clean and neat condition. Any defects in material and installation shall be
repaired, and damaged products that cannot be satisfactorily repaired shall be replaced.
Submit three sets of Maintenance Manuals describing proper cleaning and minor repair
procedures.
MEASUREMENT AND PAYMENT
All work specified in this section shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
12705 - 6
ADDENDUM NO. 3
FURNITURE SYSTEMS
SECTION 13123
ACOUSTIC ENCLOSURES
PART 1--GENERAL
1.01
DESCRIPTION
A.
SCOPE: This Section specifies acoustic enclosures for sound attenuation of foul air
fans. Acoustic enclosures shall include panels, insulation, structural members,
enclosure ventilation systems, sound traps, and all other incidentals specified in the
Contract Documents.
B.
EQUIPMENT LIST:
Description
KAI-ODOR, TIPS Acoustic Enclosure
ENC 500,101
KAI-ODOR, TIPS Foul Air Fan 1
F 500,110
KAI-ODOR, TIPS Foul Air Fan 2
F 500,120
KAI-ODOR, TIPS Inlet Sound Trap 1
ST 500,130
KAI-ODOR, TIPS Inlet Sound Trap 2
ST 500,131
KAI-ODOR, TIPS Discharge Sound Trap
ST 500,132
KAI-ODOR, HDWKS Discharge Sound Trap
ST 550,130
KAN-ODOR, Acoustic Enclosure
1.02
Equipment No.
ENC 900,101
KAN-ODOR, Foul Air Fan 1
F 900,110
KAN-ODOR, Foul Air Fan 2
F 900,120
KAN-ODOR, Inlet Sound Trap 1
ST 900,130
KAN-ODOR, Inlet Sound Trap 2
ST 900,131
KAN-ODOR, Discharge Sound Trap
ST 900,132
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this Section
and those of the listed documents, the requirements of this Section shall prevail.
Unless otherwise specified, references to documents shall mean the documents in
effect on the effective date of Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replaced documents issued or otherwise identified by that organization, or if
there are no replacement documents, the last version of the document before it was
discontinued.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-1
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
Reference
1.03
Title
ASCE 7-05
Minimum Design Loads for Buildings and Other Structures
ASTM A167
Standard Specification for Stainless and Heat-Resisting
Chromium-Nickel Steel Plate, Sheet, and Strip
ASTM C423
Standard Test Method for Sound Absorption and Sound
Absorption Coefficients by the Reverberation Room
Method
ASTM E84
Standard Test Method for Surface Burning Characteristics
of Building Materials
ASTM E90
Standard Test Method for Laboratory Measurement of
Airborne Sound Transmission Loss of Building Partitions
and Elements
ASTM E477
Standard Test Method for Measuring Acoustical and
Airflow Performance of Duct Liner Materials and
Prefabricated Silencers
IBC 2006
International Building Code 2006 with City and County of
Honolulu local amendments
B.
SPECIAL WARRANTY: Provide a Special Warranty in accordance with Section 01740.
Manufacturer shall warrant the acoustic enclosure structure, components, and
accessories against defects in materials and workmanship for 1 year.
C.
QUALIFICATIONS: Manufacturer’s minimum requirements for qualification shall be 5
years of experience in design and fabrication of acoustical enclosures and evidence
of satisfactory completion of five projects comparable in scope to the work specified
in the Contract Documents.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
Manufacturer’s qualifications of five years of experience and five comparable
projects, including names and locations of projects.
3.
A letter signed by both the manufacturer of the centrifugal FRP fans specified
in Section 15828 and the manufacturer of the acoustic enclosures specified
herein stating that they have coordinated the sizes of the acoustic enclosures
to accommodate the fans.
4.
Dimensioned shop drawings showing plan, elevations, cross sections and
details of the enclosure, doors, duct penetrations, conduits, tubing,
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-2
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
acoustical and weather stripping and any special treatment at the man doors,
roofing, enclosure bottom to slab connection, and other structural
components. Shop drawings and calculations for the acoustic enclosure shall
be stamped and sealed by a structural engineer registered in the State of
Hawaii. Calculations signed by a structural engineer registered in a state
other than Hawaii will not be accepted.
1.04
5.
Manufacturer product information, specifications, and installation
instructions for enclosure components and accessories. This includes
providing complete erection drawings showing anchor bolt settings and
installation details to clearly indicate the proper assembly of enclosure
components.
6.
The following data for each Sound Trap furnished:
a.
Manufacturer's catalog and/or other data confirming conformance to
specified design, material and equipment requirements.
b.
Dynamic insertion loss, self-noise power levels, aerodynamic
performance for reverse and forward flow, and pressure drop at
design air volume.
c.
Certified copies of factory test results that the equipment can obtain
the sound reduction values as published by manufacturer after the
equipment is installed in the system and coordinated with the sound
information of the system fans.
PERFORMANCE REQUIREMENTS:
A.
SERVICE CONDITIONS: Acoustic enclosures shall be suitable for installation and
service at a wastewater treatment plant, under the environmental conditions
specified in Section 01800.
B.
DESIGN REQUIREMENTS:
1.
Enclosure No.
ENC 500,101
ENC 900,101
ACOUSTIC ENCLOSURES:
Enclosed
Equipment No.
Enclosed Equipment Description
F 500,110
KAI-ODOR, TIPS Foul Air Fan 1
F 500,120
KAI-ODOR, TIPS Foul Air Fan 2
F 900,110
KAN-ODOR, Foul Air Fan 1
F 900,120
KAN-ODOR, Foul Air Fan 2
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-3
ADDENDUM NO. 3
Enclosure Interior
Dimensions
(L x W x H)
26’-0” x 17’-8” x
25’-6”
22’-0” x 13’-8” x
15’-4”
ACOUSTIC ENCLOSURES
Acoustic Performance Ratings
Octave Band
Center Frequency (Hz)
2
3
4
5
6
7
8
62.5
125
250
500
1000
2000
4000
8000
31
34
35
44
54
63
62
68
48
-
0.60
1.13
1.12
1.09
1.03
0.91
1.04
1.10
Min Transmission Losses (dB)
Min Absorption Coefficient
2.
STC /
NRC
1
SOUND TRAPS:
Equipment No.
Enclosure No.
Size
Pressure Drop
at 2000 fpm
ENC 500,101
42” I.D. x 84” L
0.05 inch
See Note
54” I.D. x 108” L
0.05 inch
ENC 900,101
24” I.D. x 48” L
0.05 inch
ST 500,130
ST 500,131
ST 500,132
ST 550,130
ST 900,130
ST 900,131
ST 900,132
NOTE: Sound Trap ST 550,130 is not associated with a specific acoustic enclosure
but shall conform to applicable requirements listed in this Section.
Dynamic Insertion Loss Ratings
1.05
Octave Band
1
2
3
4
5
6
7
8
Center Frequency (Hz)
62.5
125
250
500
1000
2000
4000
8000
42” I.D. x 84” L
9
16
26
32
29
24
19
16
54” I.D. x 108” L
10
18
28
34
28
22
18
16
24” I.D. x 48” L
7
13
21
26
34
25
21
16
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. The structural components, seismic
attachments, braces, and anchors to the structure for all parts or elements of the
mechanical and electrical systems shall be designed in accordance with Section
01900.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-4
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
PART 2 – PRODUCTS
2.01
CANDIDATE MANUFACTURERS/PRODUCTS
A.
Candidate manufacturers and models are listed below. To conform with specified
requirements, the manufacturer’s standard product may require modification.
1.
ACOUSTIC ENCLOSURES:
a.
b.
c.
2.
SOUND TRAPS:
a.
b.
c.
2.02
Industrial Acoustics Company (IAC)
McGill Air Silence
Or approved substitute
IAC Conic Flow, Type FCS or FCL
McGill Air Silence Soundpak, Type CSF
Or approved substitute
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
2.03
Material
Interior structural members
Hot dipped galvanized steel
Walls and roof panels
316L stainless steel
Roof covering
Fiberglass reinforced plastic
Man doors
316L stainless steel
Trim and flashing
316L stainless steel
Miscellaneous metal components
316L stainless steel
FEATURES
A.
GENERAL:
1.
Enclosures shall be of modular design allowing for full assembly and
disassembly in the field as required for installation and maintenance.
Enclosures shall include panels, insulation, doors, process duct penetrations,
ventilation duct penetrations, and all miscellaneous appurtenances
necessary to meet the requirements specified in this Section.
2.
The manufacturer shall coordinate with the Contractor regarding placement
of all duct penetrations and placement of man doors to ensure coordination
with the associated equipment outside and inside the enclosures. The
manufacturer shall prepare submittals specified in this Section only after
such coordination has been accomplished.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-5
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
B.
3.
Minimum enclosure interior dimensions shall be as specified in this Section.
Enclosures shall be sized to provide a minimum of 3 feet clearance between
equipment and the enclosure walls or interior structural members.
4.
Acoustic Enclosures shall be designed in accordance with Section 01900.
Maximum total load deflection for enclosure shall be L/200. Manufacturer
shall be responsible for determining the number of anchor bolts and size,
plus required embedment depth to resist wind and seismic forces specified in
specification Section 01900.
ACOUSTIC ENCLOSURE:
1.
Manufacturer shall provide all members and parts required to support and
assemble the acoustic enclosure components.
2.
Wall and roof panels shall be of an all welded box construction consisting of
an outer solid sheet and an inner perforated sheet with sound absorptive
material in between. Panel thickness shall be a minimum of 4 inches. Outer
solid sheets shall be a minimum 18 gauge and the inner perforated sheets
shall be a minimum 22 gauge with a minimum 23 percent effective open
area. Wall and roof panels shall be painted in accordance with Section
09900.
3.
Acoustical fill material shall be inert, mildew resistant, and vermin proof with
a useful temperature range of -30 to +1000 degrees F. Combustion ratings
for the fill material shall not be greater than the following when tested in
accordance with ASTM E84:
a.
b.
Flame Spread Rating: 25
Smoke Development Rating: 50
4.
A film wrap shall be supplied consisting of 1.5 mils polyethylene and shall
fully encapsulate the mineral wool and be impervious to water, oils, solvents,
chemicals, inks, dust, and dirt. A spacer shall be supplied between the film
wrapped fill and perforated sheet.
5.
Panel skins shall be welded to a minimum 18 gauge channel frame around
the module perimeter. Panels shall be constructed to retain their shape
ensuring fit and function for the structure’s life. Panel frames shall be welded
in a manner to create a square structure that resists racking and twisting.
6.
Additional internal structural steel required by structural design shall be
provided in accordance with Section 05100. Internal structural steel frame
members shall be painted in accordance with Section 09900.
7.
The panels shall be assembled into the specified structure via
manufacturer’s standard joiners, channels, flashings and trims through the
use of the system components. Voids shall be filled with mineral wool, with
joints and connections sealed with non-hardening caulk suitable for exterior
use.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-6
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
8.
Man doors shall be 3’-0” x 6’-8”, acoustical, nominally 2 inch thick with fully
finished edges and mortised hardware. Standard hardware includes level
swing ball-bearing butt hinges, level latch passage set, and hold open closer.
Magnetic jamb and header seals and automatic threshold seal shall be
provided. Doors shall be furnished with windows composed of double-glazed
layers of wire-reinforced tempered class, separated by an air space, and
sealed against acoustical and air leakage by interior and exterior rubber
seals. Windows shall be 24 inches wide by 30 inches high.
9.
The framed opening for the inlet and discharge ducts shall be sealed with a
metal split collar on the interior and the exterior face of the opening. The
framed opening shall be constructed such that the acoustical performance of
the enclosure does not deteriorate. Follow manufacturer’s recommendation
for gasketing and sealing of openings.
10.
The wall panels shall be extended out to intersect a minimum of 6 inches
beyond the sound trap connections on the supply and discharge ducts.
11.
Roof shall be covered with fiberglass reinforced plastic (FRP) roofing panels.
FRP roofing panels. Cladding units shall be Tuff Span® 7.2Dx1.75 Rib, Series
FR400, or equal, as required by structural design for wind loads specified.
Cladding shall have a Class 1 Flame Spread Rating (25 or less), when tested
in accordance with ASTM E84. Resin shall be premium grade, chemically
resistant Isophthalic Polyester. Reinforcement shall be straight and
continuous, with fibers oriented in two directions along the length and width
of the unit. Glass content shall be a minimum of 47 percent by weight. Panel
material shall be made from a UV stabilized resin modified with acrylic
monomers. Additional UV resistance shall come from surfacing mats and a
surface coating of an acrylic polymer.
12.
The roof system shall be complete with integrated pre-engineered trims and
flashings to establish a whether tight system. Flashing shall accommodate
reasonable variances in tolerances and thermal movement. Minor flashings
may be field fabricated. Accessories shall be of thickness, dimensions, and
profile required for a complete installation of roofing.
13.
Acoustical panels and components shall exhibit the Sound Transmission
Class (STC) ratings and Noise Reduction Characteristics (NRC) specified in
this Section. STC and NRC ratings shall be per ASTM E90 and ASTM C423,
respectively.
14.
When measured at 50 feet from the center of the blower and motor
assembly, the minimum insertion losses of the enclosure and ventilation
system shall be less than 35 dBA.
dBA
15.
Enclosure wall and ceiling panels shall be vibration isolated from the
enclosed foul air and ventilation fans.
16.
All flexible duct connections associated with enclosed equipment shall be
located totally within the enclosures.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-7
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
C.
D.
17.
Provide interior 277V volt light fixtures, number as required, LED, and surface
mounted. Fixtures shall be rated for a Class 1, Division 2, Group D classified
area. Specified foot candle level is 50 fc at 26 inches above the floor. Provide
one exterior 20 amp, 277V volt, PVC toggle switch with a gasketed, springloaded, PVC cover for manual control of the light fixtures. The switch shall be
wired to the interior lighting. All wiring and conduit shall be in accordance
with Division 16.
18.
Provide and install channels for mounting equipment and piping. Mounting
channels shall be securely fastened to walls of enclosure with 316L stainless
steel hardware.
ENCLOSURE VENTILATION:
1.
Provide a ventilation system to draw a suitable volume of air through the
room for removal of heat generated by all enclosed equipment and lighting.
2.
One fan and motor shall be provided for each enclosure. Fan and motor shall
be located on the inside of the enclosure and suitable for Class 1, Division 2,
Group D operation.
3.
Ventilation system shall maintain the acoustical integrity of the enclosure and
shall consist of the following components:
a.
Air intake opening silencers with a lined plenum or elbow-type duct
silencer built into and utilizing one of the enclosure panels. The air
intake opening shall be covered with a suitable intake grate or grille.
b.
An air discharge opening acoustically treated to the same degree as
the inlet silencer opening.
c.
An interior ventilation fan capable of drawing suitable volume of
cooling air through the enclosure and the acoustically treated intake
and discharge silencers.
4.
Ventilation fan motor shall be 460 V, 3 phase and 1/2 horsepower maximum.
Provide combination motor starter with overload protection for ventilation fan
motor. Motor starter shall be provided in a NEMA 250, Type 7 enclosure and
prewired to ventilation fan motor and thermostat.
5.
Ventilation fans shall be designed for continuous operation and maintain an
internal temperature of no greater than 100 degrees in the acoustic
enclosure.
SOUND TRAPS:
1.
Sound traps shall be round, double-walled, and internally insulated. Construct
the double-walled duct with an outer metal shell of 22 gauge minimum 316L
stainless steel sheet, acoustical filler material, and an internal perforated 24
gauge minimum 316L stainless steel metal liner.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-8
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
2.
Units shall be constructed to withstand a differential air pressure of
12-inches water from the inside to the outside of the casing. Units shall
incorporate a duct sealing compound to achieve air tight construction.
3.
Acoustical fill material shall be inert, mildew resistant, and vermin proof with
a useful temperature range of -30 to +1000 degrees F. Combustion ratings
for the fill material shall not be greater than the following when tested in
accordance with ASTM E84:
a.
b.
Flame Spread Rating: 25
Smoke Development Rating: 50
4.
All sound trap ratings shall be determined in accordance with ASTM
Specification E477.
5.
Static pressure loss of sound traps shall not exceed those listed by the
manufacturer for the airflow specified. Airflow measurements shall be made
in accordance with ASTM specification E477-99 and applicable portions of
ASME, AMCA, and ADC airflow test codes. Tests shall be reported on the
identical units for which acoustic data is presented.
PART 3 – EXECUTION
3.01
INSTALLATION
A.
B.
EQUIPMENT MOUNTING:
1.
PROCEDURES: Section 11002.
2.
Install on a Group C Equipment Mounting System in accordance with the
Equipment Mounting Schedule specified in Section 11002.
ASSEMBLY:
1.
Erect the enclosure in accordance with the Contract Documents and
manufacturer’s directions.
2.
Conform to configurations and connections indicated on reviewed and
accepted shop drawings.
3.
Accurately position and assemble panels and structural framing to lines and
members of framing system prior to permanent fastening. Protect installed
panels and structures from abuse by other trades.
4.
No field modifications to the enclosure shall be allowed unless approved by
the manufacturer in writing, with a copy to the Officer-in-Charge.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-9
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
C.
3.02
3.03
REPAIR/RESTORATION:
1.
Replace damaged panels and other components of work that cannot be
repaired by finish touch-up or similar minor repair techniques.
2.
After erection of the enclosure, remove all excess materials, tools, scaffolds,
and rubbish which has accumulated in and around the enclosure and leave
area in a clean and satisfactory condition.
COATINGS
A.
PROCEDURES: Section 09900.
B.
PRIMER COATING: Shop apply in accordance with Section 09900.
C.
FINISH COATING: Shop apply in accordance with Section 09900.
D.
TOUCH-UP COATING: Immediately after erection, clean field welds, bolted or screwed
connections, and areas where coating is abraded. Apply touch-up coating to exposed
areas using same material as used for shop finish coating in accordance with Section
09900.
MEASUREMENT AND PAYMENT
A.
Acoustic enclosures shall not be paid for directly, but shall be considered incidental
and included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13123-10
ADDENDUM NO. 3
ACOUSTIC ENCLOSURES
SECTION 13124
ACOUSTIC PLENUMS
PART 1--GENERAL
1.01
DESCRIPTION
A.
1.02
SCOPE: This Section specifies acoustic plenums for sound attenuation of noise
generated in the west and east mechanical rooms in the TIPS facility. Acoustic
plenums shall include panels, insulation, structural members, internal baffles, filter
frames, and all other incidentals specified in the Contract Documents.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this Section
and those of the listed documents, the requirements of this Section shall prevail.
Unless otherwise specified, references to documents shall mean the documents in
effect on the effective date of Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replaced documents issued or otherwise identified by that organization, or if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
Title
ASCE 7-05
Minimum Design Loads for Buildings and Other Structures
ASTM A167
Standard Specification for Stainless and Heat-Resisting
Chromium-Nickel Steel Plate, Sheet, and Strip
ASTM C423
Standard Test Method for Sound Absorption and Sound
Absorption Coefficients by the Reverberation Room
Method
ASTM E84
Standard Test Method for Surface Burning Characteristics
of Building Materials
ASTM E90
Standard Test Method for Laboratory Measurement of
Airborne Sound Transmission Loss of Building Partitions
and Elements
ASTM E413
Classification for Rating Sound Insulation
ASTM E477
Standard Test Method for Measuring Acoustical and
Airflow Performance of Duct Liner Materials and
Prefabricated Silencers
ASTM E795
Standard Practices for Mounting Test Specimens During
Sound Absorption Tests
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-1
ADDENDUM NO. 3
ACOUSTIC PLENUMS
Reference
IBC 2006
1.03
1.04
Title
International Building Code 2006 with City and County of
Honolulu local amendments
B.
SPECIAL WARRANTY: Provide a Special Warranty in accordance with Section 01740.
Manufacturer shall warrant the acoustic enclosure structure, components, and
accessories against defects in materials and workmanship for 1 year.
C.
QUALIFICATIONS: Manufacturer’s minimum requirements for qualification shall be 5
years of experience in design and fabrication of acoustical enclosures and evidence
of satisfactory completion of five projects comparable in scope to the work specified
in the Contract Documents.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
ACTION SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
Dimensioned shop drawings showing plan, elevations, cross sections and
details of the acoustic plenums, doors, baffles, filter frames, duct
penetrations, acoustical and weather stripping and any special treatment at
the man doors, roofing, plenum bottom to slab connection, and other
structural components. Shop drawings and calculations for the acoustic
plenums shall be stamped and sealed by a structural engineer registered in
the State of Hawaii. Calculations signed by a structural engineer registered in
a state other than Hawaii will not be accepted.
3.
Manufacturer product information, specifications, and installation
instructions for plenum components and accessories. This includes providing
complete erection drawings showing anchor bolt settings and installation
details to clearly indicate the proper assembly of plenum components.
4.
Acoustic and aerodynamic performance including insertion
insertion losses, selfselfgenerated noise, and predicted pressure drop at the air flow indicated on the
Drawings.
5.
Acoustic performance test results.
PERFORMANCE REQUIREMENTS:
A.
SERVICE CONDITIONS: Acoustic plenums shall be installed indoors as specified on
the Drawings. Environmental conditions for installation areas are specified in Section
01800.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-2
ADDENDUM NO. 3
ACOUSTIC PLENUMS
B.
Acoustical panel ratings shall be determined by the dual reverberation room method
in accordance with ASTM specifications EE-9090-81, E413E413-73, C423
C423423-81a,
81a, E795,
E795, or
latest versions thereof. The test setset-up and procedure shall be such that all effects
due to flanking transmission, standing waves and test chamber sound absorption are
eliminated. Data shall be presented for tests conducted using current production
samples.
samples. The minimum allowable transmission
transmission loss of the panel, including all
components, when tested in accordance with ASTM EE-9090-81 and E413E413-73, or the
latest versions thereof, shall be as indicated in this section.
C.
DESIGN REQUIREMENTS:
1.
ACOUSTIC PLENUM WALLS AND BAFFLES:
Acoustic Performance Ratings
Octave Band
Center Frequency (Hz)
Min Transmission Losses (dB)
2
3
4
5
6
7
8
62.5
125
250
500
1000
2000
4000
8000
31
34
35
44
54
63
62
68
48
-
0.94
1.19
1.11
1.06
1.03
1.03
1.04
(1.10)
1.10)
0.95
12
17
31
42
39
22
18
15
Min Absorption Coefficient
Min Dynamic Insertion Losses
STC /
NRC
1
PART 2 – PRODUCTS
2.01
CANDIDATE MANUFACTURERS/PRODUCTS
A.
Candidate manufacturers and models are listed below. To conform to specified
requirements, the manufacturer’s standard product may require modification.
1.
ACOUSTIC PLENUMS
a.
b.
c.
d.
2.02
Industrial Acoustics Company (IAC)
McGill Air Silence
Kinetic Noise Control
Or approved substitute
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
Material
Interior structural members
Hot dipped galvanized steel
Walls and roof panels
316L stainless steel
Man doors
316L stainless steel
Trim and flashing
316L stainless steel
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-3
ADDENDUM NO. 3
ACOUSTIC PLENUMS
Component
Material
Miscellaneous metal components
2.03
316L stainless steel
FEATURES
A.
B.
GENERAL:
1.
Plenums shall be of modular design allowing for full assembly and
disassembly in the field as required for installation and maintenance.
Plenums shall include panels, insulation, doors, baffles, filter frames, duct
penetrations, and all miscellaneous appurtenances necessary to meet the
requirements specified in this Section and on the Drawings.
Drawings.
2.
Minimum plenum interior dimensions shall be as shown on the Drawings.
Drawings.
3.
Acoustic plenums shall be designed in accordance with Section 01900.
Maximum total load deflection for plenum shall be L/200. Manufacturer shall
be responsible for determining the number of anchor bolts and size, plus
required embedment depth to resist wind and seismic forces specified in
specification Section 01900.
ACOUSTIC PLENUM:
1.
Manufacturer shall provide all members and parts required to support and
assemble the acoustic plenum components.
2.
Wall and roof panels shall be of an all welded box construction consisting of
an outer solid sheet and an inner perforated sheet with sound absorptive
material in between. Panel thickness shall be a minimum of 4 inches. Outer
solid sheets shall be a minimum 18 gauge and the inner perforated sheets
shall be a minimum 22 gauge with a minimum 23 percent effective open
area. Wall and roof panels shall be painted in accordance with Section
09900.
3.
Baffles shall be of an all welded box construction consisting of perforated
sheets
sheets both inside and outside with sound absorptive material between
sheets. Baffle thickness shall be a minimum of 4 inches. Baffles shall be
rounded at the ends to improve aerodynamic performance. Outer and inner
perforated sheets shall be a minimum 22 gauge with a minimum 23 percent
effective open area. Baffles shall be unpainted.
4.
Acoustical fill material shall be inert, mildew resistant, and vermin proof with
a useful temperature range of -30 to +1000 degrees F. Combustion ratings
for the fill material shall not be greater than the following when tested in
accordance with ASTM E84:
a.
b.
Flame Spread Rating: 25
Smoke Development Rating: 50
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-4
ADDENDUM NO. 3
ACOUSTIC PLENUMS
5.
A film wrap shall be supplied consisting of 1.5 mils polyethylene and shall
fully encapsulate the mineral wool and be impervious to water, oils, solvents,
chemicals, inks, dust, and dirt. A spacer shall be supplied between the film
wrapped fill and perforated sheet.
6.
Panel skins shall be welded to a minimum 18 gauge channel frame around
the module perimeter. Panels shall be constructed to retain their shape
ensuring fit and function for the structure’s life. Panel frames shall be welded
in a manner to create a square structure that resists racking and twisting.
7.
Additional internal structural steel required by structural design shall be
provided in accordance with Section 05100. Internal structural steel frame
members shall be painted in accordance with Section 09900.
8.
The panels shall be assembled into the specified structure via
manufacturer’s standard joiners, channels, flashings and trims through the
use of the system components. Voids shall be filled with mineral wool, with
joints and connections sealed with non-hardening caulk suitable for exterior
use.
9.
Man doors shall be 3’-0” x 6’-8”, acoustical, nominally 2 inch thick with fully
finished edges and mortised hardware. Standard hardware includes level
swing ball-bearing butt hinges, level latch passage set, and hold open closer.
Magnetic jamb and header seals and automatic threshold seal shall be
provided.
10.
The framed opening for ducts shall be sealed with a metal split collar on the
interior and the exterior face of the opening. The framed opening shall be
constructed such that the acoustical performance of the plenum does not
deteriorate. Follow manufacturer’s recommendation for gasketing and
sealing of openings.
11.
Acoustical panels and components shall exhibit the Sound Transmission
Class (STC) ratings and Noise Reduction Characteristics (NRC) specified in
this Section. STC and NRC ratings shall be per ASTM E90 and ASTM C423,
respectively.
12.
When measured at 15 feet from the center of the wall louver, the minimum
insertion losses of the enclosure and ventilation system shall be as specified
in this Section.
13.
Provide and install interior 120 volt light fixtures, number as required, LED,
and surface mounted in plenums with filter racks. Light fixtures shall be on
filter removal side of rack. Specified foot candle level is 50 fc at 26 inches
above the floor. Provide and install one exterior 20 amp, 120 volt, PVC toggle
switch with a gasketed, spring-loaded, PVC cover for manual control of the
light fixtures. The switch shall be wired to the interior lighting. All wiring and
conduit shall be in accordance with Division 16.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-5
ADDENDUM NO. 3
ACOUSTIC PLENUMS
PART 3 – EXECUTION
3.01
INSTALLATION
A.
B.
C.
3.02
EQUIPMENT MOUNTING:
1.
PROCEDURES: Section 11002.
2.
Install on a Group C Equipment Mounting System in accordance with the
Equipment Mounting Schedule specified in Section 11002.
ASSEMBLY:
1.
Erect the plenum in accordance with the Contract Documents and
manufacturer’s directions.
2.
Conform to configurations and connections indicated on reviewed and
accepted shop drawings.
3.
Accurately position and assemble panels and structural framing to lines and
members of framing system prior to permanent fastening. Protect installed
panels and structures from abuse by other trades.
4.
No field modifications to the plenum shall be allowed unless approved by the
manufacturer in writing, with a copy to the Officer-in-Charge.
REPAIR/RESTORATION:
1.
Replace damaged panels and other components of work that cannot be
repaired by finish touch-up or similar minor repair techniques.
2.
After erection of the plenum, remove all excess materials, tools, scaffolds,
and rubbish which has accumulated in and around the enclosure and clean
inside of plenum as indicated in paragraph 15891-3.01F.
COATINGS
A.
PROCEDURES: Section 09900.
B.
PRIMER COATING: Shop apply in accordance with Section 09900.
C.
FINISH COATING: Shop apply in accordance with Section 09900.
D.
TOUCH-UP COATING: Immediately after erection, clean field welds, bolted or screwed
connections, and areas where coating is abraded. Apply touch-up coating to exposed
areas using same material as used for shop finish coating in accordance with Section
09900.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-6
ADDENDUM NO. 3
ACOUSTIC PLENUMS
3.03
MEASUREMENT AND PAYMENT
A.
Acoustic plenums shall not be paid for directly, but shall be considered incidental and
included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13124-7
ADDENDUM NO. 3
ACOUSTIC PLENUMS
SECTION 13225
FIBERGLASS REINFORCED PLASTIC (FRP) TANKS FOR CARBON
PART 1 – GENERAL
1.01
DESCRIPTION
A.
SCOPE: This section specifies fiberglass reinforced plastic (FRP) tanks to serve as vapor
phase activated carbon scrubbers. Tanks shall be vertical, cylindrical, filament wound
construction and supplied complete with all nozzles, level fittings, hatches, ladder/
platforms, and anchoring system. Tanks shall be designed for use with activated carbon
and shall handle corrosive and potentially flammable wastewater gases.
B.
EQUIPMENT LIST:
Item
1.02
Equipment No.
KAI-ODOR, TIPS Activated Carbon Scrubber 1
SCR 500,410
KAI-ODOR, TIPS Activated Carbon Scrubber 2
SCR 500,420
KAI-ODOR, TIPS Activated Carbon Scrubber 3
SCR 500,430
KAI-ODOR, HDWKS Activated Carbon Scrubber 1
SCR 550,210
KAI-ODOR, HDWKS Activated Carbon Scrubber 2
SCR 550,220
KAI-ODOR, HDWKS Activated Carbon Scrubber 3
SCR 550,230
KAI-ODOR, HDWKS Activated Carbon Scrubber 4
SCR 550,240
KAN-ODOR, Activated Carbon Scrubber
SCR 900,410
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This section incorporates by reference the latest revisions of
the following documents. They are part of this section insofar as specified and modified
herein. In the event of conflict between the requirements of this section and those of
the listed documents, the requirements of this section shall prevail. Unless otherwise
specified, references to documents shall mean the documents in effect on the effective
date of Agreement. If referenced documents have been discontinued by the issuing
organization, references to those documents shall mean the replaced documents
issued or otherwise identified by that organization, or if there are no replacement
documents, the last version of the document before it was discontinued.
Reference
Title
ANSI
American National Standards Institute
ASME/ANSI RTP-1
Reinforced Thermoset Plastic Corrosion Resistant Equipment
IBC
International Building Code
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-1
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
B.
C.
FACTORY TESTS:
1.
GENERAL: Tanks shall be factory tested for compliance with the requirements
specified herein and a certificate for the results of these tests shall be
submitted to the Officer-in-Charge upon delivery. In addition, the following
specific tests specified below shall be conducted.
2.
AIR INHIBITION TEST: Surfaces shall be tested for acetone sensitivity as an
indication of air inhibition. Air-inhibited surfaces are not allowed.
3.
SPARK TEST: All welded thermoplastic seams shall be subjected to a nondestructive AC spark test in accordance with the Fabricator’s recommendations.
4.
BURN TEST: A minimum of two burn tests from nozzle cutouts shall be
performed on each vessel to verify glass/resin ratio.
SOURCE QUALITY CONTROL:
1.
EQUIPMENT INSPECTION: The Fabricator shall retain and pay for the services of
an independent FRP inspector, or shall designate at least one employee as
inspector, for the purpose of inspection during fabrication of the odor control
vessels. If an employee is designated then the vessel manufacturer shall have a
certified Quality Management System in place that is registered and monitored
by National Quality Assurance (NQA) for compliance with ISO 9001. The
Inspector shall be present at each fabrication step between the days before the
first equipment is started until the day after the last equipment is shipped to the
site and have at least 10 years of FRP inspection experience. The Inspector
shall keep a log of all activities performed and the progress of each vessel. If
the Inspector does not witness any step of the fabrication process, the
equipment in question shall
shall be rejected. Inspector shall be supervised by a
registered professional engineer who shall submit to the OfficerOfficer-inin-Charge
stamped reports of the manufacturing progress every 3 weeks. Each piece of
equipment delivered shall have a transmittal letter, signed by the inspector,
which notes that the equipment has met the specifications and the transmittal
letter shall contain copies of all test results performed on the vessel
accompanied by all vessel cutouts. Any equipment shipped to the site not
accompanied
accompanied by such a letter will not be accepted. Vendor shall allow the
OfficerOfficer-inin-Charge complete access at all times to the facility that contains
equipment to be supplied under this Section. If the inspector is more than 5
working days late with the weekly report
report or found not keeping current records,
all equipment in progress will be rejected.
2.
Fabricator shall submit Inspector’s resume, a signed statement that the
inspector will have no other duties relating to the production of equipment
specified under
under this section, other than inspecting the equipment, and a signed
statement that the Inspector does not report to or is not supervised by any
personnel involved in the production of the equipment specified under this
section.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-2
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
3.
1.03
OFFICEROFFICER-ININ-CHARGE’S INSPECTION:
INSPECTION: Fabricator shall allow for factory visits by
the OfficerOfficer-inin-Charge as specified in Section 13230 to perform equipment
inspections. Transportation and accommodation costs, including meals, for two
people shall be provided for up to two factory visits.
visits. For USA factories, air
transport shall be coach class. For nonnon-USA factories air transport shall be
business class.
D.
SHIPMENT AND STORAGE: Fabricator’s recommendations on shipping and handling and
the shipping and handling procedures, as recommend by SPI “Recommended Practice
for Shipping and Installation of Reinforced Plastic Tanks”, and as described in NBS
PS15 and ASTM D4097 shall be adhered to.
E.
SPECIAL
SPECIAL WARRANTY: Provide Fabricator’s extended guarantee or warranty, with the City
named as beneficiary, in writing, as a special guarantee. Special guarantee shall
provide for correction, or at the option of the City, removal and replacement of Work
specified
specified in the Section found defective during a period of 365 days after the date of
substantial completion. Duties and obligations for correction or removal and
replacement of defective work shall be as specified.
F.
QUALIFICATIONS:
1.
Fabricator shall be recognized in the design, production and operation of FRP
tanks for carbon in the United States. The Fabricator shall have at least 10
years experience in design and fabrication of FRP vessels similar in capacity to
the type specified in this section.
section.
2.
The Fabricator’s place of business and vessel manufacturing facility shall be
open for inspection. Fabricator shall be capable of providing the City with
training and monitoring support on one day’s notice during the first year of
operation.
3.
The Fabricator shall provide a list of at least five different locations where their
equipment has been installed and is currently in service. The installations
provided must be associated with the removal of hydrogen sulfide and/or
typical organic municipal
municipal wastewater odors and have performance
requirements similar to those specified in this Section.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations.
2.
Complete design calculations certifying that the tanks have been designed to
meet all specified design criteria. Calculations shall be signed and sealed by a
professional engineer registered in the State of Hawaii. Calculations signed by a
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-3
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
professional engineer registered in a state other than Hawaii will not be
accepted.
3.
Complete information developed by the Fabricator which describes specifically
how the equipment is to be built. Information shall be provided in the form of
shop drawings, standards, specifications, other shop instructions, or QC records.
Information provided shall include, but not be limited to the following:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Resin type.
Type and amount of fillers.
Nominal corrosion liner description.
Reinforcement types for hand lay-up laminates.
For filament wound laminates:
1)
Helix angle.
2)
Glass content range.
3)
Strand yield.
4)
Strand per inch in the winding band.
5)
Ply thickness.
6)
Amount of chop or unidirectional roving interspersed with
winding, if any, and location within laminate.
For all other components:
1)
Construction type.
2)
Laminate thicknesses.
3)
Ply sequences.
4)
Glass content range.
For all secondary overlays (both interior and exterior):
1)
Laminate thicknesses.
2)
Ply sequences and widths.
Construction details for all assembly and other special configurations,
including:
1)
Bottom/top attachments with knuckle configuration and
overlays and thicknesses.
2)
Support and anchor lugs, including attachment details.
3)
Nozzles and installation, including cutout reinforcement,
gusseting, etc.
4)
Lateral or other support fabrication details, including ladder and
platform attachment clips and/or shoulders.
5)
Configuration and fabrication details of internals support
system and other specialty items.
Assembly and erection plans as specified in Section 13230.
4.
Signed affidavit by the tank Fabricator indicating that the tank was successfully
factory tested.
5.
Statement by the tank Fabricator certifying that the tank material meets the test
properties specified.
6.
Fabricator’s operating and maintenance information as specified in Section
01730.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-4
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
1.04
7.
Fabricator’s inspection reports as specified in Section 13230.
8.
Fabricator’s Installation Certification Form (Form 11000-A, Section 01999)
certifying that the equipment has been properly installed, aligned, and tested
and meets all requirements for satisfactory performance under the conditions
specified.
9.
Fabricator’s Instruction Certification Form (Form 11000-B, Section 01999)
certifying that instruction to operators has been completed.
PERFORMANCE REQUIREMENTS
A.
SERVICE CONDITIONS:
Tanks shall be suitable for installation and service at a wastewater treatment plant,
under the environmental conditions specified in Section 01800.
B.
C.
OPERATING CONDITIONS:
Equipment No.
Air Flow, scfm
Air Flow Direction
SCR 500,410
6,667
Up / Down
SCR 500,420
6,667
Up / Down
SCR 500,430
6,667
Up / Down
SCR 550,210
7,600
Up / Down
SCR 550,220
7,600
Up / Down
SCR 550,230
7,600
Up / Down
SCR 550,240
7,600
Up / Down
SCR 900,410
5,400
Up / Down
DESIGN REQUIREMENTS:
Equipment No.
Inside
Diameter,
feet
No. of
Access
Hatches
No. of
Carbon
Beds
Carbon
Bed Depth,
feet
Weight of
Carbon Bed,
pounds
Max.
Pressure
Rating, in w.c.
SCR 500,410
10
2
2
3
6,650
-12
SCR 500,420
10
2
2
3
6,650
-12
SCR 500,430
10
2
2
3
6,650
-12
SCR 550,210
11
2
2
3
8,050
-12
SCR 550,220
11
2
2
3
8,050
-12
SCR 550,230
11
2
2
3
8,050
-12
SCR 550,240
11
2
2
3
8,050
-12
SCR 900,410
9
2
2
3
5,400
-12
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-5
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
1.05
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. The structural components, seismic attachments,
braces, and anchors to the structure for all parts or elements of the mechanical and
electrical systems shall be designed in accordance with Section 01900.
PART 2 – PRODUCTS
2.01
CANDIDATE FABRICATORS/PRODUCTS
A.
Candidate Fabricators are listed below. To conform with specified requirements, the
Fabricator’s standard product may require modification.
1.
2.
3.
2.02
ECS Environmental Solutions
Daniel Mechanical
Or Approved substitute
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
2.03
Material
Vessel
Fiberglass reinforced plastic (FRP)
Ladder/Platforms
Fiberglass reinforced plastic (FRP)
Gaskets
Neoprene, or as specified
Sample Ports (Probe and Valve)
CPVC
Metal Appurtenances
316L stainless steel
FEATURES
A.
GENERAL: The requirements of Section 13230 shall apply to all aspects of this Section.
For purposes of this Section, references to Drawings, construction details, laminate
sequences, or laminate charges herein or contained in Section 13230 shall be
construed as references to the Fabricator’s approved design submittal.
B.
FRP TANKS:
1.
Tanks shall be fabricated and assembled as specified in the Contract
Documents. Filament winding utilizing either a helical wind or a hoop wind in
combination with weft unidirectional tape shall be the fabrication method.
Filament winding angle shall be 60 degrees ±5 degrees.
2.
The Fabricator shall perform all calculations necessary to ensure long-term, low
risk service of the FRP equipment with minimum reasonable maintenance
requirements. The design shall ensure proper functioning of the equipment at
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-6
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
the stated operating conditions. The design shall include as a minimum,
engineering calculations, materials selection and documented physical and
mechanical properties, and all detailed drawings required for fabrication and
assembly of the equipment.
3.
The design shall satisfy all applicable national, regional, and local design and
building codes. Seismic forces shall be determined in accordance with the IBC
for the tank fully loaded with carbon.
4.
Detailed design of FRP tanks shall follow the procedures and methods, utilize
the equations and formulas, and incorporate safety factors and allowable
design stresses and strains set forth in ASME/ANSI RTP-1.
5.
The design shall consider the interaction of the installed system including, but
not limited to, thermal expansion of duct, tanks, and vessels and the effects of
external loading from piping, fans, pumps, platforms, and other system
components.
6.
Tanks shall be shop assembled to assure proper fit. Subassemblies shall be
numbered and mating flanges or elements shall be match marked to assure
correct alignment and field assembly.
7.
The design shall allow for the most severe combination of conditions which may
include any or all of the following:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
Internal or external pressure.
Static head of contents (working and test conditions).
Mass of structure and contents.
Design temperature including upset conditions.
Superimposed loads, such as seismic forces.
Bending moments due to eccentric loads.
Localized loads acting at supports, lugs, and other attachments.
Shock loads.
Loads due to heating or cooling and thermal gradients.
Loads applied during transport or erection.
Loads imposed by personnel during erection and operations.
Fatigue.
Specifically:
1)
Shell overturning due to wind/seismic:
a)
Critical buckling.
b)
Design factor on tension side.
2)
Anchoring, due to overturning or internal pressure:
a)
Lug design.
b)
Analysis of attachment to shell.
c)
Effect on shell knuckle.
d)
Maximum pullout forces and moments reported for the
foundation design.
3)
Appendage support:
a)
Effect of point loads on shells.
b)
Interaction between towers under any load.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-7
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
4)
n.
Internal pressure or vacuum:
a)
Main shells, hoop and axial.
b)
Cutout reinforcements at nozzles.
c)
Effect on any discontinuities or special components,
such as internal cone.
5)
Thermal:
a)
Differential expansion at temperature extremes.
b)
Thermal gradient through laminate.
6)
Special loads:
a)
Effect of agitators on nozzles.
b)
Dead or live loads on domes.
c)
Platforms.
There will typically be other aspects which should be considered. It is
the responsibility of the Fabricator to identify and consider their effects
and to provide this information to the Officer-in-Charge for review.
8.
The Fabricator shall provide documentation for all laminate properties used in
the design. Laminates shall be similar in construction, layer sequence, resin
type and cure to those used to determine tested properties. All properties shall
be adjusted to reflect any reductions at operating temperatures.
9.
Reinforcement surfacing veil shall be C-glass surfacing veil, as specified in
Section 13230.
10.
Interior layers of glass mat shall consist of three layers of 1-1/2 ounce per
square foot glass mat.
11.
All exterior surfaces shall be resin rich and reinforced with one layer of C-glass
surfacing veil.
12.
Resin shall be premium grade vinyl ester resin, Vipel K0, Derakane 510-A, Dion
9300 or approved substitute. Resin shall achieve ASTM Class I fire retardance
without the use of antimony.
13.
For all laminates, the corrosion resistant liner shall be followed by a filament
wound structural laminate applied in accordance with Section 13230.
14.
The corrosion liner shall be a minimum of 100 mils in thickness and
documentation shall be provided by the Fabricator verifying veil type, liner
thickness, and resin cure. Excess liner thickness shall be added to the total wall
thickness, but shall not conflict with tolerance requirements. Fifty mils of the
corrosion liner shall be considered sacrificial and not included in determining
structural wall thickness. Structural wall thickness shall be determined in
accordance with ASME/ANSI RTP-1 and shall not be less than 0.375-inch for
tanks and vessels. The requirements of ASME/ANSI RTP-1 shall govern the
design.
15.
Laminate types may include hand lay-up, helical winding, and hoop/chop
construction methods. In laminates with helix angles greater than 75 degrees
and in all hoop/chop laminates, approximately 10 percent of the structural wall
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-8
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
thickness shall be oriented at 0 degrees (longitudinal direction). This
reinforcement shall be applied in two layers of weft unidirectional fabric and
equally spaced within the structural wall. Laminate defects and their allowable
limits and tolerances shall be in accordance with Section 13230. Laminates
shall be designed for a minimum acceptable Barcol Hardness of 36.
C.
D.
16.
Laminate sequences and thicknesses, as specified, shall be maintained.
17.
Pigments shall not be used in the inner lamina. However, a pigmented surface
coat shall be applied to the exterior surface of the tanks in accordance with
Section 13230. The color shall be as directed in writing by the City.
18.
Nozzles, gussets, access ways and shell reinforcements shall be determined
according to the applicable text, tables and formulas in ASME/ANSI RTP-1.
19.
Anchoring for tanks shall be accomplished using lugs and a continuous filament
wound band or an integral filament wound load ledge with external anchor clips.
20.
Internal beams and support attachments shall be designed using a maximum of
25 psi shear stress for secondary bonds. This shall also apply to design of
external lugs required for ladders, platforms, and other system components.
21.
Tanks shall be designed to support the specified carbon bed depth. Carbon
support system shall include a polypropylene carbon support membrane, as
recommended by the carbon manufacturer, supported by fiberglass grating,
supported by fiberglass beams. Carbon support system shall be designed to
prevent carbon pellets from slipping through the grating. Carbon support
system shall be coordinated with activated carbon supplier for pellet sizing.
Carbon support system shall have a design safety factor of 300 percent.
ACCESS PORTS:
1.
Access ports with clear acrylic covers shall be provided for each vessel. They
shall be minimum 24 inch diameter with flanged and bolted openings.
2.
Each vessel shall have a minimum of one access port for each carbon bed.
LADDER/PLATFORM ASSEMBLIES:
1.
Ladder/platform assemblies shall be configured to provide access to elevated
access ports and elevated dampers, as specified on the Drawings.
2.
Assemblies shall be structurally attached to and supported by the vessel.
Structural design calculations, including documentation for all physical
properties used in the design shall be sealed by a registered professional
engineer who is regularly engaged in the design of composite structures.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-9
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
3.
The access ladder shall be provided with a safety cage and the access
platforms shall be provided with safety rails.
4.
Ladder/platform assemblies shall conform to all applicable code requirements
and loads per Section 01900. See Section 06500 for FRP platform, railing, and
ladder requirements.
E.
FITTINGS: Drain flanges shall be ANSI 150#. Air inlet and outlet flanges shall be as
specified in Section 13234.
F.
METAL APPURTENANCES: Wires, anchor lugs, bolts, fasteners, and all other required
metal appurtenances shall be provided as specified in this Section
G.
GASKETS: Gaskets shall be provided as specified in this Section.
H.
AIR SAMPLE PORTS: Each tank shall have 1-1/2 inch diameter air sample ports at the
following locations at a minimum. Air sample ports shall be operator-accessible from
ground-level.
1.
2.
3.
One (1) port at the vessel intake plenum.
One (1) port located 6 inches above the top of the upper carbon bed.
One (1) port located 6 inches below the bottom of the lower carbon bed.
I.
GROUNDING: A grounding rod shall be provided for each carbon bed and grounded at
base of vessel.
J.
CARBON SAMPLE PORTS: Each carbon bed shall have three 1-1/2 inch diameter carbon
sample ports extending 6 inches into carbon media. Ports shall be seated with a full
port ball valve.
K.
CARBON BED MONITORING: A media life sampling probe to allow external viewing of the
remaining carbon life shall be provided in each bed. Probe shall be sealed against
internal vessel air pressure.
L.
PRESSURE DIFFERENTIAL INDICATORS: The vessel shall have pressure differential
indicators for measuring the pressure drop across each media bed in each vessel. The
pressure differential indicator gauges shall be operator accessible from ground level.
The differential pressure indicator assembly shall be configured to prevent migration of
water from the tubing into the gauge and be equipped with a valve/petcock to drain
condensate from the tubing.
PART 3 – EXECUTION
3.01
INSTALLATION
A.
EQUIPMENT MOUNTING:
1.
PROCEDURES: Section 11002.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-10
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
B.
3.02
2.
Install tanks on a Group D Equipment Mounting System in accordance with the
Equipment Mounting Schedule specified in Section 11002.
3.
Each tank shall rest on a level, even base of concrete such that the entire
bottom of the tank is supported.
INSTALLATION OF CARBON:
1.
The activated carbon specified in Section 13540 shall be installed.
2.
Carbon shall be evenly spread and compacted. Special care shall be taken to
ensure there are no voids or opportunities for short circuiting. Carbon shall be
placed in lifts not exceeding 1 foot in depth.
3.
Notify the Officer-in-Charge at least 10 working days prior to the scheduled date
for carbon installation. Quantities of each type of carbon, a delivery date, and an
installation time shall be provided.
4.
Arrange with the Officer-in-Charge at least 10 working days prior to carbon
installation for a representative of the City to be on site when the carbon is
installed. The representative shall be familiar with carbon vessel maintenance
procedures and inspect each lift of carbon as it is installed.
COMPONENT TEST PHASE
A.
PROCEDURES: Sections 01600 and Section 01662.
B.
TESTING: Prior to installation of carbon, perform the following tests:
1.
AIR LEAK TEST:
a.
b.
c.
3.03
Connect tanks to ductwork system.
Test tank and ductwork system under specified design conditions.
Monitor tanks for air leaks and correct any leaks prior to acceptance.
MEASUREMENT AND PAYMENT
A.
FRP Tanks for Carbon shall not be paid for directly, but shall be considered incidental
and included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13225-11
ADDENDUM NO. 3
FIBERGLASS REINFORCED PLASTIC
(FRP) TANKS FOR CARBON
SECTION 13234
FIBERGLASS REINFORCED PLASTIC (FRP) DUCTWORK
PART 1 – GENERAL
1.01
SUMMARY
A.
1.02
SCOPE: This section specifies fiberglass reinforced plastic (FRP) ductwork. Unless
otherwise specified, all ductwork shall be filament wound construction.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this Section
and those of the listed documents, the requirements of this Section shall prevail.
Unless otherwise specified, references to documents shall mean the documents in
effect on the effective date of Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replaced documents issued or otherwise identified by that organization, or if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
B.
1.03
Title
AMCA
Air Movement Control Association
AMCA 500
Methods of Testing Heavy Duty Dampers for Rating
ASTM E 84
Standard Test Method for Surface Burning Characteristics of
Building Materials
GENERAL: The requirements of Section 13230 shall apply to all aspects of this
specification section. In cases of conflict, this section shall take precedence over
Section 13230.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
Proposed FRP ductwork plan, including hanger and support types and
locations, field joint locations, inspection ports, drain sumps, dampers,
flexible connections, expansion boots, and any other ductwork
appurtenances. Approval is required prior to the start of fabrication.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-1
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
1.04
3.
Calculations and complete fabrication details of special system components
specified in this Section. Approval is required prior to the start of fabrication.
4.
Certification from the Fabricator that the ductwork specified herein will be
fabricated in the Fabricator’s own manufacturing facility and will not be
outsourced to a partner’s facility.
5.
Certification from the resin manufacturer that the selected resin and catalyst
systems are appropriate for the service conditions of the duct systems, as
specified in this Section and Section 01800.
6.
Qualifications of the Fabricator and Field Joining Contractor.
7.
Complete damper product information including shop drawings illustrating
component configuration, dimensions, connection and assembly details, and
materials list.
8.
Certified damper leakage, pressure drop characteristics, and operator torque
test results.
9.
Manufacturer’s Installation Certification Form (Form 11000-A, Section
01999).
10.
Damper operating and maintenance information as specified in Section
01730.
PERFORMANCE REQUIREMENTS
A.
SERVICE CONDITIONS: Ductwork shall be suitable for installation and service at a
wastewater treatment plant, under the environmental conditions specified in Section
01800.
B.
OPERATING CONDITIONS:
Operating Condition
Saturated air stream temperature, degrees F
Value
50–100
Max hydrogen sulfide concentration of air stream, ppm (a)
100
Max Pressure, inches w.c.
30
Max Vacuum Pressure, inches w.c.
12
Notes:
a.
Air stream will contain droplets of sulfuric acid.
1.05
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. The structural components, seismic
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-2
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
attachments, braces, and anchors to the structure for all parts or elements of the
mechanical and electrical systems shall be designed in accordance with Section
01900.
PART 2 – PRODUCTS
2.01
CANDIDATE FABRICATORS/PRODUCTS
A.
Candidate Fabricators are listed below. To conform with specified requirements, the
Fabricator’s standard product may require modification.
1.
2.
3.
4.
2.02
ECS Environmental Solutions
Daniel Mechanical
Spunstrand
Or approved substitute
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
2.03
Material
Ductwork
Fiber reinforced plastic (FRP)
Fasteners
Type 316L stainless steel
FEATURES
A.
FRP DUCTWORK
1.
RESIN: Resin shall be premium grade vinyl ester resin, Vipel K0, Derakane
510-A, Dion 9300 or approved substitute. Resin shall achieve ASTM Class I
fire retardance without the use of antimony.
2.
SPECIAL CATALYST: In accordance with the recommendations of the resin
manufacturer for the intended service.
3.
MINIMUM BARCOL HARDNESS: 30
4.
SURFACING VEIL (INNER SURFACE): One layer of 10 mil C-glass surfacing veil.
5.
INTERIOR LAYER: Two layers of 1-1/2 ounce per square foot mat.
6.
CORROSION LINER: Minimum thickness of 100 mils.
7.
FILAMENT WINDING: Helix angle shall be between 55 degrees and 65
degrees with a tolerance of ±2 degrees. Cycle wall thickness shall be 0.06
inch maximum. Structural wall glass content shall between 55 percent and
65 percent.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-3
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
B.
8.
SAFETY FACTORS: A minimum structural safety factor of 10:1 shall be used
in the design of ductwork for tensile or flexural stress conditions. A minimum
safety factor of 5:1 shall be used for conditions of elastic stability, such as
buckling under vacuum loads.
9.
STRUCTURAL LAYERS: Natural color, no pigments allowed.
10.
EXTERIOR SURFACE:
a.
Provide an exterior surface gel coat and 10 mil C-glass surfacing veil.
Color to be determined by the City.
b.
The exterior of all FRP duct to be located inside of any buildings shall
be coated with two coats of PPG Speedhide Flat Latex Paint, No 42-7,
or equal, in accordance with the Fabricator’s recommendations, for
smoke rating and additional fire retardancy. Any damage to this paint
coat occurring during installation shall be repaired promptly, restoring
the paint coat to the original condition.
11.
POSTCURE: Equipment to be postcured in accordance with the
recommendations of the resin manufacturer for the intended service.
12.
MARKING: In addition to the requirements specified in Section 13230, all
spool assemblies and pieces shall be identified with piece mark numbers
using non-water-soluble paint, easily removable with agents that will not
attack the finish of the FRP Ductwork.
DETAILS: As a minimum, FRP ductwork shall be constructed in accordance with the
thicknesses, laminate sequences and detail drawings specified in this Section. If the
design requirements dictate that increased thickness or other changes are required,
they shall be submitted for approval of the Officer-in-Charge. Details are to be used in
conjunction with Contract Documents.
Detail 1 – FRP Duct and Fitting Thickness
Detail 2 – FRP Flanges
Detail 4 – FRP Butt and Miter Joints
Detail 5 – FRP Tee and Lateral Joints
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-4
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
Duct I.D.
Up to 12”
14”
16”
18”
20”
24”
30”
32”
36"
42"
48"
54”
60”
F.W. Wall
Thickness
0.21”
0.21”
0.21”
0.24”
0.24”
0.27”
0.32”
0.35”
0.35"
0.38"
0.41"
0.41"
0.41"
H.L.U. Wall
Thickness
0.24”
0.24”
0.24”
0.33”
0.33”
0.33”
0.39”
0.46”
0.46"
0.50"
0.54"
0.64”
0.64”
NOTE:
1. See Tables 1 and 2 in Paragraph 2.03-C for filament wound (F.W.) and hand-lay-up (H.L.U.)
laminate sequencing.
FRP DUCT AND FITTING THICKNESS
DETAIL 1
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-5
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
FRP DRILLED FLANGE - DUCT DRILLING
Nozzle I.D.
Nozzle
O.D.
Bolt Circle
No. of
Bolt Holes
Dia. of
Bolt Holes
A
B
(See Note)
C
D
Up to 12"
14"
16"
18"
20"
24"
30"
32”
36”
42”
48”
54”
60”
16 3/8"
18 3/8"
20 3/8"
22 3/8"
24 3/8"
28 3/8"
34 3/8"
36 3/8”
40 3/8”
46 3/8”
54 3/8”
66 3/8”
66 3/8”
15"
17"
19"
21"
23"
27"
33"
35”
39”
45”
52”
58”
64”
12
12
16
16
20
20
28
30
32
36
44
44
52
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2”
1/2"
5/8”
5/8”
5/8”
2"
2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
2 1/2"
3”
4”
4”
4”
0.24"
0.24"
0.24"
0.33"
0.33"
0.33"
0.39"
0.46”
0.46”
0.50”
0.54”
0.64”
0.64”
0.37"
0.37"
0.44"
0.48"
0.48"
0.48"
0.51"
0.55”
0.55”
0.63”
0.77”
1.00”
1.00”
0.50"
0.50"
0.63"
0.63"
0.63"
0.63"
0.63"
0.63”
0.63”
0.75”
1.00”
1.00”
1.00”
NOTE:
1. See Table 2 in Paragraph 2.03-C for external overlay laminate sequencing.
FRP FLANGES
DETAIL 2
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-6
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
FRP DUCT BUTT AND MITER JOINT OVERLAY
External Overlay
Duct I.D.
Thickness
Width
Up to 12"
0.24"
8"
14"
0.24"
8"
16"
0.24"
8"
18"
0.33"
10"
20"
0.33"
10"
24"
0.33"
10"
30"
0.46"
12"
32”
0.46”
12”
36"
0.46"
12"
42"
0.54"
12"
48”
0.54”
12”
54”
0.64”
14”
60”
0.64”
16”
NOTES:
1. See Section 13230 for assembly tolerances.
2. For 24 inches diameter and larger, and where accessible, apply an internal overlay (MMC) 6"
wide.
3. See Table 2 in Paragraph 2.03-C for external overlay laminate sequencing.
FRP BUTT AND MITER JOINTS
DETAIL 3
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-7
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
FRP DUCT TEE AND LATERAL JOINT OVERLAY
Duct
External Overlay
I.D.
Thickness
Width
Up to 10”
0.24"
8”
12"
0.33"
10"
14"
0.33"
10"
16"
0.33"
10"
18"
0.39"
12"
20"
0.39"
12"
24"
0.39"
12"
30"
0.46"
14"
32”
0.50”
14”
36"
0.54"
14"
42"
0.57"
16"
48”
0.64"
16”
54”
0.64"
16”
60”
0.64"
16”
NOTES:
1. See Section 13230 for assembly tolerances.
2. Fill voids with resin putty as shown. Flare putty into a radius 1/4 inch minimum to 3/8 inch
maximum.
3. For header diameter 24 inches and larger, and where accessible, apply an internal overlay
(MMC) 6 inches wide.
4. See Table 2 in Paragraph 2.03-C for external overlay laminate sequencing.
FRP TEE AND LATERAL JOINTS
DETAIL 4
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-8
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
C.
LAMINATE SEQUENCE:
Key for Tables 1 and 2:
C=
10 mil C-glass surfacing veil
M=
1-1/2 ounce per square foot mat
E=
Exotherm ply, 1-1/2 ounce per square foot mat
R=
24 ounce per square yard, 5x4 plain weave, woven roving
FW = Filament winding to the thickness specified
Table 1. Helix Wound Laminate Composition
Thk.
0.21”
0.24”
0.27”
0.32”
0.35”
0.38”
0.41”
C
2
2
2
2
2
2
2
M
1
1
1
1
1
1
1
E
1
1
1
1
1
1
1
R
Sequence of plies.
CME ⇒ 0.11" F.W. ⇒C
CME ⇒ 0.14" F.W. ⇒C
CME ⇒ 0.17" F.W. ⇒C
CME ⇒ 0.22" F.W. ⇒C
CME ⇒ 0.25" F.W. ⇒C
CME ⇒ 0.28" F.W. ⇒C
CME ⇒ 0.31" F.W. ⇒C
Table 2. Hand Lay-Up Laminate Composition
Thk.
0.24”
0.33”
0.39”
0.46”
0.50”
0.54”
0.57”
0.64”
C
2
2
2
2
2
2
2
2
M
4
5
6
6
7
7
8
9
E
1
1
1
2
2
2
2
2
R
1
2
3
4
4
5
5
6
Sequence of plies.
CME MRMMC
CME MRMRMMC
CME MRMRMRMMC
CME MRMRE MRMRMC
CME MRMRMRE MRMMC
CME MRMRMRE MRMRMC
CME MRMRMRE MRMRMMC
CME MRMRMRE MRMRMRMMC
D.
ELBOWS: Elbows 30 inches in diameter and smaller shall be 1-piece molded,
smooth turn, hand lay-up construction unless otherwise noted. Elbows greater than
30 inches in diameter may be fabricated from straight duct sections using miter
joints per the drawing details in this Section. Mitered elbows 45 degrees and less
shall be 2-piece with 1 miter joint. Mitered elbows 46 to 90 degrees shall be 3-piece
with 2 miter joints. Unless specified otherwise, all elbows shall be short radius (1.0
times the diameter).
E.
SPECIAL SYSTEM COMPONENTS: Fabricator shall be responsible for the design of
rectangular duct, transitions, or any special system components not specifically
detailed in this Section. Deflection of flat panels shall be limited to 1 percent of the
panel width at the system operating pressure. Rectangular duct and flanges shall be
fabricated in one piece with a minimum radius of 1/2" in all corners. Rectangular
duct shall not be assembled from multiple flat panels.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-9
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
F.
TURNING VANES:
1.
Turning vanes shall be provided in accordance with ASHRAE
recommendations. Duct fabricator shall propose and submit construction,
location, and installation details of vanes and splitters.
2.
All vanes shall have sufficient section and stiffness to operate without flutter
or vibration under the airflow conditions indicated. Turning vanes shall be
airfoil section with internal metal reinforcement and FRP laminate overlay or
airfoil section, all Type 316 stainless steel.
G.
FASTENERS: Bolts, nuts, and washers shall be as specified in this Section. Backing
strips, drilled for the above bolting requirements, shall be employed for all
connections at fans, demisting sections, and wherever shear or moment loads may
be encountered on duct connections.
H.
GASKETS: Gaskets shall be as specified in Section 15050.
I.
FLEXIBLE CONNECTIONS:
1.
Flexible connections shall be provided for transitions between ductwork and
equipment, as specified on the drawings. Flexible connections shall be round,
rectangular, square, transition from round to rectangular, or reducing.
2.
Flexible connections shall be pre-fabricated flanged type unless specifically
indicated to be plain end (slip-on) type on the drawings. Flanged type flexible
connections shall be W-design configuration, constructed with compound
curve molded corners with arch pre-molded. Corners on rectangular flexible
connections shall be completely molded and free of splices.
3.
Backing rings shall be 3/8-inch thick, 2 inches wide, Type 316L stainless
steel, ANSI/ASME B16.1, Class 25 diameter and drilling. Thickness shall be
1/4-inch, minimum; flanges shall be a minimum of 3/4-inch thick. Length
shall be 12 inches flange-to-flange with the following additional dimensions:
a.
b.
c.
4.
J.
Extension: 1 inch.
Compression: 2 inches.
Lateral Offset: 1-1/2 inches.
Flexible connections shall be Mercer Rubber Company, Duct Connector
Model MI-9, Holz Rubber Company, Style 945 (flanged style), or approved
substitute.
EXPANSION BOOTS:
1.
Unless specified otherwise, Contractor shall locate and size expansion boots
based on the environmental conditions specified in Section 01800 using the
coefficient of thermal expansion for the particular ductwork being provided by
the Fabricator.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-10
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
K.
L.
2.
Expansion boots shall be flanged one-piece molded reinforced EPDM, a
minimum thickness of 1/8 inch with 316L stainless steel split retaining rings.
3.
Provide a 1/2 inch diameter galvanized U-bolt to function as a guide at the
closest pipe support on each side of the expansion boot. Install U-bolt with
approximately 1/8 inch clearance between duct and U-bolt to allow axial
movement of duct.
4.
Expansion boots shall be Mercer Rubber Company, Duct Connector Model MI9, Holz Rubber Company, Style 945 (flanged style), or approved substitute.
HANGERS AND SUPPORTS:
1.
Hangers and supports for FRP ductwork shall be as specified in Section
15050 and Section 15096.
2.
Hangers and supports shall conform to the requirements of Section 01900.
3.
Hangers and support shall transmit all ductwork loads into the structural
frame through a series of intermediate beams and struts, as necessary to
accommodate the requirements of these Specifications. Large elbows and
terminal ends of ducts shall be supported independently.
4.
Hangers and supports shall be lined with 1/8 inch thick neoprene, bonded to
the metal hanger or support, to cushion the duct. Hangers and supports shall
fit the exterior of the duct closely and extend completely around the duct.
Minimum width shall be 4 inches or 1/8 of the duct diameter, whichever is
greater.
DAMPERS
1.
GENERAL:
a.
Dampers shall be provided as specified on the Drawings. Unless
specified otherwise, all dampers shall be round bubble-tight type.
b.
Dampers shall have FRP or Type 316L stainless steel blades, Type
316L stainless steel shafts and hardware, and permanently
lubricated graphite filled Teflon bearings. A 100 mil interior vinyl
ester resin corrosion liner conforming to the requirements of Section
13230 shall be provided for all exposed interior surfaces.
c.
Dampers shall be constructed between two flanges unless specified
otherwise. Minimum damper blade thickness shall be equal to flange
thickness. Damper body and frame shall be fabricated to match
connecting ductwork and conform to the requirements of Section
13230. Flanges shall be pre-punched and match duct flanges and
bolt patterns as specified in this Section. No shop fabricated or
spooled-in duct dampers will be allowed.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-11
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
2.
3.
c.
Stuffing boxes shall be provided for gas-tight seals to prevent leakage
at all shaft ductwork penetrations. Stuffing boxes shall be adjustable
and shall contain a minimum of two sets of packing glands. Bearings
shall be flange mounted, located outside the air stream. Bearings
may be oil impregnated sintered bronze or relubricable rolling
element.
d.
Damper linkage shall be capable of transmitting twice the maximum
torque required by the damper at 30 inches differential pressure.
Linkage lever arms shall be a minimum of 3 inches, and the lever
arms shall be welded to the axles. All linkage connections shall be
supplied with oil impregnated bronze bearings.
e.
Operators for dampers having torque requirements of 500 inchpounds or less shall have heavy-duty manual locking quadrants.
Operators for dampers having torque requirements in excess of 500
inch-pounds shall have manual worm gear actuators with hand wheel.
Damper operators not readily accessible shall be provided with chain
wheel operators.
f.
Dampers shall be tested for leakage, pressure drop, and torque for
each damper type and size. Dampers shall be tested in accordance
with AMCA 500 in an AMCA certified testing facility.
ROUND LOW-LEAK DAMPERS:
a.
Round low-leak dampers shall be butterfly type suitable for balancing
and shut-off.
b.
Blade seal shall be a flat wiper EPDM seal. Blade stops are not
acceptable. Shaft seal shall be Viton O-ring. Leakage through the
closed damper at 70° F and a differential pressure of 30 inches water
column shall not exceed 5 cfm per square foot of duct cross-sectional
area. All seals shall be easily replaceable by maintenance personnel.
c.
Round low-leak dampers shall be ECS X02, DanELAST Model 203,
Swartwout Model 914, or approved substitute.
ROUND BUBBLE-TIGHT DAMPERS:
a.
Round bubble-tight dampers shall be butterfly type suitable for
balancing and shut-off.
b.
Blade seal shall be a PTFE encapsulated O-ring. Non-PTFE seals or
bladder-type seals molded into the body are not acceptable. Shaft
seal shall be Viton O-ring. Leakage through the closed damper at 70°
F and a differential pressure of 30 inches water column shall be 0
cfm.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-12
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
c.
4.
5.
BACKDRAFT DAMPERS
a.
Backdraft dampers shall be butterfly or parallel blade type. Inlet and
outlet shall be suitable for duct design shown on the drawings.
b.
Blades shall be airfoil-shape, FRP construction with FRP or FRPencapsulated stiffeners, if required. Blades shall not protrude beyond
the body.
c.
Shaft and linkage shall be 316L stainless steel and out of the air
stream. Shaft seals shall be air tight sealing, and leak free at 30
inches water column pressure for one hour. Shaft seal shall be Viton
O-ring.
d.
Backdraft dampers shall be ECS BD Series, DanFLO, or approved
substitute.
e.
Where indicated, backdraft damper shall be provided with
counterbalance weight(s) to control the pressure differential at which
the damper blad
blades begin to open (counterbalance
(counterbalance weight shall be
positioned on the low pressure side of the shafts)
shafts). Counterbalance
arm, weight, and fasteners shall be 316 stainless steel. See drawings
for information on opening pressure.
FIRE DAMPERS
a.
M.
Round bubble-tight dampers shall be ECS X03, DanELAST Model 303,
Ershigs Type B, or approved substitute.
Fire dampers shall be as specified on the Drawings and in Section
15912.
INSPECTION PORTS:
1.
In addition to the locations specified on the Drawings, inspection ports shall
be provided at all fan inlet and discharge connections and either upstream or
downstream from all operable fittings, such as dampers and sound traps,
and all primary instrument locations. Fabricator shall propose and submit
construction, location, and installation details for inspection ports not shown
on the Drawings.
2.
Inspection ports shall be removable type as specified on the Drawings and
fabricated out of the same material as the parent duct. All internal surfaces
exposed to the duct interior shall have a full corrosion barrier as specified in
this Section.
3.
Doors shall have an external overlap of no less than 1 inch or as required to
provide an airtight seal with the parent duct. All overlap surfaces shall have
an EPDM gasket bonded to the door surface. The gasket shall not move when
the door is open.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-13
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
4.
N.
O.
P.
Q.
Locations of inspection ports shall be configured to prevent collection of
condensate on the interior of the inspection port viewport.
DRAIN SUMPS:
1.
Drain sumps shall be provided at all duct low points as specified on the
Drawings.
2.
Drain sumps shall be 6” FRP flanges equipped with a 2 inch FRP full coupling
laminated in the blind and a 2 inch PVC ball valve, as shown on the Drawings.
Drain sumps shall make an airtight seal with the parent duct and be
configured to maximize collection of condensate in the sump.
SAMPLING PORTS:
1.
Sampling ports for monitoring of hydrogen sulfide concentrations shall be as
specified on the Drawings.
2.
Sampling ports shall be 4-inch FRP flanges equipped with a 1-inch FRP full
coupling laminated in the blind and a 1-inch PVC ball valve, as shown on the
Drawings. Sampling ports shall make an airtight seal with the parent duct and
be configured to prevent collection of condensate in the flange connection.
RETURN/EXHAUST GRILLES:
1.
Grilles for FRP ductwork shall be bladed-type as specified in Section 15940.
2.
Grilles shall be constructed of aluminum with 316 SS fasteners. Grilles shall
be of the size, capacity, and configuration indicated on the drawings.
TRANSITION BETWEEN PIPE MATERIALS: When transitioning between FRP and a
different pipe material, a full flat face is required to be formed at mating flanges.
Where a full flat face cannot be achieved due to the use of a backing ring or a raised
face flange, an appropriately sized ring spacer is required to fill the gap to prevent
bolt loads from bending and breaking the FRP flange.
PART 3 – EXECUTION
3.01
INSTALLATION
A.
GENERAL: All material and equipment shall be installed as specified by the
applicable state and local codes. All ductwork indicated on the drawings is
schematic. Changes in duct size, duct configuration, and duct location may be
necessary to conform to field conditions. All such changes shall be submitted to the
Officer-in-Charge for approval prior to fabrication or construction.
B.
FIELD JOINING MATERIALS: FRP duct Fabricator shall supply all materials needed for
any required FRP duct field joining. Supply of these materials shall be in accordance
with the requirements of this Section and Section 13230.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-14
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
C.
3.02
3.03
COMPONENT TEST PHASE
A.
PROCEDURES: Section 01660 and Section 01662.
B.
TESTING: All ductwork shall be leak-tested as specified in Section 15050. All audible
leaks shall be sealed. Schedule all tests with the Officer-in-Charge a minimum of 5
working days prior to the test. The Contractor shall provide necessary fittings, blind
flanges, and other appurtenances necessary to isolate sections of duct and enable
all sections of ductwork to be tested.
FABRICATOR’S SERVICES
A.
3.04
FIELD JOINING: Any required field joining shall be accomplished by the Field Joining
Contractor in accordance with the requirements of this section and Section 13230.
The field joining contractor shall have a minimum 5 years experience in FRP
ductwork.
ON-SITE INSPECTIONS AND TRAINING:
1.
The Fabricator shall provide a representative on-site to supervise installation
of the FRP ductwork system. To ensure the contractor is employing the proper
procedures, the Fabricator shall remain on-site to witness the installation of
all ductwork. The Fabricator shall be on-site no less than two 8 hour days
during the start of installation.
2.
The Fabricator shall instruct the Contractor on the proper installation
procedures at any time the Fabricator or Officer-in-Charge witness improper
installation practices.
MEASUREMENT AND PAYMENT
A.
FRP ductwork shall not be paid for directly, but shall be considered incidental and
included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13234-15
ADDENDUM NO. 3
FIBERGLASS REINFORCED
PLASTIC (FRP) DUCTWORK
SECTION 13577
BIOTRICKLING FILTER ODOR CONTROL SYSTEM
PART 1 – GENERAL
1.01
DESCRIPTION
A.
SCOPE: This section specifies biotrickling filter systems for treating odorous exhaust
airstreams from municipal wastewater operations. Biotrickling filter systems shall
include, but are not limited to, FRP reaction vessel, chemical resistant media and
support grating, piping, spray system, nutrient feed system, electrical controls,
valves, recirculation pumps, nutrient tank, nutrient pumps, and all necessary
appurtenances specified herein.
System Identifier
B.
System Description
Location
System A
KAN-ODOR, Biotrickling Filter System
KWPTF
System B
KAI-ODOR, TIPS Biotrickling Filter System
KRWWTP
EQUIPMENT LIST:
Item
System
Equipment No.
KAN-ODOR, Biotrickling Filter
A
BTF 900,310
KAN-ODOR, Biotrickling Filter Mist Eliminator
A
MME 900,311
KAN-ODOR, Biotrickling Filter Recirculation Pump 1
A
P 900,201
KAN-ODOR, Biotrickling Filter Recirculation Pump 2
A
P 900,202
KAN-ODOR, Biotrickling Filter Nutrient Feed Pump 1
A
P 900,211
KAN-ODOR, Biotrickling Filter Nutrient Feed Pump 2
A
P 900,212
KAN-ODOR, Biotrickling Filter Nutrient Tank
A
P 900,210
KAN-ODOR, Biotrickling Filter Control Panel
A
ICP 900,976
KAI-ODOR, TIPS Biotrickling Filter 1
B
BTF 500,310
KAI-ODOR, TIPS Biotrickling Filter 1 Mist Eliminator
B
MME 500,311
KAI-ODOR, TIPS Biotrickling Filter 2
B
BTF 500,320
KAI-ODOR, TIPS Biotrickling Filter 2 Mist Eliminator
B
MME 500,321
KAI-ODOR, TIPS Biotrickling Filter Recirculation Pump 1
B
P 500,201
KAI-ODOR, TIPS Biotrickling Filter Recirculation Pump 2
B
P 500,202
KAI-ODOR, TIPS Biotrickling Filter Recirculation Pump 3
B
P 500,203
KAI-ODOR, TIPS Biotrickling Filter Nutrient Feed Pump 1
B
P 500,211
KAI-ODOR, TIPS Biotrickling Filter Nutrient Feed Pump 2
B
P 500,212
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-1
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
1.02
Item
System
Equipment No.
KAI-ODOR, TIPS Biotrickling Filter Nutrient Feed Pump 3
B
P 500,213
KAI-ODOR, TIPS Biotrickling Filter Nutrient Tank
B
T 500,210
KAI-ODOR, TIPS Biotrickling Filter Control Panel
B
ICP 500,976
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this Section
and those of the listed documents, the requirements of this Section shall prevail.
Unless otherwise specified, references to documents shall mean the documents in
effect on the effective date of Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replaced documents issued or otherwise identified by that organization, or if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
Title
ASTM D2563
Standard Practice for Classifying Visual Defects in Glass
Reinforced Plastic Laminate Parts
ASTM D2584
Standard Test Method for Ignition Loss of Cured
Reinforced Resins
ASTM D3299
Standard Specifications for Filament-Wound Glass-FiberReinforced Thermoset Resin Corrosion-Resistant Tanks
ASTM D4097
Standard Specification for contact-molded glass-fiberreinforced Thermoset Resin Corrosion-Resistant Tanks
National Bureau of
Standards (NBS): PS 15
Custom Molded Reinforced Polyester for Chemical
Resistant Process Equipment.
ISO 9001
International Organization for Standardization
B.
UNIT RESPONSIBILITY: Assign unit responsibility, as specified in Section 11000, to
the Biotrickling Filter Odor Control System Vendor for the reaction vessel, chemical
resistant media and support grating, piping, spray system, nutrient feed system,
valves, recirculation pumps, nutrient tank, nutrient pumps, and all necessary
appurtenances specified in this Section, as well as conduit, wiring, control strategies,
PLC code and HMI development for integration of the Biotrickling Filter Odor Control
System. This Vendor is the unit responsibility Vendor and has unit responsibility, as
defined in Section 11000, for equipment specified in this Section.
C.
FACTORY TESTS:
1.
GENERAL: All equipment shall be factory tested for compliance with the
requirements specified herein and a certificate for the results of these tests
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-2
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
shall be submitted to the Officer-in-Charge upon delivery. In addition, the
specific tests specified below shall be conducted.
D.
2.
BURN TESTS: A minimum of two burn tests from nozzle cutouts shall be
performed on each vessel to verify glass/resin ratio.
3.
LEAK TEST: Perform a four hour fully hydrostatic atmospheric leak test for the
sump area. Zero leakage is allowed.
4.
STRAIN
STRAIN TEST: Perform a pressure test under pressure and vacuum
conditions. Design strain shall be verified by strain gauge testing during this
test.
SOURCE QUALITY CONTROL:
1.
EQUIPMENT INSPECTION: The Vendor shall retain and pay for the services of
an independent FRP inspector, or shall designate at least one employee as
inspector, for the purpose of inspection during fabrication of the odor control
vessels. If an employee is designated then the vessel manufa
manufacturer shall
have a certified Quality Management System in place that is registered and
monitored by National Quality Assurance (NQA) for compliance with ISO
9001.
9001. The Inspector shall be present at each fabrication step between the
days before the first equipment is started until the day after the last
equipment is shipped to the site and have at least 10 years of FRP inspection
experience. The Inspector shall keep a log of all activities performed and the
progress of each vessel. If the Inspector does not witness any step of the
fabrication process, the equipment in question shall be rejected. Inspector
shall be supervised by a registered professional engineer who shall submit to
the Officer-in-Charge stamped reports of the manufacturing progress every 3
weeks. Each piece of equipment delivered shall have a transmittal letter,
signed by the inspector, which notes that the equipment has met the
specifications and the transmittal letter shall contain copies of all test results
performed on the vessel accompanied by all vessel cutouts. Any equipment
shipped to the site not accompanied by such a letter will not be accepted.
Vendor shall allow the Officer-in-Charge complete access at all times to the
facility that contains equipment to be supplied under this Section. If the
inspector is more than 5 working days late with the weekly report or found
not keeping current records, all equipment in progress will be rejected.
2.
Vendor shall submit Inspector’s resume, a signed statement that the
inspector will have no other duties relating to the production of equipment
specified under this section, other than inspecting the equipment, and a
signed statement that the Inspector does not report to or is not supervised by
any personnel involved in the production of the equipment specified under
this section.
3.
OFFICEROFFICER-ININ-CHARGE’S INSPECTION: Vendor shall allow for factory visits by
the OfficerOfficer-inin-Charge as specified in Section 13230 to perform equipment
inspections. Transportation and accommodation costs,
costs, including meals,
meals, for
two people per visit shall be provided for up to two factory visits. For USA
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-3
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
factories, air transport shall be coach class. For nonnon-USA factories air
transport shall be business class.
1.03
E.
SHIPMENT AND STORAGE: Vendor’s recommendations on shipping and handling and
the shipping and handling procedures, as recommend by SPI “Recommended
Practice for Shipping and Installation of Reinforced Plastic Tanks”, and as described
in NBS PS15 and ASTM D4097 shall be adhered to.
F.
SPECIAL WARRANTY: Provide Vendor’s extended guarantee or warranty, with the City
named as beneficiary, in writing, as a special guarantee. Special guarantee shall
provide for correction, or at the option of the City, removal and replacement of Work
specified in the Section found defective during a period of 365 days after the date of
substantial completion. Duties and obligations for correction or removal and
replacement of defective work shall be as specified.
G.
QUALIFICATIONS:
1.
Vendor shall be recognized in the design, production and operation of
biotrickling filter systems in the United States. The Vendor’s Process Designer
shall each have at least 10 years experience in design and fabrication of FRP
biotrickling filter systems similar to the type specified for this section with
either their present or previous employer.
2.
The Vendor’s place of business and vessel manufacturing facility shall be
open for inspection. Vendor shall be capable of providing the City with
training and monitoring support on one day’s notice during the first year of
operation.
3.
The Vendor shall provide a list of at least five different locations where their
equipment has been installed and is currently in service. The installations
provided must be biotrickling filters associated with the removal of hydrogen
sulfide and/or typical organic municipal wastewater odors and have odor
performance requirements similar to those specified in this Section.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
Unit Responsibility Certification Form (Form 11000-C, Section 01999)
attesting that unit responsibility has been assigned in accordance with the
requirements of this section. No other submittal material will be reviewed
until the certificate has been found in conformance with this requirement.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-4
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
3.
Detailed structural and mechanical layout drawings showing system
fabrication, dimensions, size, and locations of connections to other work and
fully describing system operation.
4.
Complete process and mechanical design calculations for the odor control
system, including annual utility costs, biotrickling filter vessel pressure drop
calculations, calculations showing that the media(s) as provided will meet the
required performance criteria, anticipated nutrient feed requirement based
upon design airflow and hydrogen sulfide inlet concentrations specified in
this Section.
5.
Shop drawings including the make, model, weight, and horsepower of each
equipment assembly. Vendor’s catalog information, descriptive literature,
specifications, and identification of materials of construction shall also be
included.
6.
Structural calculations and drawings which include, but are not limited to,
dead loads, live loads, environmental loads (wind, seismic), anchor lug
attachment to shell, anchor bolt size and embedment requirements.
Consideration of effect of all cutouts and openings into the vessel wall shall
be considered. Attachment lugs for piping, structural members, and other
appurtenances, media support design, and the deflection of the vessel at the
point of connection with the ductwork and all material property values used
for structural calculations shall be verified by actual physical tests on similar
type laminates. Test data shall be submitted with all structural calculations.
All structural drawings and calculations shall be signed and sealed by a
professional engineer, meeting requirements of Article Qualifications.
Structural design criteria
criteria shall be clearly listed at the beginning of the
structural calculations.
7.
A certificate from the resin manufacturer listing the nomenclature,
composition, and characteristics of the resin shall be furnished with the
vessel.
8.
A reference list of five existing projects where similar equipment by the
Vendor is currently in service. Length of service, facility names, telephone
number and mailing addresses of design engineer, City, and installation
contractor shall be provided for each reference.
9.
A copy of the fiberglass fabrication Quality Assurance procedures as Specified
in this Section.
10.
Process and Instrumentation drawings (P&ID) showing all components, flow
rates, and unit requirements along with Vendor’s catalog information,
descriptive literature, specifications, and identification of materials of
construction.
11.
Vessel data indicating equipment number, pressure rating, diameter, straight
lengths, overall lengths, and wall thickness with Vendor’s information on the
media including air pressure drop data through media and mist eliminator
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-5
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
measured at design airflow rate and proposed media depth (height-feet) and
media volume (cubic feet).
12.
Operating data from previous installations to substantiate media
performance shall be provided and certified by the Process Designer.
13.
External utility requirements such as air, water, power, drain, etc., for each
component.
14.
Confirmation that the air delivery system shown on the contract drawings is
acceptable.
15.
Functional description of internal and external instrumentation and controls
to be supplied, including list of parameters monitored, controlled, or alarmed
along with control panel elevation drawings showing construction and
placement of operator interface devices and other elements.
16.
Power and control wiring diagrams, including terminals and numbers and
shop and field painting systems: which include the Vendor’s descriptive
technical catalog literature and specifications.
17.
Vendor Coordination: Contractor shall obtain approval of Biotrickling Filter
Odor Control system Vendor of all documentation used to integrate the
system into the plant control system. This includes but is not limited to
associated motor elementary drawings, loop drawings, PLC card drawings,
P&IDs, network drawings, control strategies, PLC code, and HMI development
files. Approval shall be obtained before installation and programming of the
plant control system associated with the BTF equipment. Submittal to the
vendor shall meet the same requirements of this contract. Vendor’s
representative shall approve commissioning of the Vendor equipment.
Vendor coordination is a requirement for the Vendor unit responsibility.
18.
Qualifications of the FRP inspector as specified in this Section.
19.
Qualifications, projects, and resume of the Process Designer as specified in
this Section.
20.
Operation and Maintenance Data, as specified in Section 01730, with the
Vendor’s Certificate of Proper Installation.
21.
Detailed factory testing plan, which includes test equipment used and
sampling and analysis procedures.
22.
Detailed performance testing plan, which includes test equipment used and
sampling and analysis procedures.
23.
Calibration and setup procedures and specific testing methodology used
along with the sampling and analysis procedures.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-6
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
1.04
24.
Final report consisting of a narrative of the sampling activities, a copy of the
original sampling log, photographs showing locations of velocity and pressure
measurements, tabular summary of velocity, airflow rates, pressures, H2S
and odor removal data, calculated results, and conclusions of these results. If
necessary, report shall be revised in accordance with written comments from
the Officer-in-Charge and resubmitted.
25.
Manufacturer’s Installation Certification Form (Form 11000-A, Section
01999).
26.
Manufacturer’s Instruction Certification Form (Form 11000-B, Section
01999).
PERFORMANCE REQUIREMENTS
A.
SERVICE CONDITIONS: Equipment shall be suitable for installation and service at a
wastewater treatment plant, under the environmental conditions specified in Section
01800.
B.
OPERATING CONDITIONS:
System A Operating Conditions
Operating Condition
Value
Duty
Design
Total airflow rate, cfm
5,400
Average inlet H2S concentration, ppm(v)
25
Peak inlet H2S concentration, ppm(v)
100
Peak inlet methyl mercaptan concentration, ppm(v)
1
Peak inlet dimethyl sulfide concentration, ppm(v)
1
Peak inlet carbon disulfide concentration, ppm(v)
0.5
Peak inlet carbonyl sulfide concentration, ppm(v)
0.5
Peak inlet dimethyl sulfide concentration, ppm(v)
0.5
Max recirculation rate per train, gpm
90
Average inlet relatively humidity, percent
50–100
Inlet air temperature range, deg F
50–100
Minimum H2S removal efficiency, percent
99
Max outlet H2S concentration when inlet H2S
concentration is less than average, ppm
0.5
Max air pressure drop per vessel, inlet flange to outlet
flange, inches w.c.
2.1
Minimum EBRT, sec
14.0
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-7
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
System B Operating Conditions
Operating Condition
Value
Duty
Design
Emergency
Airflow rate per train, cfm
10,000
20,000
Number of parallel trains
2
1
10,000
20,000
Avg. inlet H2S concentration, ppm(v)
50
50
Peak inlet H2S concentration, ppm(v)
140
140
Peak inlet methyl mercaptan concentration, ppm(v)
1
1
Peak inlet dimethyl sulfide concentration, ppm(v)
1
1
Peak inlet carbon disulfide concentration, ppm(v)
0.5
0.5
Peak inlet carbonyl sulfide concentration, ppm(v)
0.5
0.5
Peak inlet dimethyl sulfide concentration, ppm(v)
0.5
0.5
Max recirculation rate per train, gpm
125
125
Avg. inlet relatively humidity, percent
50–100
50–100
Inlet air temperature range, °F
50–110
50–110
Min H2S removal efficiency, percent
99
N/A
Max outlet H2S concentration when inlet H2S
concentration is less than average, ppm
0.5
N/A
Max air pressure drop per vessel, inlet flange to
outlet flange, inches w.c.
2.7
5.2
Min EBRT, sec
14.0
7.0
Total airflow rate, cfm
C.
DESIGN REQUIREMENTS:
Design Requirement
System A
System B
Round
Round
FRP
FRP
Synthetic Material
Synthetic Material
Vessel diameter, ft
12
14
Vessel height, maximum, ft
33
33
Media depth, minimum, ft
11.2
15.2
72 x 15
72 x 18
24
42
-15 to +12.0 in w.c.
-15 to +12.0 in w.c.
Vessel type
Material of construction
Media type
Inlet flange size, rectangular, inches
Outlet flange diameter, inches
Max pressure rating
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-8
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
1.05
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. The structural components, seismic
attachments, braces, and anchors to the structure for all parts or elements of the
mechanical and electrical systems shall be designed in accordance with Section
01900.
PART 2 – PRODUCTS
2.01
CANDIDATE VENDORS/PRODUCTS
A.
Candidate Vendors are listed below. To conform with specified requirements, the
Vendor’s standard product may require modification.
1.
2.
3.
2.02
Evoqua Water Technologies
Daniel Mechanical
Or approved substitute
MATERIALS AND FEATURES:
A.
GENERAL:
1.
System shall consist of biotrickling filter vessel, chemically resistant media
and support grating, piping, spray system, nutrient feed system, electrical
controls, valves, recycle sump, recirculation pumps, nutrient tank, inlet and
outlet connections, access platforms, and all necessary appurtenances
specified herein. System fabrication details and materials shall be included in
Shop Drawings and submitted for approval before fabrication. In order to
achieve standardization of appearance, operation, maintenance, spare parts,
and vendor’s services, all equipment specified herein shall be obtained from
one Vendor.
2.
Vendor shall coordinate the electrical, mechanical and structural interfaces
between all equipment required for a complete functioning odor control
system. The entire odor control system and coordination of all items,
including biotrickling filter vessels and media, recirculation pump,
instrumentation and controls, and all appurtenances necessary for complete
system shall be included in the design.
3.
This Section specifies minimum system operating requirements and
descriptive specifications are given for all major components of the system.
All components necessary for a functioning system shall be provided. Piping
and cable and conduit runs shown are based upon vendor information
provided during the preparation of the Contract Documents. No additional
compensation will be made for changes required to install the system to
meet the functional specifications.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-9
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
4.
B.
Biotrickling filter systems shall be capable of removing 50 percent of total
odor units based on the compound concentrations specified in this Section.
BIOTRICKLING FILTER VESSEL:
1.
Vessel shall be filament wound, cylindrical in shape with up-flow air passage
and countercurrent liquid flow. Plastic HDPE or PPL vessels are not
acceptable. The vessel design shall include material selection, wall thickness,
methods and locations of support, and stiffener requirements.
2.
FRP construction shall be manufactured in accordance with Section 13230,
NBS PS 15, ASTM D3299 Grade 1, and ASTM D4097. Contact molded
accessories shall be manufactured in accordance with NBS PS 15. All metal
parts shall be Type 316 stainless steel with no metallic parts contacting the
media except for grounding purposes.
3.
Structural aspects of the vessel shall be sufficient to meet code
recommended requirements, including relevant seismic requirements for all
conditions during the design life. Requirements shall be in accordance with
Section 01900.
4.
The minimum required dimensions and tolerances wall thickness for the
cylinder straight shell shall be sufficient to support its own weight in an
upright position without any external support. All dimensions shall be taken
with the tank in the vertical position, unfilled. The tolerance for the outside
diameter, including out-of-roundness, shall be per ASTM D1998. The
tolerance for fitting placements shall be plus or minus 0.5 in. in elevation and
2 degrees radial ambient temperature.
5.
Each tank shall be marked with the fabricator’s name, capacity in gallons,
maximum temperature, design pressure/vacuum, specific gravity, pH, resin,
minimum thickness, vessel number, vessel name, and date of manufacture.
Seal decals, labels, etc. into the laminate exterior with clear resin.
6.
Visual workmanship defects per ASTM D2563, shall not exceed Level II on
the vessel interior and Level III on the vessel exterior. Finished vessel wall
shall be free, as commercially practicable, of visual defects such as foreign
inclusions, air bubbles, pinholes, pimples, crazing, cracking, and
delaminations that will impair the serviceability of the vessel. All cut edges
where openings are cut into the tanks shall be trimmed smooth.
7.
Beds of media shall be supported with FRP grating sized for maximum
deflection of 1/4 inch.
8.
The air inlet and outlet connections to the vessel shall be flanged and sized
as specified on the Drawings. FRP blind flanges, with gaskets, constructed to
the same standards as the vessels, shall be provided for use on all flanged
openings. Gasket material shall be suitable for use in a corrosive
environment.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-10
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
C.
9.
Provide flanged or FNPT couplings with PVC ball valves for drain, fill, and
overflow connections.
10.
Pressure ports shall utilize a 1 inch FNPT FRP coupling. Other ports specified
in the Contract Documents shall be provided by the Vendor.
11.
The circulating liquid sump shall be an integral part of the vessel located
directly below the media beds. Overflow and drain connections shall be
provided to the sump.
12.
All flanged connections shall be gusseted to the tank wall with 1/4 inch thick
flat plate gussets. The vessel shall be provided with a sight gauge that will
give a visual level indication from a point 4 inches above the bottom to a
point 4 inches above the absorber section of the vessel. The gauge shall be
1 inch clear PVC and provided with shutoff ball valves.
13.
Tank wall nozzle cutouts shall be labeled in accordance with the submittal
drawings. All cutouts shall be reinforced as required by the conditions
Specified. Press molded or compression molded flanged nozzles are not
acceptable.
14.
Tie down lugs and lifting shall be integrally molded into walls of the vessel.
15.
The vessel shall have one 1 inch diameter air sample port at the inlet, outlet,
and media mid-point of each media bed in each vessel. The sampling port for
the media shall extend 12 inches into the packing column, extend outside
the vessel wall, and be operator-accessible from ground level for obtaining air
samples. All sampling ports shall be blocked off with a 1 inch valve. Ball
valve shall be CPVC construction as manufactured by Chemtrol, HillsMcCanna, or approved substitute.
FRP MATERIAL
1.
GENERAL: All FRP components shall conform to the requirements of Section
13230. Laminate consisting of a corrosion barrier, a structural layer, and
exterior finish must meet the requirements of the mechanical properties and
visual acceptance criteria specified in Section 13230.
2.
RESIN: Resin shall be premium grade vinyl ester resin, Vipel, Derakane, Dion
or approved substitute. Resin shall achieve ASTM Class I fire retardance
without the use of antimony.
3.
RESIN CURING SYSTEM: Use resin manufacturer’s currently recommended
cure system. Products cured to a minimum of 90% of the minimum Barcol
hardness specified by resin manufacturer. Measure Barcol hardness
according to ASTM D2583. Post-cure the tank and appurtenances in
accordance with resin manufacturer’s recommendation for time and
temperature. Post curing shall be completed with warm-to-hot dry air, free of
combustion products. Hot spots shall be avoided.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-11
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
4.
5.
D.
E.
REINFORCEMENT:
a.
Corrosion Barrier shall have a resin rich interior surface of 100 mils.
Reinforce inner surface with a resin rich surfacing veil of 10 to 20
mils. At least two plies of chopped strand mat to back the veil and no
additive in the corrosion barrier. The resin content of the inner
surface shall be a minimum of 80% by weight. Glass content of
combined inner surface and interior layer shall be 27 percent ±5%.
The structural layer shall be filament wound with a continuous strand
roving to provide a glass content of 50 to 80 percent.
b.
Reinforcing materials shall consist of chopped strand Mat: Type E
glass, minimum 1-1/2 ounces per square foot, with silence finish and
styrene soluble binder. Continuous roving Type E glass with silane
type finish with a nominal yield of at least 110 strand yards per pound
shall be used for filament winding. Type E glass with a nominal 24
ounces per square yard, 4 by 5 weave, with silane type finish shall be
used for woven roving. No reinforcement is required for the exterior
finish.
CORROSION LAYER: Laminate for the inner corrosion layer shall be resin rich,
not to exceed 20 percent ±5 percent glass by weight, and a minimum
thickness of 15 mils. It shall be followed by at least two layers of chopped
strand mat or two passes of chopped roving to a total of 3 ounces per square
foot. A chopped roving technique shall be employed and the chopped fibers
shall be 1/2 inch to 2 inches in length. The total corrosion barrier shall total
100 mils minimum and be 27 percent ±5 percent glass by weight. Exterior
finish shall have a gel coat. Color shall be selected by the City.
MIST ELIMINATOR:
1.
A vertical flow mist eliminator shall be installed above the spray-header in the
biotrickling filter vessel and designed for the operating conditions specified in
this Section. Mist eliminator shall be polypropylene or 316L stainless steel
and configured per the Vendor’s recommendations.
2.
Mist eliminator shall remove 90% of droplets greater than 10 microns in
diameter and 99% of droplets greater than 40 microns in diameter. Face
velocity through the mist eliminator shall not exceed 900 feet per minute to
avoid moisture carry over.
3.
A 1 inch water line with permanent spray nozzle shall be provided for
cleaning of the mist eliminator, as required.
ACCESS PORTS:
1.
Access ports shall be provided at the following locations for each vessel.
a.
b.
One port immediately above the maximum water level of the sump.
One port at the bottom of each media bed.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-12
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
c.
d.
2.
F.
G.
H.
One port at the elevation of the distribution nozzles that enable
access to the nozzles for maintenance.
One port on the top of the vessel that enables access to the integral
mist eliminator.
Access ports shall be minimum 24 inches in diameter with flanged and
bolted openings. Ports at the sump, distribution nozzles, and mist eliminator
shall have clear acrylic covers with a 2 inch wide FRP backing ring. All other
ports shall be solid FRP.
LADDER/PLATFORM ASSEMBLIES:
1.
Ladder/platform assemblies shall be configured to provide access to the
distribution nozzle assembly, the integral mist eliminator, and all elevated
dampers, as specified on the Drawings.
2.
Ladder/platform assemblies shall be structurally attached to and supported
by the vessel. Structural design calculations, including documentation for all
physical properties used in the design shall be sealed by a registered
professional engineer who is regularly engaged in the design of composite
structures.
3.
The access ladder shall be provided with a safety cage and the access
platforms shall be provided with safety rails.
4.
Ladder/platform assemblies shall conform to all applicable code
requirements and loads per Section 01900. See Section 06500 for FRP
platform, railing, and ladder requirements.
MEDIA:
1.
Media shall be non-proprietary synthetic media with no mineral or activated
carbon components.
2.
Media shall be guaranteed by the Vendor against subsidence greater than 5
percent, biological fouling, and/or general lack of performance for a period of
ten years after the acceptance of the system. System shall be operated in
accordance with the Vendor’s operation and maintenance information.
RECIRCULATION WATER SYSTEM:
1.
GENERAL:
a.
The recirculation water system shall consist of recirculation pump(s),
spray nozzles, CPVC piping, pH probe/transmitter with piping loop,
pressure gauges, flow meter and valves, and all components
specified in the Contract Documents.
b.
Irrigation system shall be capable of completely covering the entire
media bed with the recirculated water.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-13
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
2.
RECIRCULATION PUMP AND MOTOR:
a.
Each vessel shall have one primary recirculation pump and one
installed standby pump for redundancy purposes. In systems with
multiple trains, a single pump can serve as a backup for multiple
biotrickling filter vessels.
b.
Recirculation pumps shall be seal-less, centrifugal, magnetic driven
type with non-metallic wetted parts. Pump shall be over hung design
with close-coupled drivers. Pumps shall provide the recirculation flow
specified in this Section at a pressure required by the nozzles and
biotrickling filter pipe system.
c.
Bearings shall be a one-piece design press fit into the inner magnet
Front thrust bearing system shall consist of a two collar design with a
replaceable axial thrust surface. Rear thrust bearing system shall
consist of a one-piece design with replaceable axial thrust collar.
Bearing material shall be chemically resistant and suitable for the
fluid being pumped.
d.
Pump shafts shall be silicon carbide or high purity alumnia ceramic.
The driven magnet shall be fully encapsulated, as recommended by
the pump manufacturer. Outer drive magnet shall be dynamically
balanced and capable of mounting directly to standard NEMA motors.
Pump frame shall include a non-metallic reinforced plastic base and
shall not use the motor for support.
e.
Pumps shall be properly sized by the Vendor for the proper flow rate
and head conditions as required for the installation. The pump shall
be free from cavitation and damaging vibration over the range of
operating conditions under which it will perform.
f.
Recirculation pumps shall be Iwaki, Sundyne, Finish Thompson, or
approved substitute.
g.
Noise emission shall not exceed 85 dBA at a distance of 3 feet from
the equipment.
h.
Recirculation pumps shall be driven by a 230/460 VAC, 3 phase, 60
hertz TEFC electrical motor and shall include a 1.15 service factor.
Motors shall conform to the requirements specified in Section 11060.
i.
Motor shall be mounted with a cast iron mounting bracket and
connected to the pump shaft by means of a flexible coupling. Motors
shall be 5 horsepower. Motor controllers shall conform to the
requirements of Division 16.
j.
All motors and electrical equipment shall be designed and
constructed in complete accordance with the latest edition and
revision of all applicable IEEE, NEMA, NEC, and NFPA codes and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-14
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
regulations. Mechanical components shall be designed and
constructed in accordance with the latest edition and revision of all
applicable NBS, ASTM, ANSI, and ASME codes and regulations.
3.
I.
J.
PIPING AND APPURTENANCES:
a.
Recirculation system piping and spray header piping shall be
Schedule 80 CPVC.
b.
Pressure gauge and sample port with CPVC ball valves shall be
installed at the recirculation pump discharge and vessel recirculation
water inlet.
c.
A flow transmitter shall be installed in the recirculation piping to
provide a signal to the instrumentation and control system specified
in this Section.
d.
The pH probe/transmitter shall be installed in the recirculation piping
and shall be as specified in Section 17215.
MAKE-UP WATER SYSTEM:
1.
The make-up water system shall consist of a rotameter, pressure regulator,
pressure gauge, CPVC piping and valves.
2.
Rotameter shall provide local indication and manual adjustment of make-up
water flow and shall be acrylic-tube with a 5 inch scale and stainless steel
frame. Flow scales shall indicate the units of flow. It shall be mid-range
capacity and capable of metering 10 gpm of make-up water into the vessel
sump.
3.
Rotameters shall be King Series 7000 or approved substitute.
4.
Pressure regulator shall be installed to provide constant system pressure. A
0-60 psi pressure gauge shall be installed in the make-up water line
downstream of the pressure regulator with a 1 inch CPVC schedule 80 piping
and globe valve. Solenoid valves controlled via a Vendor-supplied control
panel shall allow make-up water addition as required. Solenoid valves shall
be as specified in Section 15147.
5.
All make-up water components shall be mounted inside an FRP cabinet for
protection against sunlight and for better accessibility.
NUTRIENT FEED SYSTEM:
1.
Biological nutrients stored in the nutrient tank are delivered to the spray
nozzle where the solution is circulated through the packing media. Each
vessel shall have one primary nutrient feed pump and one installed standby
pump for redundancy purposes. All piping and equipment necessary to
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-15
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
deliver nutrients from the reservoir to the spray nozzles shall be included as
part of the nutrient feed system.
K.
2.
Nutrient feed pumps shall be positive displacement, solenoid-driven
diaphragm metering pumps. Pumps shall be designed and selected for
pumping biological nutrients typically used in biotrickling filter systems. Pump
drive and electronic components shall be totally enclosed and separated
from the pumped liquid with no moving parts. The drive shall have a fully
encapsulated solid-state electronic pulser with quick connect terminals.
Pumps shall be constructed of chemical-resistant glass fiber reinforced
thermoplastic. All exposed fasteners shall be Type 316L stainless steel.
Pump shall be ball type with ceramic balls. Valve seat and seal-ring shall be
renewable by replacing the combination seat-seal ring or cartridge assembly.
Pump head shall be transparent acrylic material suitable for the pumped
liquid. Pump output shall be adjustable while the pump is running.
3.
Nutrient feed pumps shall be Wallace & Tiernan Products Premia 75 series,
LMI Milton Roy Series C, ProMinent Gamma L, Iwaki/Walchem EKB series, or
approved substitute.
4.
A nutrient tank of FRP construction shall be provided for containment of
biological nutrients. The tank shall be suitable for storage in direct sunlight.
Pipe connections for tank drain, outlet, inlet, pressurized water connection,
low level indicator, and vent shall be provided with the nutrient tank. Flanged
connections shall be of the same materials at the tank wall. Threaded
connections shall of standard NPT. The nutrient tank shall have a connection
to the pressurized water source that is controlled by a ball valve.
5.
Nutrient tank shall be sized to provide a minimum of 30 days of nutrient
supply, based on the requirements specified in this Section, before requiring
a refill.
6.
A level indicating transmitter shall be provided for local indication of the
nutrient tank level and for monitoring at the Vendor supplied control panel as
specified in this Section.
INSTRUMENTATION AND CONTROL:
1.
GENERAL:
a.
Conduit and wiring will be provided as specified in Division 16 to the
control panel for recirculation pump power circuiting.
b.
All wiring from the control panel to system components shall be
provided as part of the Vendor system specified in this Section. Panel
construction shall meet the requirements of Divisions 16 and 17.
c.
All instrumentation within 3 feet of a foul air stream shall be rated for
Class I, Division 2, Group D.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-16
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
2.
3.
L.
CONTROL PANEL:
a.
NEMA 4X, 316L stainless steel, free standing enclosure rated for
230/460V, 20 amp input. Control panel shall be mounted
independent of the odor control system and at least 3 feet away from
any odor leakage source.
b.
Controls shall be as shown on the P&IDs, wiring diagrams, and
described in the Control Strategies, Section 17500. See CS-500 and
CS-901.
c.
Control panel and all required associated hardware shall be provided
for this panel, as specified in Division 16, to provide operation as
described in the contract documentation.
RECIRCULATION WATER CONTROLS:
a.
A flow transmitter installed in the recirculation piping shall provide a
digital readout of recirculation flow in the control panel and a low flow
relay to shut the recirculation pump off at low flow conditions.
b.
Flow transmitter shall be Signet 2536 or approved substitute.
ACCESSORIES:
1.
PRESSURE DIFFERENTIAL INDICATORS: The vessel shall have pressure
differential indicators for measuring the pressure drop across each media
bed and the integral mist eliminator in each vessel. The pressure differential
indicator gauges shall be operator accessible from ground level. The
differential pressure indicator assembly shall be configured to prevent
migration of water from the tubing into the gauge and be equipped with a
valve/petcock to drain condensate from the tubing.
2.
EQUIPMENT IDENTIFICATION PLATES: Equipment identification plates shall
consist of a 16 gauge, type 316L stainless steel plate or FRP laminate and
shall be securely mounted on the equipment in a readily visible location. The
plate shall bear the 1/4 inch die-stamped equipment number specified in
this Section.
3.
LIFTING LUGS: Equipment over 100 pounds in weight shall be provided with
lifting lugs.
4.
ANCHOR BOLTS AND TIE DOWN LUGS: All anchor bolts shall be provided.
Anchor bolts and tie down lugs shall be type 316L stainless steel. Final size
shall be coordinate with final shop drawings.
5.
PAINTING: Shop painting shall be Vendor’s standard. Color to be specified by
the City.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-17
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
2.04
SPARE PARTS
A.
Provide the following spare parts:
1.
2.
3.
4.
5.
2.05
One complete set of vessel cover gaskets per unit.
One pH meter per unit.
One solenoid valve per unit.
One flow meter per unit.
One complete spray nozzle set per unit.
EQUIPMENT AND SYSTEM CONTROLS
A.
Division 17 specifies control system requirements.
PART 3 – EXECUTION
3.01
INSTALLATION
A.
3.02
1.
PROCEDURES: Section 11002.
2.
Install biotrickling filter vessel on a Group D Equipment Mounting System in
accordance with the Equipment Mounting Schedule specified in Section
11002.
3.
Install recirculation pumps, makeup water system, nutrient feed system,
and control panel in accordance with Section 11002 and Vendor’s
recommendations.
COATINGS
A.
3.03
EQUIPMENT MOUNTING:
PROCEDURES: Repair and touch up of factory finish as specified in Section 09900.
COMPONENT TEST PHASE
A.
PROCEDURES: Section 01660 and Section 01662.
B.
FUNCTIONAL TESTS:
1.
ALIGNMENT TEST: An alignment test checks complete assemblies for correct
rotation, proper alignment and connection, and quiet operation.
2.
AIR BALANCING TEST: Provide for services of an independent air balancing
and testing firm to balance the odorous air into odor control system as
specified in the Contract Documents. Certification of functional acceptance
prior to commencing performance testing must be provided.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-18
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
3.
ODOR CONTROL SYSTEM TESTS: Test all system components for proper
adjustment and operation in both the manual and automatic operating
modes. Vendor shall coordinate the testing of the equipment operation in
both manual and automatic with the Section 17000’s System Integrator and
the requirements of Section 17030. Section 17000’s System Integrator shall
be programming the plant control system (PCS) PLC and HMI. The Vendor’s
technical representative system tests shall include the Biotrickling Filter Odor
Control System operation through the PCS PLC and the control, monitoring
and alarming at the PCS HMI.
C.
SYSTEM STARTUP: System startup shall be performed by Vendor and shall
commence following a visual inspection and check out of the system by the Vendor’s
technical representative. Vendor shall test the equipment operation in both manual
and automatic with the Section 17000’s System Integrator in accordance to the
requirements of this Section and Section 17030.
D.
PERFORMANCE TESTING:
1.
Performance testing shall be conducted to demonstrate that the system
furnished hereunder is installed and performs in accordance with the
provisions of these specifications. Performance testing shall be performed
after a minimum acclimation period of 28 days following start-up of the
system.
2.
The performance test shall not commence until a Performance Testing Plan
has been submitted and approved, and the functional testing has been
completed. The Performance Test Plan shall contain written procedures and
guarantee points to be used.
3.
A minimum of 12 hours of testing on each tower shall be performed on actual
odors. Vendor shall coordinate with the Officer-in-Charge to test during a
period where both the average and peak odors specified in this Section are
expected to occur.
4.
Vendor shall provide, install and maintain, if required, all temporary metering
and analytical equipment necessary to measure the various performance
parameters.
5.
Vendor shall inform the Officer-in-Charge at least 10 working days prior to the
start of any performance testing. The Officer-in-Charge shall have the right to
observe, sample, and make any parallel determinations during the
performance test.
6.
Within 20 working days after the conclusion of the test period, the Vendor
shall submit a Performance Test Report, including all laboratory and field test
data, stating the conclusions of the test with regard to the performance
criteria.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-19
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
E.
SAMPLING AND DATA MEASUREMENT:
During the test period, as a minimum, data and measurements shall be taken at the
frequency specified in the Performance Testing Plan for the overall system airflow
rate (cfm), fan discharge pressure (inches WC) and the following:
F.
1.
INLET AIRFLOWS (cfm): Measurement of airflows shall be performed using an
anemometer or pitot tube instrument previously approved by Officer-inCharge.
2.
HYDROGEN SULFIDE INLET CONCENTRATIONS (ppbv/ppmv): H2S
measurements shall be performed by instruments previously approved by
Officer-in-Charge.
3.
HYDROGEN SULFIDE OUTLET CONCENTRATIONS (ppbv):
a.
H2S measurements shall be performed by hand-held instruments
previously approved by Officer-in-Charge.
b.
Individual sampling event performance results shall then be
calculated by Percent Removal = (Inlet – Outlet) / Inlet. Individual
hourly removal rates shall be averaged to determine system average
removal rates for hydrogen sulfide.
4.
SAMPLING LOG: A sampling log shall be maintained that shall include which
includes the date, time, location, sampler, and results of each sample,
weather conditions for the sampling day, a qualitative description of the
operation of the wastewater and wastewater treatment processes and a
description of exceptions from the sampling plan.
5.
MEDIA BED PRESSURE DROP: Pressure differential measurements shall
demonstrate that differential pressure (pressure drop) across the media bed
does not exceed pressure limits specified.
RETESTING:
1.
In the event the system fails to meet the performance requirements, the
Vendor shall immediately make the necessary modifications, adjustments, or
facility expansions to meet these requirements. The steps taken by the
Vendor shall include, as necessary, design, and construction of additional
system capacity, upgrades to the air distribution system, and replacements of
the media at no additional cost to the City. Additional performance tests shall
be conducted by the Vendor until the performance requirements are met, at
no additional cost to the City.
2.
If after two retests the performance requirements are still not met, the City
will have the option, at the City’s sole discretion, to accept the system as is or
obtain a replacement at the expense of the Vendor. The maximum time
between each retest shall be 20 working days.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-20
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
G.
3.04
DEMONSTRATION OF PERFORMANCE: Within 10 working days of submission of
Performance Test Report documenting compliance with specified performance
requirements, the Officer-in-Charge will give written notice of the final acceptance of
the system to the Vendor.
VENDOR’S SERVICES
A.
ONSITE INSPECTIONS AND TRAINING: A Vendor’s representative for the equipment
specified herein shall be present at the jobsite or classroom designated by the
Officer-in-Charge for the minimum person-days listed for the services herein under,
travel time excluded. Services shall be at such times as requested by the City.
1.
2.
3.
3.05
Four person-days during construction for installation assistance, inspection,
and certification of the installation.
One person-day for classroom or site training.
Two person-days for functional testing and plant startup.
MEASUREMENT AND PAYMENT
A.
Biotrickling filter odor control systems shall not be paid for directly, but shall be
considered incidental and included in the lump sum bids for the respective items in the
Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
13577-21
ADDENDUM NO. 3
BIOTRICKLING FILTER
ODOR CONTROL SYSTEM
SECTION 14670
UNDER RUNNING PNEUMATIC BRIDGE CRANE,
EXPLOSION PROOF
PART 1--GENERAL
1.01
DESCRIPTION
A.
SCOPE: This Section specifies bridge cranes with hoists, trolleys, bridges, end trucks,
crane rails, associated pneumatic drive units and controls. The crane shall be single
girder under riding bridge crane type. Hoist shall be under riding chain type. The
bridges, hoists and trolleys shall be air motorized. Crane shall be provided to operate in
a Class I, Division I, Group D hazardous environment. Moving part including but not
limited to wheels, hook, chain, sheaves, festoons, etc. shall be spark resistant. Crane
operates in a highly corrosive environment. Provide corrosion resistant materials for all
crane components. All metals shall be Type 316L stainless steel unless noted
otherwise.
B.
EQUIPMENT LIST:
Item
Equipment No.
Wet Well Pneumatic Bridge Crane
1.02
CRN 200,092
QUALITY ASSURANCE
A.
REFERENCES:
1.
This Section contains references to the following documents. They are a part of
this Section as specified and modified. Where a referenced document contains
references to other standards, those documents are included as references
under this Section as if referenced directly. In the event of conflict between the
requirements of this Section and those of the listed documents, the
requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the documents
in effect at the time of Advertisement for Bids or Invitation to Bid (or on the
effective date of the Agreement if there were no Bids). If referenced documents
have been discontinued by the issuing organization, references to those
documents shall mean the replacement documents issued or otherwise
identified by that organization or, if there are no replacement documents, the
last version of the document before it was discontinued. Where document
dates are given in the following listing, references to those documents shall
mean the specific document version associated with that date, regardless of
whether the document has been superseded by a version with a later date,
discontinued or replaced.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-1
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
Reference
Title
AISC 360-05
Specification for Structural Steel Buildings
ASME B30.10
Hooks
ASME B30.11
Monorails and Underhung Cranes - Safety Standard for
Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings
ASME B30.16
Overhead Hoists (Underhung)
ASME NOG-1
Rules for Construction of Overhead and Gantry Cranes (Top
Running Bridge, Multiple Girder)
ASTM A492
Standard Specification for Stainless Steel Rope Wire
ASME NUM-1
Rules for Construction of Cranes, Monorails, and Hoists with
Bridge or Trolley or Hoist of the Underhung Type
ASTM A193
Standard Specification for Alloy-Steel and Stainless Steel
Bolting Materials for High Temperature or High Pressure
Service and Other Special Purpose Applications
ASTM A194
Standard Specification for Carbon and Alloy Steel Nuts for
Bolts for High Pressure or High Temperature Service
ASTM A240
Specification for Heat Resisting Chromium and Chromium
Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels
ASTM A275
Standard Test Method for Magnetic Particle Examination of
Steel Forgings
ASTM A276
Specification for Stainless Steel Bars and Shapes
ASTM A312
Standard Specification for Seamless and Welded Austenitic
Stainless steel Pipes
ASME HST-5
Performance Standard for Air Chain Hoists
AWS D1.1
Structural Welding Code - Steel
AWS-D1.6
Structural Welding Code—Stainless Steel
AWS D14.1
Specification for Welding Industrial and Mill Cranes and Other
Material Handling Equipment
CMAA 74
Specifications for Top Running and Under Running Single
Girder Electric Overhead Cranes Utilizing Under Running Trolley
Hoist, No. 74
IBC
2006 International Building Code
MHI MH27.1
Specifications for Underhung Cranes and Monorail Systems
B.
MANUFACTURER QUALIFICATION: Overhead electric crane system, including sub-system
components manufactured by vendors, must be designed and manufactured by a
company with a minimum of 10 years of specialized experience in designing and
manufacturing the type of overhead crane required to meet requirements of the
Contract Documents.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-2
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
1.03
SUBMITTALS
A.
The following information shall be provided in accordance with Section 01300:
1.
A copy of this specification section, with addendum updates included, and all
referenced and applicable sections, with addendum updates included, with
each paragraph check-marked to indicate specification compliance or marked
to indicate requested deviations from specification requirements. Check marks
( ) shall denote full compliance with a paragraph as a whole. If deviations from
the specifications are indicated and, therefore, requested by the Contractor,
each deviation shall be underlined and denoted by a number in the margin to
the right of the identified paragraph. The remaining portions of the paragraph
not underlined will signify compliance on the part of the Contractor with the
specifications. The submittal shall be accompanied by a detailed, written
justification for each deviation. Failure to include a copy of the marked-up
specification sections, along with justification(s) for any requested deviations to
the specification requirements, with the submittal shall be sufficient cause for
rejection of the entire submittal with no further consideration.
2.
Manufacturer's catalog data confirming rated capacity, equipment speeds, and
pneumatic requirements. Submit product data for rail system, pneumatic chain
hoist, trolleys, pendant pushbutton station, hook proof test, bridge festoon
system, runway track hose festoon system, bumpers, and end stops.
3.
Detailed Shop Drawings: Submit shop Drawings showing crane capacity, hook
envelope, and the general arrangement of the track beam system, clearances,
principal dimensions, details of structural connections, and all component
details. Show construction details, reinforcement, anchorage, and installation
with relation to the building construction.
4.
Pneumatic drawings: Complete schematic diagrams shall be furnished,
identifying all pneumatic equipment including manufacturer's name, model
number, hose types, and sizes as applicable.
5.
Submit structural design calculations verifying the size of structural members,
structural supports (fittings, rods, brackets, and components), and beams for
the runway system. Include stress and loading diagrams. Calculations shall be
stamped by a Professional Engineer licensed in State of Hawaii.
6.
Operations and maintenance information as specified in Section 01730.
7.
Submit test reports for 125 percent rated load test, no-load test, post-erection
inspection, operational tests, rated load speed test, chain breaking strength,
and hook NDT report.
8.
Submit certifications listed below.
9.
Manufacturer’s qualifications per Para 1.02 B.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-3
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
1.04
SYSTEM REQUIREMENTS
A.
TIPS WET WELL PNEUMATIC BRIDGE CRANE:
Item
Rated capacity, tons
Value
1
Rated runway beams capacity, tons
Bridge type
2 (for future crane capacity increase)
Under running single girder
Trolley-hoist type
Under running
Hoist type
Explosion proof chain
Maximum span between runways, feet
14.67
Elevation of hook in highest position not
lower than, feet
(-)15.75
Operating floor elevation, feet
(-)23.75
Wet Well Elevation
(-)73.00
Speeds, fpm
Hoist
12
Bridge
90
Trolley
90
Air Consumption, cfm
Hoist
74
Bridge
50
Trolley
35
Control
1.05
Hoist and Trolley
Pendent
Bridge
Pendent
CERTIFICATES
A.
Certification of minimum Load Chain Proof Test, clearly indicating load chain breaking
strength for each hoist, and clearly identified for traceability. Submit factory certification
of load chain rated capacity.
B.
Hook Proof Test certification that the hoist hook was subjected to a minimum static load
of 200 percent of rated capacity for at least 10 minutes without deformation.
C.
Certification of brake settings, including the allowable range of adjustment for hoist and
trolley brakes and the initial setting of each.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-4
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
1.06
PRE-ERECTION INSPECTION
A.
1.07
Before erection, the Contractor and the manufacturer's representative shall inspect the
rail and hoist systems and components at the job site to determine compliance with
specifications and manufacturer's data and shop drawings as approved. Notify the
Officer-in-Charge 14 days before the inspection.
DELIVERY AND STORAGE
A.
Inspect materials delivered to site for damage; unload and store with minimum
handling. Store materials on site in enclosures or under protective coverings. Protect
materials not suitable for outdoor storage to prevent damage or corrosion during
periods of inclement weather, including, precipitation, and high winds. Store materials
susceptible to deterioration by direct sunlight under cover and avoid damage due to
high temperatures. Do not store materials directly on ground. When special precautions
are required, prominently and legibly stencil instructions for such precautions on outside
of equipment or its crating.
PART 2--PRODUCTS
2.01
IDENTIFICATION PLATES
A.
2.02
Provide manufacturer installed identification plates of non-corrosive metal showing, in
clearly legible permanent lettering, the manufacturer's name, model number, capacity
rating in Tons, and other essential information. Also provide runway beam identification
plates showing the capacity of the system, in Tons, legible from the floor and inside of
the runway beam.
UNDER RUNNING CRANE SYSTEM
A.
Provide under running single girder overhead pneumatic traveling crane conforming to
CMAA 74, Class A (Standby or Infrequent Service) for outdoor service, ASME B30.11,
with a vertical lift of 57’-3” and as specified herein. The crane must be designed to
operate in a Class I, Division I, Group D hazardous environment with ambient
temperature between 50 and 100 degrees Fahrenheit.
B.
The crane to have pneumatic pendant for hoist and trolley and another one for the
bridge. The hoist pendant controller must be mounted so that operator can use from
wet well walkway with hoist extend to ends of bridge. Bridge pendant controller to be
mounted in the center of the bridge.
C.
Air powered chain hoist shall conform to ASME HST-5.
D.
All mechanical components shall be spark resistant. These components include but not
limited to bronze hooks and trolley wheels, geared trolley and stainless steel chain as
described in detail within this Section.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-5
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
2.03
SAFETY
A.
2.04
2.05
2.06
Comply with the mandatory and advisory safety requirements of ASME B30.10, ASME
B30.11, ASTM B30.16, and 29 CFR 1910.179. The Contractor is responsible for
checking the proper operation and condition of safety devices, pneumatic components,
mechanical equipment, and structural assemblies prior to installation. Immediately
report any observed defective components and replace.
STRUCTURAL REQUIREMENTS
A.
Structural requirements must be in accordance with CMAA 74, Section 3.
B.
Consider seismic forces in the design of the crane. See specification 01900 for seismic
criteria. Apply seismic forces laterally, parallel to the bridge girders and parallel to the
runway, girders as two separate load cases. Apply seismic forces concurrently with the
dead load (DL) and trolley load (TL). Locate the concentrated load in the same positions
as when calculating vertical shears and bending moments. Consider torsion due to
eccentric horizontal forces. Allowable combined stresses must be in accordance with
CMAA 74.
RUNWAY SYSTEM
A.
Provide stainless steel runway beams. The structural joint must conform to AISC 360.
Size beam, as a minimum, to withstand all expected forces and the load combinations.
B.
Design and installation of the runway system is the responsibility of the Contractor.
Support runway system from structural steel members shown on design drawings.
Provide all bolts and clamps required to secure runways. Provide lateral bracing for
runways as recommended by crane manufacturer. Provide additional supports as
required to carry lateral and longitudinal runway system loads to the structural members
shown.
C.
Runway end stops shall be of the bolted type and shall be capable of withstanding the
impact of a fully loaded crane traveling at 50 percent of the full load speed.
CRANE BRIDGE
A.
CRANE BRIDGE GIRDER: Provide stainless steel girder, in accordance with MHI MH27.1
for the crane bridge girder. The summation of all normal stresses on a girder section
under analysis can not exceed the allowable stress for tension or compression as stated
in CMAA 74.
B.
BRIDGE END TRUCKS: The bridge crane end truck drives shall be air motor driven, nonspark construction capable of moving the loaded crane at 90 fpm. Air consumption
shall not exceed 50 scfm at 90 psig. Vendor of the end truck air drive to be the same as
the vendor of the motorized trolley mounted hoist for component coordination. The
crane vendor shall design the drive mechanism to power both end trucks from the
common two-button air pendant and drive motor located in the middle of the bridge
girder. Provide two button pendant control with steel braided hose, ½” premium rubber
festoon hose rated at 250 psig, and IR series 2,000 lubricator with lubrication fluid
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-6
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
mounted on the end truck in accordance with the air drive motor vendor’s
recommendation. If air exhaust noise exceeds 80 dB A provide exhaust silencer.
C.
2.07
2.08
BUMPERS: Provide trolley and bridge bumpers conforming to CMAA 74 guidelines.
HOIST AND TROLLEY
A.
MOTORIZED TROLLEY MOUNTED AIR HOIST: The motorized trolley mounted air hoist
shall be a heavy-duty, all-air driven hoist and trolley in spark-resistant construction with
2,400 pound lifting capacity, IR 7798AL or approved substitute. Lift speed at rated
load, 12 fpm. Combined hoist and trolley air consumption shall not exceed 110 scfm at
90 psig. Provide four button pendant control with steel braided hose, ½” premium
rubber festoon hose rated at 250 psig, chain basket, IR series 2000 lubricator with
lubrication fluid mounted on the trolley in accordance with the hoist manufacturer’s
recommendation. The vendor of the motorized trolley air hoist shall coordinate the
design and installation of the festoon hose air supply to both the motorized trolley
mounted hoist and the bridge crane end truck air drive motor. If air exhaust noise
exceeds 80 dB A, provide exhaust silencer.
B.
AIR HOIST BRAKE: Air hoists shall be provided with a braking means that prevents the
lowering of the load in the event of a loss of air supply and can stop and hold 131.25
percent of rated capacity.
C.
Provide an unpainted single barbed bronze alloy hooks with stainless steel hook
latches. Hook dimensions must be as shown on the Drawings. Fit hook with safety
latches designed to preclude inadvertent displacement of slings from the hook saddle.
Provide hook nut with a removable type set screw or other similar fastener, installed in a
plane parallel to the longitudinal axis of the hook shank. Do not weld hook nut. Hook
must be free to rotate through 360 degrees when supporting a test load up to 131.25
percent of the rated capacity. Provide only hooks which are designed and commercially
rated in accordance with CMAA and conforming to ASME B30.10, and CMAA 74.
HOSE FESTOON SYSTEM
A.
Provide hose festoon system consisting of a support rail, hose carrier trollies, hose, hose
connectors and accessories. Hose loops shall not drop below the hook high position.
Provide spark resistance and corrosion resistant festoon system hardware. Provide steel
braided hose, 3/4” minimum inside diameter premium rubber festoon hose rated at
250 psig.
PART 3--EXECUTION
3.01
ERECTION AND INSTALLATION
A.
3.02
Erect and install the crane system, complete in accordance with the approved
submittals and in condition to perform the operational and acceptance tests.
ERECTION SERVICES
A.
Provide supervisory erection services from the crane system manufacturer.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-7
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
3.03
FIELD QUALITY CONTROL
A.
POST-ERECTION INSPECTION: After erection, the Contractor, and the Officer-In-Charge,
shall jointly inspect the runways, bridge and hoist systems and components to
determine compliance with specifications and approved submittals. Notify the Officer-InCharge 14 days before the inspection. A list of deficient items, including a
determination of criticality will be provided to the Contractor for corrective action.
Outstanding items shall be noted for correction during the inspection. Items considered
critical (load bearing, load controlling, or operational safety devices) shall be corrected
prior to further testing. Upon correction, provide a report of the inspection indicating the
crane system is considered ready for operational tests.
B.
OPERATIONAL TESTS:
1.
After erection and inspection, test the bridge, hoist, and trolley as specified
herein. Test the systems in service to determine that each component of the
system operates as specified, is properly installed and adjusted, and is free
from defects in material, manufacturing, installation, and workmanship. Rectify
all deficiencies disclosed by testing and retest the system or component to
prove the crane system is operational.
2.
Furnish test loads, operating personnel, instruments, and other apparatus as
necessary to conduct field tests on bridge, hoist and runways. Perform test and
final adjustments of the equipment under the supervision of the Officer-inCharge, and a representative of the City crane maintaining organization.
C.
TEST DATA: Record test data on appropriate test record forms suitable for retention for
the life of the crane system. Compare recorded values with design specifications or
manufacturer's recommended values. Abnormal differences (i.e., greater than 10
percent from manufacturer's or design values) shall be justified or appropriate
adjustments performed. In addition, note any high air consumptions or abnormal
operation of any equipment or machinery, investigate and correct. Record hoist, trolley
and bridge speeds during each test cycle.
D.
LOAD TEST
1.
HOIST.
a.
Static Load Test 125 percent only: Check entire structure, holding
brake and hoisting components as follows: With the trolley in the center
of the bridge span, raise the test load approximately one foot. Hold the
load for 10 minutes. Rotate the load and hook 360 degrees to check
bearing operation with no binding. Observe lowering that may occur
which indicates a weakness in the structure or malfunction of hoisting
components or brakes. Verify that maximum beam and girder
deflections do not exceed CMAA 74 design limits.
b.
Raise and lower and test load through the full lift range. Lower the load
to the wet well bottom, wait 5 minutes, then raise and lower the load
through two more cycles. Operate continuously for a minimum of 5
minutes. In addition, the dynamic test of test load sequence number 2
KAILUA RWWTP TUNNEL INFLUENT
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FACILITY, JOB NO. W1-13
14670-8
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
(125 percent of rated load) must be repeated for 10 cycles at rated
speed, in order to demonstrate proper operation and repeatability of all
functions without component overheating or malfunction. Completely
stop the machinery at least once in each direction during each cycle to
ensure proper brake operation. Do not stop hoist for more than 15
seconds prior to commencing the next cycle.
3.04
c.
Hoist Load Brake 125 percent only: Raise test load approximately 5
feet. With the hoist controller in the neutral position, release (by hand)
the holding brake. Document the method used to release the holding
brake. The load brake must hold the test load. Again with the holding
brake in the released position start the test load down (first point) and
return the controller to the "off" position as the test load lowers. The
load brake must stop and hold the test load.
d.
Hoist Loss of Air Test 125 percent only: Raise the test load to
approximately 8 feet. While slowly lowering the test load (first point),
disconnect the crane's air source. Verify that the test load does not
lower and that the brake is set.
2.
TROLLEY: Operate the trolley the full distance of the bridge rails in each
direction with a test load of 125 percent of rated load on the hook (one cycle).
3.
BRIDGE: With a test load of 125 percent of rated load on the hook, operate the
bridge for the full length of the runway in one direction with the trolley at the
extreme end of the bridge, and in the opposite direction with the trolley at the
opposite extreme end of the bridge (one cycle). Check proper functioning of all
drive speed control points. Record deficiencies. Secure from testing if
deficiencies are found.
4.
RATED TRAVEL TESTS: Repeat travel tests for trolley and bridge with a test load
of 100 percent of rated load. Repeat the test for 5 cycles at rated speed to
demonstrate proper operation and repeatability of all functions without the
overheating or malfunction of any components. Do not stop machinery for more
than 15 seconds prior to commencing the next cycle.
MEASUREMENT AND PAYMENT
A.
Under Running Pneumatic Bridge Crane, Explosion Proof shall not be paid for directly,
but shall be considered incidental and included in the lump sum bids for the
respective line items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
14670-9
ADDENDUM 3
UNDER RUNNING PNEUMATIC
BRIDGE CRANE, EXPLOSION PROOF
SECTION 15050
PIPING SYSTEMS
PART 1--GENERAL
1.01
SUMMARY
A.
B.
1.02
SCOPE:
1.
GENERAL: This Section specifies process piping and general requirements for
piping systems. Detailed specifications for the components listed on the Piping
Specification Sheets (PIPESPEC) are referenced from this Section. Use this
Section in conjunction with the referenced sections. Except where alternate
provisions are indicated in referenced specifications, the requirements of this
Section shall apply to all piping systems listed herein.
2.
CONTRACTOR DESIGN OF PIPING SYSTEMS: In addition to materials and
labor required to construct piping systems, Contractor shall provide
professional engineering services for a piping system design engineer
(hereinafter and in all referenced sections the "Design Professional") for the
design and inspection of piping systems work. Except as otherwise specified
in this Section, expansion control design and design of pipe supports and
seismic restraints for piping 20-inch diameter and larger are not included in
the Design Professional’s design responsibilities. The Design Professional
shall provide the final design, inspection, and certification for the piping
supports and seismic restraints as defined in paragraph 15050-1.04.B, in
the Drawings and the following sections:
a.
Pipe hangers and supports and inspection requirements are specified
in Section 15096.
b.
Seismic restraints are specified in Section 15097.
c.
Pipe expansion control systems are specified in Section 15098.
DEFINITIONS: Pressure terms used in this Section are defined as follows:
1.
MAXIMUM: The greatest continuous pressure at which the piping system
operates.
2.
TEST: The hydrostatic pressure used to determine system acceptance.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS:
1.
This Section incorporates by reference the latest revisions of the following
documents. They are part of this Section insofar as specified and modified
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-1
ADDENDUM NO. 3
PIPING SYSTEMS
herein. In the event of conflict between the requirements of this Section and
those of the listed documents, the requirements of this Section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect on the effective date of the Agreement. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or
otherwise identified by that organization or, if there are no replacement
documents, the last version of the document before it was discontinued.
Reference
Title
ANSI B1.20.1
Pipe Threads, General Purpose (Inch)
ANSI B16.1
Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800
ANSI B16.3
Malleable Iron Threaded Fittings Class 150 and 300
ANSI B16.5
Pipe Flanges and Flanged Fittings
ANSI B16.9
Factory-Made Wrought Steel Buttwelding Fittings
ANSI B16.11
Forged Steel Fittings, Socket Welding and Threaded
ANSI B16.12
Cast Iron Threaded Drainage Fittings
ANSI B16.34
Valves - Flanged, Threaded, and Welding End
API 598
Valve Inspection and Testing
ASME B31.3
Process Piping -ASME Code for Pressure Piping, B31
ASME Section IX
Boiler and Pressure Vessel Code; Welding and Brazing Qualifications
ASTM A53
Pipe, Steel, Black and Hot Dipped, Zinc-Coated Welded and Seamless
ASTM A74
Cast Iron Soil Pipe and Fittings
ASTM A105/A105M
Forgings, Carbon Steel, for Piping Components
ASTM A106
Seamless Carbon Steel Pipe for High-Temperature Service
ASTM A126
Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe
Fittings
ASTM A197
Cupola Malleable Iron
ASTM A216
Standard Specification for Steel Castings, Carbon, Suitable for Fusion
Welding, for High-Temperature Service
ASTM A234/A234M
Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and
Elevated Temperatures
ASTM A276
Standard Specification for Stainless Steel Bars and Shapes
ASTM A536
Ductile Iron Castings
ASTM B61
Standard Specification for Steam or Valve Bronze Castings
ASTM C564
Rubber Gaskets for Cast Iron Soil Pipe and Fittings
ASTM D1248
Polyethylene Plastics Molding and Extrusion Materials
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-2
ADDENDUM NO. 3
PIPING SYSTEMS
Reference
Title
ASTM D1784
Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl
Chloride) (CPVC) Compounds
ASTM D1785
Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120
ASTM D2241
Poly (Vinyl Chloride) (PVC) Plastic Pipe (SDR-PR)
ASTM D2665
Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings
ASTM D3034
Standard Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe
and Fittings
AWWA C105
Polyethylene Encasement for Ductile-Iron Piping for Water and Other
Liquids
AWWA C110
Ductile-Iron and Gray-Iron Fittings, 3 Inch Through 48 Inch, for Water and
Other Liquids
AWWA C111
Rubber-Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and
Fittings
AWWA C115
Flanged Ductile-Iron and Gray-Iron Pipe with Threaded Flanges
AWWA C151
Ductile-Iron Pipe, Centrifugally Cast in Metal Molds or Sand-Lined Molds,
for Water or Other Liquids
AWWA C200
Steel Water Pipe 6 Inches and Larger
AWWA C205
Cement-Mortar Protective Lining and Coating for Steel Water Pipe--4 In.
and Larger--Shop Applied
AWWA C206
Field Welding of Steel Water Pipe
AWWA C207
Steel Pipe Flanges for Waterworks Services--Sizes 4 In. through 144 In.
AWWA C208
Dimensions for Fabricated Steel Water Pipe Fittings
AWWA C209
Cold-Applied Tape Coating for Special Sections, Connections, and Fittings
for Steel Water Pipelines
AWWA C210
Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water
Pipe
AWWA C214
Tape Coating Systems for the Exterior of Steel Water Pipelines
AWWA C600
Installation of Ductile-Iron Water Mains and Their Appurtenances
AWWA C651
Disinfecting Water Mains
AWWA C900
Polyvinyl Chloride (PVC) Pressure Pipe, 4 Inches Through 12 Inches, for
Water
AWWA C905
Polyvinyl Chloride (PVC) Pressure Pipe, 14 Inches Through 48 Inches, for
Water
AWWA M11
Steel Pipe--A Guide for Design and Installation
FEDSPEC L-C-530B(1)
Coating, Pipe, Thermoplastic Resin or Thermosetting Epoxy
MIL-H-13528B
Hydrochloric Acid, Inhibited, Rust Removing
MIL-STD-810C
Environmental Test Methods
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-3
ADDENDUM NO. 3
PIPING SYSTEMS
Reference
Title
MSS-SP 80
Bronze Gate, Globe, Angle and Check Valves
MSS-SP 110
Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared
Ends
UPC
Uniform Plumbing Code
1.03
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations from
Section requirements.
2.
Qualifications of the Design Professional charged with design, inspection and
certification of pipe hangers and supports and seismic restraint; provide
educational background, proof of registration, proof of insurance and
previous experience in performing this type of work. No further submittals
under this or any related section will be considered until the Design
Professional’s qualifications have been reviewed and accepted by the Officerin-Charge.
3.
Drawings for structural attachments, pipe supports and seismic restraints as
specified in this section, Section 15096, Section 15097, and Section 15098.
Drawings shall be arranged by piping system and area and sealed by the
Design Professional.
4.
Manufacturer’s product literature on each bend, coupling, fitting, bolt, gasket,
restraint or other item provided pursuant to this Section.
5.
Piping layout drawings, for both exposed and buried piping systems, depicting
supports, locations of support, fittings and restraints, expansion joints, seismic
restraint provisions, thrust restraint provisions and other pertinent information,
including wall and floor penetrations, where applicable. Piping layout drawings
shall include details of connections to new and existing equipment, piping and
structures. Drawings shall be original layouts by the Contractor; photocopies
of Contract Drawings are not acceptable. Identify the invert elevation of
buried pipe at changes in slope, pipe crossings, and connections to
structures on piping layout drawings in addition to providing coordinates for
locating changes in horizontal alignment of buried pipe.
6.
Calculations for structural attachments, pipe supports and seismic restraints as
specified in this section, Section 15096, Section 15097, and Section 15098.
Calculations shall be arranged by piping system and area and sealed by the
Design Professional. The Design Professional shall affirm that loads on
structures are within the load limits noted in Section 15098.
KAILUA RWWTP TUNNEL INFLUENT
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15050-4
ADDENDUM NO. 3
PIPING SYSTEMS
1.04
PIPING SYSTEM DESIGN
A.
B.
DESIGN PROFESSIONAL:
1.
Contractor shall provide professional engineering services (“Design
Professional”) for the design and inspection of piping systems work. The design
of these systems shall be the product of a professional engineer retained by the
Contractor and currently licensed to practice in the State of Hawaii. This
requirement shall not be construed as relieving the Contractor of overall
responsibility for this portion of the work. The Design Professional shall have
not less than ten years experience in the type of piping support and seismic
restraint design work required for this project.
2.
The Design Professional shall obtain and maintain professional liability
insurance in the amount of $1,000,000 aggregate to be in effect for the
duration of this project plus 1 year.
PIPING SYSTEM DESIGN AND INSPECTION:
1.
The Design Professional shall provide the final design, inspection, and
certification for piping supports and seismic restraints as specified herein and in
referenced Sections. Expansion control features are specified in the
Construction Documents. The Design Professional shall coordinate pipe
support design, seismic restraint design, and pipe guides with the expansion
control design criteria provided by the City.
2.
The work of the Design Professional shall be complementary to the design
elements specified in the Construction Documents, to provide complete piping
system designs. The Design Professional’s inspection responsibilities also
complement inspections by the City. The general division of responsibility for
inspection work is as follows:
Piping system element
(Specification)
Design professional’s
responsibility
Pipe material and thickness, test
pressures and other properties
(PIPESPEC 15050)
City’s responsibility
All piping
Contractor fabrication/layout drawings
(15050)
All piping
Pipe supports (Sections 15096 and
Section 01900)
Up to and including 19-inch
20-inch and larger pipe and
(nominal) pipe and duct; conduit duct
and cable tray
Seismic bracing (Sections 15097 and
Section 01900)
Up to and including 19-inch
(nominal) pipe and duct.,
conduit and cable tray
KAILUA RWWTP TUNNEL INFLUENT
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15050-5
ADDENDUM NO. 3
20-inch and larger pipe and
duct
PIPING SYSTEMS
Piping system element
(Specification)
Design professional’s
responsibility
City’s responsibility
Expansion and Contraction Design Only
(Section 15098)
Axial pipe guides and
coordination with pipe support
design
Inspection – General. For design and
specification conformance (Section
15096 and related)
Up to and including 19-inch
20-inch and larger pipe and
(nominal) pipe and duct; conduit duct
and cable tray
Inspection - Special
N/A
3.
Thermal strain control design –
All piping
City
The design standards for use by the Design Professional shall be selected from
the following list. Others may be used upon written request by Design
Professional and justification, through Contractor, to Officer-in-Charge.
a.
Process Piping, and piping not otherwise specified - ANSI/ASME B31.3.
b.
Building Services Piping - ANSI/ASME B31.9.
c.
Digester and other flammable, non-fuel gas piping -– ANSI/ASME
B31.1.
d.
Fuel gas piping –NFPA 54 (ANSI Z223.1) National Fuel Gas Code and
ANSI/ASME B31.1.
e.
Steel water pipe - ANSI/ASME B31.3 (piping within the scope of AWWA
M11, may be designed in accordance with AWWA M11).
4.
Expansion control, anchorage, and pipe flexibility provisions are specified on the
Drawings and in Section 15098. The Design Professional’s piping system
design shall not interfere with the function of expansion control and pipe
flexibility elements. Where pipe anchors are specified they have been
designed for longitudinal seismic loading, in addition to other longitudinal
forces associated with expansion control, and pipe thrust for the associated
piping that is anchored. The Contractor’s Design Professional is responsible
for lateral seismic bracing on piping with anchors and shall rely on the
specified anchors for longitudinal seismic bracing of the pipe in these
instances.
5.
Additionally, design of piping systems and appurtenances shall include, but
not be limited to, consideration of and provisions for:
a.
Piping support and restraint independent of equipment and no
equipment supported loads exceeding equipment manufacturer’s
requirements. Design Professional shall obtain maximum nozzle
loads from the Contractor.
b.
Piping shall be routed to provide access aisles free of obstruction and
worker hazards. Unless otherwise noted or approved by Officer-in-
KAILUA RWWTP TUNNEL INFLUENT
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15050-6
ADDENDUM NO. 3
PIPING SYSTEMS
Charge, the minimum clear space between equipment shall be 3 feet
horizontally. Minimum vertical clearance shall be 7-feet above the
floor or local grade at access aisles and egress paths. Minimum
vertical clearance shall be 8 feet above the floor in utilidors.
c.
Electrical bonding for all gas, fuel and pneumatic conveyance
systems.
d.
Dielectric separation, as specified.
6.
Piping submittals by the Contractor shall include all elements of piping
systems required for fabrication and construction, including those portions
specified on the Drawings. Submittals shall depict couplings, restraint,
anchorage, expansion control measures and other elements of the piping
system. The Contractor’s Design Professional shall, as part of the submittal
process, notify the Officer-in-Charge if he believes any restraint or expansion
element is incompatible with the overall piping system and its function.
7.
Hangers, supports, seismic bracing, and other mounting elements for piping
that is less than 20-inch diameter are generally not shown on the Drawings.
Where a specific support, hanger guide, structural attachment, joint or
seismic restraint detail for pipe less than 20-inch is shown, it indicates a
required configuration or general arrangement to be developed by the Design
Professional.
8.
Hangers, supports, expansion provisions, and seismic restraints for piping
20-inch and larger are specified on the Drawings.
9.
Fitting angles and vertical and horizontal pipe locations shall be determined by
Contractor and depicted on piping layout Drawings.
10.
Where the use of particular piping elements are required for expansion control
or pipe flexibility they are specified on the Drawings. The Contractor’s pipe
support and seismic restraint design shall not interfere with the function of
anchorage, flexibility, and expansion control provisions.
PART 2--PRODUCTS
2.01
PIPING
A.
MATERIALS:
1.
Materials, including pipe, gaskets, fittings, connection and joint assemblies,
linings and coatings, shall be selected from those listed on the piping system
specification (PIPESPEC) sheets.
2.
New and existing piping is designated by service rather than pipe material.
Existing pipe material types may not be the same as material types specified for
KAILUA RWWTP TUNNEL INFLUENT
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15050-7
ADDENDUM NO. 3
PIPING SYSTEMS
new piping. Contractor shall investigate and provide suitable connections,
including electrical isolation, as necessary.
2.02
B.
FITTINGS AND COUPLING COMPATIBILITY: To assure uniformity and compatibility of
piping components, fittings and couplings for grooved-end or shouldered-end piping
systems shall be furnished by the same manufacturer.
C.
BURIED PIPING:
1.
All buried piping shall be fully-restrained systems. Where required, Design
Professional shall size temporary and/or permanent thrust restraints. Restraint
systems shall be designated to allow complete piping system disassembly
without destructive measures.
2.
Buried piping shall be provided as specified. Unless otherwise noted, materials
specified in the piping specification sheets shall be used. Thicknesses specified
in the piping specification sheets or referenced specifications shall be
considered minimums. Excavation, installation and backfill shall be as
specified.
PIPING IDENTIFICATION
A.
PLASTIC CODING MARKERS:
1.
Plastic markers for coding pipe shall conform to ANSI A13.1 and shall be as
manufactured by W. H. Brady Company, Seton Name Plate Corporation, Marking
Services Inc., or equal. Markers shall be the mechanically attached type that
are easily removable; they shall not be the adhesive applied type. Markers shall
consist of pressure sensitive legends applied to plastic backing which is
strapped or otherwise mechanically attached to the pipe. Legend and backing
shall be resistant to petroleum based oils and grease and shall meet criteria for
humidity, solar radiation, rain, salt, fog and leakage fungus, as specified by
MIL-STD-810C. Markers shall withstand a continuous operating temperature
range of -40 degrees F to 180 degrees F. Plastic coding markers shall not be
the individual letter type but shall be manufactured and applied in one
continuous length of plastic.
2.
Markers bearing the legends on the background colors specified in the
PIPESPEC shall be provided in the following letter heights:
Outside pipe diameter,a
inches
Letter height,
inches
Less than 1-1/2
1/2
1-1/2 through 3
1-1/8
Greater than 3
2-1/4
a Outside
pipe diameter shall include insulation and jacketing.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-8
ADDENDUM NO. 3
PIPING SYSTEMS
3.
B.
2.03
1.
Tracer tape shall be 6 inches wide, colored the same as the background colors
as specified in Table A, paragraph 15050-3.06, and made of inert plastic
material suitable for direct burial. Tape shall be capable of stretching to twice
its original length and shall be as manufactured by Allen Systems, W. H. Brady
Co., Seton Name Plate Corporation, Marking Services Inc., or equal.
2.
A messages shall be printed on the tape. It shall read "CAUTION CAUTION
CAUTION---CAUTION----PIPE
----PIPE BURIED BELOW" with bold letters approximately 2 inches high.
The blank shall be filled with the particular system fluid such as chlorine, oxygen
or sulfur dioxide. The messages shall be printed at maximum intervals of 2 feet.
Valves of the same size and type shall be provided by a single valve manufacturer.
Packing shall be non-asbestos material. Actual length of valves shall be within 1/16
inch (plus or minus) of the manufacturer's specified length. Flanges shall meet the
requirement of ANSI B16.5. Push-on and mechanical joints shall meet the
requirements of AWWA C111.
PIPE AND VALVE COMPATIBILITY
A.
2.05
PLASTIC TRACER TAPE:
VALVES
A.
2.04
In addition, pipe markers shall include uni- and bi-directional arrows in the same
sizes as the legend. Legends and arrows shall be white on blue or red
backgrounds and black on other specified backgrounds.
Selected pipe and pipe end connections for valves, or other equipment, shall be fully
compatible within each piping system. Coordinate the selection of pipe materials,
linings and end connections so that valves operate properly over their entire range (e.g.,
sufficient disk clearance for butterfly valves). Selected end connections shall also be
suitable for specified valve or equipment (e.g., wafer style valves or spectacle flanges
shall be properly supported between flanges of equal inside diameter).
BONDING JUMPERS
A.
Jumpers shall be plated, flexible copper braid with unplated copper ferrules for
attachment to pipe flanges. Jumpers shall be rated for a 100 amp minimum.
Provide Burndy Electrical, Type B series, or equal, and sufficient conductive, antioxidant compound (Burndy Electrical Penetrox series or approved substitute) to
protect ferrules.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-9
ADDENDUM NO. 3
PIPING SYSTEMS
PART 3--EXECUTION
3.01
INSTALLATION
A.
LOCATION:
1.
The Drawings are, in part, diagrammatic. Piping shall be provided as specified
except for adjustments to avoid architectural and structural features and shall
be coordinated with electrical construction. Adjustments to new piping shall be
made to avoid interference and shown on the piping layout drawings.
2.
Submitted piping layout drawings shall clarify detailed connections to new and
existing equipment, piping and structures. Unless otherwise specified on
Drawings, piping fitting angles and vertical and horizontal pipe locations shall be
determined by Contractor.
B.
PIPING SIZES: Where the size of piping is not specified, the Contractor shall provide
piping of the sizes required by UPC. Unless specified otherwise, small piping (less than
1 inch in diameter) required for services not described by UPC shall be 1/2 inch.
C.
EXISTING PIPING MATERIALS: Contractor shall pothole existing pipe at connections to
new pipe to confirm material and joints prior to commencement of work.
D.
PIPE SUPPORT, ANCHORAGE AND SEISMIC BRACING:
1.
GENERAL:
a.
Piping shall be supported by anchor brackets, guides, saddles or
hangers. Pipe movement due to thermal expansion and internal
pressure and dynamic forces shall be accommodated by pipe springing,
anchors, expansion joints, and guides selected for the specific purpose
as specified on the Drawings. The details for the piping support,
anchorage, seismic bracing, and expansion control systems shall be
submitted with the Contractor's piping layout drawings under the
provisions of paragraph 15050-1.03.
b.
Acceptable types of supports, guides, saddles, expansion joints, flexible
couplings, hangers and structure attachments for general piping
support, expansion/contraction and for seismic bracing, as well as
anchorage details, are referenced in Sections 15096, 15097, 15098,
15085, and 15090 or specified on the Drawings. Where a specific type
of support or anchorage is specified on the Drawings, then only that
type shall be used at that location.
c.
Piping shall be vertically supported by anchor brackets, guides, saddles
or hangers and shall be seismically braced as required to resist seismic
loads. Supports shall be provided at each change of direction.
d.
Do not use existing pipes and supports to support new piping
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-10
ADDENDUM NO. 3
PIPING SYSTEMS
2.
PIPING CONNECTIONS TO MACHINES: Piping at machine connections shall be
aligned in all planes to permit insertion of bolts at bolted connections or
coupling screwed connections without using jacks, come-a-longs or other
mechanical means to align field piping with the connections at the machines.
Bolts shall not be forced into mating flange bolt holes and shall be capable of
being withdrawn using finger pressure alone. The use of ‘dutchmen’ mitered
sections or similar specials to achieve the required alignment with machine
connections are strictly prohibited.
E.
ANCHORAGE FOR BURIED PIPING: All plugs, caps, tees and bends in buried pressure
piping systems shall be anchored by means of reaction backing or restrained joints as
specified.
F.
BEDDING AND BACKFILL: Bedding and backfill for buried piping shall be as specified in
Section 02200 and as specified on the Drawings.
G.
BURIED PIPE AT STRUCTURES: In accordance with Section 15085, and as specified
on the Drawings, provide two flexible fittings or couplings where buried pipe passes
through structures. Provide restraints across each joint.
H.
EQUIPMENT CONNECTION FITTINGS: Where specified on the Drawings, equipment
connection fittings, as specified in Section 15085, shall be provided between field
piping systems and equipment inlet and outlet connections.
I.
JOINT AND FITTING OPTIONS: Pipe connection (joint and fitting) options for a
particular piping system shall be as specified on the PIPESPEC sheet. If the
PIPESPEC sheet lists several connection options, then any of the listed options may
be consistently used. For example, if flanged or grooved are acceptable and grooved
are represented on the Drawings, then flanged may be substituted. Takedown
couplings shall be provided for all piping systems in accordance with Section 15085.
Takedown couplings shall be provided at connections to equipment, at valves, and as
specified on the Drawings. Continuous welding for straight runs of pipe is acceptable
only where the individual PIPESPEC sheet allows welding as a connection option.
Where connections other than those indicated on the PIPESPEC sheets are specified
on the Drawings, the connections shall be specifically located where indicated.
Integrity of rigid, non-rotating connections must be maintained at all valves and other
equipment.
J.
BONDING: For flammable gas, flammable liquid, pneumatic conveyance and other
services where static electricity and/or a spark may be a potential hazard, piping
systems shall be constructed as electrically continuous and connected directly or
indirectly to earth ground. Where sections of pipe are interrupted with nonconducting sections, fully lined valves that are not through bolted, or other
interruption in continuity, Contractor shall provide jumpers. Remove any coatings,
dirt, grease or other contaminants from flanges where jumpers are to be installed.
Apply sufficient conductive, anti-oxidant compound to protect the entire ferrule from
galvanic action and hydrogen sulfide attack.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-11
ADDENDUM NO. 3
PIPING SYSTEMS
3.02
PIPE INSTALLATION
A.
B.
PROTECTION OF WORK:
1.
Cover openings in piping, and temporarily seal to protect from contamination.
2.
Protect materials and equipment from damage due to environmental
conditions. Use protective cover, and protect from surface water by elevating
above floor or surrounding grade.
3.
Protect unfinished work at end of each workday from damage, contamination
and moisture by use of plugs, caps or covers.
4.
Protect piping and valves from damage pending performance of system tests.
INSTALLATION:
1.
Install piping parallel to walls. Clear obstructions, preserve headroom, and
keep openings and passageways clear.
2.
Should interference with structural elements or other work prevent
installation of pipes or setting of equipment at locations specified, necessary
minor deviations will be allowed, as approved by the Officer-in-Charge.
3.
Expanding or swaging of tubing to fit IPS (Iron Pipe Size) fitting sockets will
not be permitted.
4.
Use reducing fittings where change in pipe size occurs.
5.
Install pipe in standard lengths whenever possible. Use couplings only where
pipe runs are longer than standard supplied pipe lengths.
6.
Make exposed polished or enameled connections to fixtures or equipment
with special care to avoid damage to finished surfaces.
7.
Make changes in direction only with fittings.
8.
Provide expansion loops or bends where specified to allow for proper pipe
expansion. Construct bends with long radius welded fittings.
9.
Use proper length bolts for each size flange on flanged connections. Bolts
with excessive length of exposed threads will not be permitted. Minimum of
3 full threads shall be exposed beyond nut after tightening assembly. Allthread rod is not acceptable for bolting flanges.
10.
Prevent entry of foreign matter during handling, assembling and installation.
Use compressed air, wire brush, solvent and other acceptable means to
remove residual scale, dirt and other foreign matter from interior of piping
before final connections are made. Protect open ends of pipe by capping,
plugging or other acceptable means.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-12
ADDENDUM NO. 3
PIPING SYSTEMS
C.
D.
11.
Install piping with sufficient pitch to ensure adequate drainage and venting.
12.
Provide unions or flanges in piping connections to equipment.
13.
Electrically isolate connections between dissimilar metal piping with dielectric
couplings or fittings.
14.
Install class of piping as specified.
15.
Do not run water piping over electric switchboards, transformers, cable tray
or electric motor starters.
16.
Protect against external corrosion where pipes pass through, under or
otherwise in contact with soil, cinders, concrete or other corrosive material.
17.
Flange bolt holes shall be “Two-Holed” to maintain consistent flange bolt hole
positions along the entire length or run of the pipe. (Flange bolt holes shall
straddle the vertical and horizontal centerline of the flange with flange bolt
holes equidistant from the flange centerline.) For pipe installed with a
horizontal axis, flange bolt holes shall be positioned so that the vertical
centerline of the flange face bisects the arc between flange bolt holes. For
pipe installed with a vertical axis, flange bolt holes shall be positioned so that
the horizontal centerline of the flange face bisects the arc between flange
bolt holes and is perpendicular to the closest structural wall.
SEWER AND DRAIN PIPING:
1.
Run horizontal drainage piping as straight as practicable and at uniform
pitch.
2.
Install pipe 3 inches or less in diameter with pitch of not less than 1/4 inch
per foot unless otherwise specified on the Drawings.
3.
Install pipe larger than 3-inch diameter with pitch of not less than 1/8 inch
per foot unless otherwise specified on the Drawings or required by the
Uniform Plumbing Code.
CAST IRON SOIL PIPING:
1.
For bell and spigot pipe, make joints with neoprene push-on gasket.
2.
For neoprene gasketed plain spigot end pipe, insert gaskets, lubricate inside
of gaskets and outside of pipe, and join together with suitable tool as
recommended by manufacturer. Reference spec Section 15085.
3.
For hubless pipe, install in accordance with CISPI and the Uniform Plumbing
Code.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-13
ADDENDUM NO. 3
PIPING SYSTEMS
E.
F.
G.
H.
COPPER PIPING:
1.
Make joints with 95-5 tin-antimony solder.
2.
Clean outside of tube and inside of fitting at point of contact before joining.
Take care to prevent overheating of tube and fitting before joining.
WALL PENETRATIONS FOR PLASTIC PIPING (HDPE, PVC, CPVC, and PP):
1.
Below grade and submerged wall or floor penetrations using plastic pipe are
not permitted. Contact the Officer-in-Charge for resolution if any below grade
or submerged wall or floor penetrations are specified on the Drawings.
2.
Plastic pipe penetrations through concrete shall consist of plastic pipe
penetrating walls or floors through sleeves embedded in concrete. The
annular space between the pipe and the embedded sleeve shall be sealed as
specified in the specified wall penetration detail.
PIPE JOINTS AND CONNECTIONS:
1.
Field cuts for glass-lined pipe are not permitted.
2.
Cut pipe with appropriate tool and deburr. Make joints tight. Test and
remake leaky joints with new materials. Do not use thread cement or
caulking to remake joints. Do not use sharp-toothed wrench in making up
brass pipe, or chrome-plated items.
3.
Provide thread forms and length in accordance with ASME standards. Use
lubricant or sealant on male threads suitable for proposed pipe service.
4.
Clean joint before soldering. Use appropriate flux and alloy for operating
temperature level as specified.
5.
Welding procedures, qualifications of welders, and testing shall be in
accordance with ASME Section IX.
6.
Provide gasket coated with recommended lubricant between contact faces of
flanges. Reference spec Section 15085.
UNIONS, FLANGES AND GASKETS:
1.
Provide unions where specified and at each threaded or soldered connection
to equipment, tanks and valves with the following exceptions:
a.
b.
2.
Only one union is required at each manually operated threaded valve.
None required at compression stops.
Locate unions so piping can be easily disconnected for removal of equipment
or valve.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-14
ADDENDUM NO. 3
PIPING SYSTEMS
3.
3.03
VALVE IDENTIFICATION
A.
3.04
3.05
Provide flanges at each flanged connection to equipment and valves. Provide
matching flange faces at each connection. Tighten fastener system to
indicated torque.
Stainless steel tags bearing the specified valve number stamped in ¼-inch high letters
shall be installed on valve flanges in a position visible from floor level for numbered
valves listed in Section 15185. Flangeless valves 8 inches in diameter and larger shall
have tags attached to the valve body by self-tapping corrosion resistant metal screws.
Flangeless valves 6 inches in diameter and smaller shall have tags attached to the
valve stem by stainless steel wire. Wire shall be 0.063 inch minimum.
INSPECTION
A.
Inspection shall be conducted as specified in Section 15096. Monthly inspection
reports, authored, sealed and signed by the Design Professional.
B.
The Design Professional's final report shall be submitted to the Officer-in-Charge
before beneficial occupancy by the City.
FIELD TESTING
A.
GENERAL: Upon completion of installation, but prior to application of insulation on
exposed piping, test the piping systems. Test pressure, medium, and duration shall be
as specified in the PIPESPEC. Isolate equipment which may be damaged by the
specified test conditions. To determine leakage rates, use calibrated test gages and
calibrated volumetric measuring equipment. Select each test gage so that the specified
test pressure falls within the upper half of the measurement range. Notify the Officerin-Charge two working days hours prior to each test. Prior to starting an air test, air
shall be at ambient temperature and the specified test pressure. Test drain systems,
other than pumped drain systems, in accordance with UPC. Testing shall include
existing piping systems which connect with new pipe systems. Existing pipe shall be
tested to the nearest existing valve. Repair piping which fails the test. Repair of
existing piping will be considered and paid for as extra work.
B.
HYDROSTATIC TESTING: The following procedure for Hydrostatic testing shall be
used unless otherwise specified.
1.
Install temporary bulkheads, plugs or blind flanges for the purpose of testing.
2.
Provide temporary supports and/or suitably restrain pipe to resist the thrust of
the test pressure without damage to or movement of the adjacent pipe or
structures.
3.
Fill pipeline at a rate that will not cause any surges and expel all air trapped
within the section of pipe prior to testing.
4.
Lined pipelines: Allow filled pipeline or section thereof to stand under a slight
pressure for at least 8 hours (24 hours for cement mortar lining) to allow the
lining to absorb water and to allow the escape of air from air pockets.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-15
ADDENDUM NO. 3
PIPING SYSTEMS
C.
5.
The hydrostatic test shall consist of holding the specified test pressure on the
pipeline segment for the period indicated in the PIPESPEC. Acceptable leakage
rate is zero.
6.
For Pipelines that fail to pass the leakage test, determine the cause of the
leakage and take corrective measures necessary to repair the leak(s). Test the
pipeline again, repeating repairs and testing, as necessary, until the pipeline
passes.
NITROGEN OR AIR PRESSURE TESTING:
1.
The Contractor shall use nitrogen gas or oil free dry air to test piping systems
where air or nitrogen is the specified testing medium in the PIPESPEC.
Submit a testing plan and a safety plan for each piping system that will be
pressure tested with nitrogen gas or oil free dry air. Pressure testing with air
or nitrogen shall not commence until a favorable review of the safety plan
and testing plan for the piping system has been returned from the Officer-inCharge.
2.
The piping under test shall be provided with a separate pressure relief valve,
within visual range of the test gauge and with exhaust to a safe location,
which will relieve at not more than full test pressure plus 10 percent. The
testing shall be continuously monitored and controlled by the Contractor to
assure personnel safety and piping integrity. Remove all personnel from
areas where piping will be subjected to pressure tests and prevent entry into
testing areas until pressure has been relieved and/or pressure testing is
successfully completed. Protect installed work from potential damage from
pressure testing failures. The Contractor shall be responsible for any damage
or injury resulting from failed pressure testing with air or nitrogen.
3.
Testing consists of gradually introducing nitrogen gas or dry air up to one
quarter of test pressure or 50 psig (whichever is lower) and maintaining this
pressure while testing the line for leaks with soapy water (no less than 10
minutes). When the system is free from leaks at this pressure, the test
pressure shall then be increased in increments of one quarter of test
pressure or 50 psig (whichever is lower) up to a maximum of 150 psig. At
each stepped increase in pressure, and a period of not less than 10 minutes,
the Contractor shall check for leaks and take corrective action as necessary.
When the system is free from leaks at the final test pressure, the system
shall then be depressurized, the test source disconnected, and the system
capped to prevent the entrance of water. Provide or maintain nitrogen pad,
as specified.
4.
For testing with nitrogen gas, the Contractor shall use cylinders of dry high
purity nitrogen gas, nitrogen handling cylinder mounted pressure regulator 0
to 300 psig, and necessary fittings and adapters to complete connection
between the source and system header. Pressure regulator shall be self
relieving type which vents to the atmosphere and include a throttling valve.
5.
For testing with air, the Contractor shall provide oil free air with a relative
humidity of zero. All fittings, adapters, and accessories, pressure regulator
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-16
ADDENDUM NO. 3
PIPING SYSTEMS
and throttling valve shall be suitable for pressure testing with air and rated
for 300 psig service.
3.06
CLEANING AND FLUSHING
A.
GENERAL: Piping systems shall be cleaned following completion of testing and prior to
connection to operating, control, regulating, or instrumentation equipment. Piping 24
inches in diameter and smaller shall first be cleaned by pulling a tightly fitting cleaning
ball or swab through the system. Piping larger than 24 inches in diameter may be
cleaned manually or with a cleaning ball or swab.
B.
TEMPORARY SCREENS:
1.
Upon completion of the cleaning, the Contractor shall connect the piping
systems to related process equipment. Temporary screens, provided with
locator tabs which remain visible from the outside when the screens are in
place, shall be inserted in pipelines at the suction of pumps and compressors in
accordance with the following table:
Equipment suction or pipe diameter,
inches
Maximum screen opening,
inches
0 –1
1/16
1-1/4 – 3
1/4
3-1/2 – 6
1/2
Over 6
1
2.
Maintain the screens during testing, initial start-up, and initial operating phases
of the commissioning process. In special cases, screens may be removed as
required for performance tests. Remove the temporary screens and make the
final piping connections after the screens have remained clean for at least 24
consecutive hours of operation. Liquid systems handling solids shall have
screens in place for clear water testing and operation. Initial operation on solids
following clear water testing may be without screens.
C.
GAS, AIR AND VAPOR SYSTEMS: Gas and air system piping 6 inches in diameter and
smaller shall be blown out, using air or the testing medium specified. Piping larger than
6 inches shall be cleaned by having a swab or "pig" drawn through the separate reaches
of pipe. After connection to the equipment, it shall then be blown out using the
equipment. Upon completion of cleaning, the piping shall be drained and dried with an
airstream. Sludge gas, natural gas and propane systems shall be purged with nitrogen
and a nitrogen pad maintained at 10 psi until put in service.
D.
LIQUID SYSTEMS: After completion of cleaning, liquid systems, unless otherwise
specified, shall be flushed with clean water. With temporary screens in place, the liquid
shall be circulated through the piping system using connected equipment for a
minimum period of 15 minutes and until no debris is collected on the screens.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-17
ADDENDUM NO. 3
PIPING SYSTEMS
E.
POTABLE WATER SYSTEMS: Flush and disinfect potable water piping in accordance
with AWWA C651.
F.
STEAM SYSTEMS:
G.
3.07
1.
Before the steam system is put into service, cleaning shall be performed to
remove such contaminants as mill scale, weld scale, corrosion products, oil,
grease, dust and dirt. Cleaning shall include a water flush performed at a
velocity not less than 2 feet per second, steam blowdown, and an alkaline flush
boilout of the boiler.
2.
After flushing as indicated above, the boiler shall be treated with a caustic
compound such as sodium triphosphate, soda ash, sodium tripolyphosphate, or
caustic soda. The cleaning process shall be in accordance with steam system
cleaning schemes developed by Dowell, the Mogul Division of Dexter Corp.,
Bentz Entec, or approved substitute.
3.
After cleaning and flushing, and prior to continuous operation of the steam
system, adequate corrosion protection shall be provided by maintaining the
system full of steam or potable water. If continuous operation does not occur
within 60 days after cleaning and flushing, the steam or potable water shall be
treated with an acceptable corrosion inhibiting chemical to assure adequate
corrosion protection of the steam system.
HEATING HOT WATER SYSTEMS: Prior to existing heating hot water piping being put into
service, a pre-cleaning step to remove corrosion by-products shall be competed. This
step shall include circulating a mild cleaner to remove corrosion by-products from the
system for 24 hours. System strainers shall be employed and periodically cleaned
during this process. Cleaner shall not be detrimental to gaskets or clean metal in the
system and shall be RealChem 507 or approved substitute. Following the pre-cleaning
step a final running flush will be completed with the mild cleaner.
PIPING SPECIFICATION SHEETS (PIPESPEC)
A.
Piping and appurtenances for similar plant processes are specified on individual piping
specification sheets (PIPESPEC). Piping services are grouped by the chemical and
physical properties of the fluid conveyed, by temperature or pressure requirements,
and/or by appropriate piping material. Each grouping of services (PIPESPEC) is
identified by a piping system number.
B.
Piping services specified in the PIPESPEC and on the Drawings are listed alphabetically
in Table A by designated service symbols. Table A indicates the fluid conveyed, system
number, and fluid category.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-18
ADDENDUM NO. 3
PIPING SYSTEMS
Table A, Piping Systems
Symbol
Service
System
Fluid category
Pipe marker
background color
BFC
Biotrickling Filter Chemical
19
Chemical
Yellow
BTR
Biotrickling Filter Recirculation
13
Wastewater
Green
CD
Chemical Drain
25
Drain/vent
Yellow
EE
Engine Exhaust
31
Air
Red
FA
Foul Air
22
Chemical
Yellow
FOR
Fuel Oil Return
18
Petroleum
White
FOS
Fuel Oil Supply
18
Petroleum
White
FP
Fire Protection
9
Water
Blue
GT
Grit
17
Grit slurry
Green
HW
Potable Water Hot
9
Water
Blue
LOR
Lube Oil Return
18
Petroleum
White
LOS
Lube Oil Supply
18
Petroleum
White
LOW
Lube Oil Waste
18
Petroleum
White
OF
Overflow
13
Wastewater
Green
PD
Pumped Drainage
12
Wastewater
Green
PDR
Process Drain
27
Drain/vent
Green
PS
Plant Sewer
13
Wastewater
Green
RSG
Raw Sewage Gravity
13
Wastewater
Green
RSP
Raw Sewage Pumped
12
Wastewater
Green
RW
Reclaimed Water
9
Water
Green
RW2
Reclaimed Water 2
9
Water
Green
RWP
Rain Water Pipe
24
Drain/vent
Green
SA
Service Air
2
Air
Orange
SD
Sanitary Drain
24
Drain/vent
Green
SEP
Septage
13
Wastewater
Green
STD
Storm Drain
27
Drain/vent
Green
V
Vent
24
Drain/vent
Green
VC
Chemical Vent
25
Drain/vent
Yellow
VP
Vent Petroleum
18
Petroleum
White
1W
Potable Water
9
Water
Blue
2W
Non-Potable Water
9
Water
Green
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-19
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING 39ECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
SA—Service Air
Test Requirements:
Medium:
Pressure:
Duration:
Air or Nitrogen - Ref. spec paragraph 15050-3.05 C.
200 psig
120 minutes
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
System--2
Compressed gasketing consisting of organic fibers (Kevlar) and
neoprene binder. Reference spec Section 15085.
N/A
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
Pipe:
2-1/2 inches and smaller:
Stainless Steel: Stainless steel pipe and fitting compression
system with ASTM A312, Type 316L seamless piping. Minimum
wall thickness; Schedule 5S. Minimum working pressure 200
psig. Lead free and NSF rated. High temperature FKM sealing
element good to 250 degrees F. Viega Systems Pro-Press
System or approved substitute.
3 inch and larger:
Stainless Steel; Reference spec Section 15067.
Type 316L, butt welded. Minimum wall thickness: 40S.
Valves:
Ball; Apollo Figure 76-100, Elite Valve, Canada, Figure E1500
or equal.
Lift check; 316 SS Lunkenheimer, Crane or equal
Encased Pipe:
(All sizes)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Same as exposed.
15050-20
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
Test Requirements:
Medium:
Pressure:
Duration:
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
1W—Potable Water
2W—Non-potable Water
FP—Fire Protection
HW—Potable Hot Water
RW—Reclaimed Water
RW2—Reclaimed Water 2
System--9
Water; ref. spec paragraph 15050-3.05 B.
125 psig
60 minutes
Compressed gasketing consisting of organic fibers (Kevlar) and
neoprene binder. Reference Section 15085.
Nitrile or Neoprene. Reference Section 15085.
Exposed Pipe and Valves:
(See drawings for pipe size and valve type. See Remarks.)
(3" and smaller) :
Pipe:
PVC; ASTM D1784, Class 12454-B, NSF certified, ASTM D1785,
Sch. 80. Ref. Section 15064. Provide magnetic tracer tape.
Conn; plain end; solvent weld with threaded or flanged adapters
for valves or as shown on drawings.
Ftgs; PVC, Sch. 80, socket weld.
Valves:
Ball; PVC, Asahi/America Duo Bloc TU Series, Chemtrol Tru Bloc
TU Series, GSR TU Series, or equal, with PTFE seats and Viton
0-rings.
(4" and greater)
Pipe:
Ductile iron; Flanged or grooved end, ceramic epoxy lining,
primer coated. Ref. Section 15062.
Restrained dismantling joints for valves.
Ftgs; ductile iron per Section 15062; coating, lining, and ends to
match pipe.
Valves:
Butterfly; Ref. Section 15103.
Swing check; spring loaded per Section 15118.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-21
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
9 (continued)
Buried and Encased Pipe and Valves:
(See drawings for pipe size and valve type. Omit coating on encased pipe.)
(3" and smaller)
Pipe:
Valves:
PVC; ASTM D1784, Class 12454-B, NSF certified, ASTM D1785,
Sch. 80. Ref. Section 15064. Provide magnetic tracer tape.
Conn; plain end; solvent weld with threaded or flanged adapters
for valves.
Ftgs; PVC, Sch. 80, socket weld.
Gate; ref. Section 15101, with extension stem and valve box.
Coating M-1 per spec Section 09900.
(4" to 12")
Pipe:
PVC; AWWA C900, DR14 [see Remark 7]. Provide magnetic
tracer tape.
Conn; Push-on with nitrile gasket.
Ftgs; PVC or ductile iron fittings per Section 15062; ends to
match pipe.
Valves:
Gate; ref. spec Section 15101, with extension stem and valve
box. Coating M-1 per Section 09900.
(Larger than 12”)
Pipe:
PVC; AWWA C905, DR14 [see Remark 7]. Provide magnetic
tracer tape.
Conn; Push-on with nitrile gasket.
Ftgs; PVC or ductile iron fittings per Section 15062; ends to
match pipe.
Valves:
Butterfly; Ref. Section 15103; same as exposed with extension
stem and valve box. Coating M-1 per Section 09900.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-22
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
9 (continued)
Remarks:
1.
Manual air vents shall be provided at the high points and drains provided at the low points of
each reach of pipeline as specified in Section 15095.
2.
HW piping shall be stainless steel Type 316L, ASTM A312, Schedule 40, butt welded if 3 inch
and above. HW that is 2-1/2 inch or less shall be stainless steel pipe and fitting compression
system with ASTM A312, Type 316L seamless piping. Minimum wall thickness; Schedule 5S.
Minimum working pressure 200 psig. Lead free and NSF rated. EPDM sealing element.. Viega
Systems Pro-Press System or approved substitute.
3.
The HW piping, fittings and valves shall be insulated as specified per Section 15250.
4.
Services other than HW shall be insulated for condensation control as specified per
Section 15250 only for segments run above suspended ceilings.
5.
All 2W and RW2 pipe exposed in wet well areas, including the associated stairways and landing
access areas, shall be stainless steel Type 316 L, ASTM A312, Schedule 40S. Ref. spec Section
15067.
6.
All exposed and embedded RW2 pipe for the TIPS wet well gate flushing located downstream of
PRV 200, 424 shall be shall be stainless steel Type 316 L, ASTM A312, Schedule 40S. Ref.
spec Section 15067.
7.
Plastic pipe shall not be encased in a concrete jacket. Ductile iron pipe, mechanical or push-on
joint, ceramic epoxy lining, asphalt material coated per Section 15062 and fittings shall be used
for the portion of pipeline to be jacketed.
8.
Potable water pipelines shall be encased in a concrete jacket where shown or wherever the
pipeline crosses under a large structure or utility larger than 16 inches diameter or wherever the
waterline crosses over or under a sewer pipeline.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-23
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
Test Requirements:
Medium:
Pressure:
Duration:
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
PD--Pumped Drainage
RSP--Raw Sewage Pressure
System--12
Water; ref. spec paragraph 15050-3.04 C.
100 psig
120 minutes
Compressed gasketing consisting of organic fibers (Kevlar) and
neoprene binder except for HDPE flanges which shall be Nitrile
or Neoprene. Reference spec Section 15085.
Nitrile or Neoprene. Reference Section 15085.
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
(3” and smaller”)
Pipe:
PVC; ASTM D1784, Class 12454-B, NSF certified, ASTM D1785,
Sch. 80. Piping and fittings exposed to sunlight shall be
painted. Ref. Section 15064.
Conn; plain end, solvent weld, flanged for valves 3 inches and
larger.
Ftgs; PVC, Sch. 80, solvent weld.
Valves:
Ball; PVC, Asahi/America Duo Bloc TU Series, Chemtrol Tru Bloc
TU Series, GSR TU Series, or equal, with PTFE seats and Viton
0-rings.
(4” and greater)
Pipe:
Ductile iron; Flanged or grooved end, ceramic epoxy lining,
primer coated. Ref. spec Section 15062.
Restrained dismantling joints for valves.
Ftgs; ductile iron per Section 15062; coating, lining, and ends to
match pipe.
Valves:
Eccentric plug; ref. spec Section 15110.
Swing check; spring loaded per spec Section 15118.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-24
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
12 (continued)
Buried and Encased Pipe and Valves:
(See drawings for pipe size and valve type.)
(3" and smaller)
Pipe:
PVC; ASTM D1784, Class 12454-B, ASTM D1785, Sch. 80. Ref.
spec Section 15064. Provide magnetic tracer tape.
Conn; plain end; solvent weld with threaded or flanged adapters
for valves.
Ftgs; PVC, Sch. 80, socket weld.
Valves:
Ball; same as exposed with extension stem and valve box.
(4" and greater)
Pipe:
HDPE: Reference spec Section 15065. SDR = 17
[see Remark 2].
Fittings and joints: Reference spec Section 15065.
Provide flanges at valves and equipment
Valves:
Eccentric plug; ref. spec Section 15110 [see Remark 3]. With
extension stem and valve box. Coating M-1 per spec Section
09900.
Remarks:
1.
Manual air vents shall be provided at the high points and drains provided at the low points of
each reach of pipeline as specified in Section 15095.
2.
Plant Sewer force main pipe material shall be ductile iron pipe inside polyethylene
encasement with ceramic epoxy lining per Section 15062 between the Plant Sewer Pump
Station and the flow meter vault. The transition to HDPE pipe material shall occur
downstream of the flow meter vault as shown on the drawings.
3.
The 42” valve installed as part of the Kaneohe Force Main Temporary Bypass shall be as
noted on the drawings and per Section 15101.
4.
Exposed piping for the Kaneohe Force Main Phase 1 Temporary Bypass pipeline shall be
steel pipe material, ASTM A-53 or AWWA C 200 with minimum wall thickness of 3/8” due to
allowable load restrictions on the Primary Treatment Facility concrete slab and to maximize
the allowable span length between pipe supports.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-25
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
RSG--Raw Sewage Gravity
BTR—Biotrickling Filter Recirculation
PS—Plant Sewer
SEP—Septage
OF—Overflow
System--13
Test Requirements:
Medium:
Pressure:
Duration:
Water; ref. spec paragraph 15050-3.04 C.
15 psig
120 minutes
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
Nitrile or Neoprene. Reference spec Section 15085.
Nitrile or Neoprene. Reference spec Section 15085.
Exposed Pipe and Valves:
None
Buried and Encased Pipe and Valves:
(See drawings for pipe size and valve type. Omit coating on encased pipe.)
(3" and smaller)
Pipe:
Valves:
(4" thru 16")
Pipe:
Valves:
(18" and larger)
Pipe:
Valves:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
PVC; ASTM D1784, Class 12454-B, ASTM D1785, Sch. 80. Ref.
Section 15064. Provide magnetic tracer tape.
Conn; plain end; solvent weld with threaded or flanged adapters
for valves.
Ftgs; PVC, Sch. 80, socket weld.
None
PVC; ASTM D3034, SDR 35. Provide magnetic tracer tape.
Conn; Push-on with nitrile gasket.
Ftgs; PVC or ductile iron per Section 15062; ends to match
pipe.
None
FRPM: Reference spec Section 15059. Pressure/Stiffness
PN/SN = 25/46. Provide magnetic tracer tape. [see Remark 1]
Conn; Fiberglass sleeve or push-on with nitrile gasket.
Ftgs; FRPM or ductile iron per Section 15062; ends to match
pipe.
None
15050-26
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
13 (continued)
Remarks:
1.
Storm Drain pipe material shall be gravity sewer ASTM D3034 / F679 (SDR 35 / PS46) as
applicable. See drawings for pipe sizes.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-27
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
GT--Grit
System--17
Test Requirements:
Medium:
Pressure:
Duration:
Water. As specified within this Section.
100 psi
120 minutes
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
Nitrile or Neoprene. Reference spec Section 15085.
NA
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
(4" and larger)
Pipe (see Remark 1 for material locations):
Ductile iron; flanged or grooved end as indicated on the
drawings, ceramic epoxy lining, primer coated. Ref. spec
Section 15062.
Fittings; ductile iron per spec Section 15062; coating, lining,
and ends to match pipe.
High Density Polyethylene (HDPE) : Dimension Ratio (DR)
13.5, ASTM D3350, Ref. Section 15065.
Connections: See Remark 1. Mechanical coupling and
flanged. Mechanical couplings shall be Victaulic Style 995 or
equal.
Fittings: Long radius elbows, ends and SDR to match pipe.
Ref. Section 15065.
Valves:
Lubricated plug; cast iron, flanged, PTFE or molydisulfide
coated plug, Nordstrom Fig. 143, Walworth Fig. 1797F, or
equal, thru 5 inch; worm gear operator, Nordstrom Fig. 149,
Walworth Fig. 1727F, or equal, 6 to 8 inch.
Swing check; spring loaded per spec Section 15118.
Buried and Encased Pipe:
(4” and larger)
Ductile iron; flanged or grooved end as indicated on the
drawings, ceramic epoxy lining, primer coated. Ref. spec
Section 15062.
Fittings: ductile iron per spec Section 15062; coating, lining,
and ends to match pipe.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-28
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
17 (continued)
Remarks:
1.
Grit pump suction and discharge piping shall be ductile iron up to the point that includes all
grit pipeline valving. Grit discharge line beyond the valving shall be HDPE. See M-342 for
transition location. The HDPE piping shall have flanged connections at each end connection
(to valving and to the downstream hopper). In between those end points shall be provided
with grooved coupling connections on maximum 8-foot intervals to allow segment pipe
replacement. All bends shall be centered between couplings.
2.
Manual air vents shall be provided at the high points and drains provided at the low points of
each reach of pipeline as specified in Section 15095.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-29
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
Test Requirements:
Medium:
Pressure:
Duration:
Gasket Requirements:
Flange:
Push-On/Mech Cpl:
FOR –Fuel Oil Return
FOS—Fuel Oil Supply
LOR--Lube Oil Return
LOS--Lube Oil Supply
LOW--Lube Oil Waste
VP--Petroleum Vent
System--18
Fuel oil; ref. spec paragraph 15050-3.04 E.
100 psig (pressure piping)
5 psig (nonpressure piping)
60 minutes
Compressed gasketing consisting of organic fibers (Kevlar) and
neoprene binder for exposed pipe only. Reference spec Section
15085.
N/A
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
2-1/2 inches and smaller:
Stainless steel pipe and fitting compression system with ASTM
A312, Type 316L seamless piping. Minimum wall thickness;
Schedule 5S. Minimum working pressure 200 psig. Lead free
and NSF rated. HNBR sealing element. Viega Systems ProPress System or approved substitute.
3 inch and larger:
Stainless Steel; Reference spec Section 15067.
Type 316L, butt welded. Minimum wall thickness: 40S.
Ftgs;
Reference Section 15067.
Valves:
Lubricated plug; Type 316L stainless steel or cast stainless
steel Type CF8M, dynamic balanced, flanged, Class 150, PTFE
coated plug, Nordstrom Fig. 1925-H or equivalent corrosion
resistant valve from Walworth or equal.
Lift check; Crane Stainless steel 27TF, Lunkenheimer stainless
steel 231, or equal.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-30
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
18 (continued)
Buried and Encased Pipe and Valves:
(See drawings for pipe size and valve type.)
All sizes
Pipe:
Valves:
Integral primary and secondary containment pipe; Ref. spec
Section 15073. Provide magnetic tracer tape.
Conn; specialty connections, reference spec Section 15073.
Ftgs; specialty fittings to match pipe, ref. spec Section 15073.
None.
Remarks:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-31
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
BFC—Biotrickling Filter Chemical
Test Requirements:
Medium:
Pressure:
Duration:
Water; ref. spec paragraph 15050-3.04 C.
100 psig
120 minutes
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
System--19
PTFE bonded EPDM, full-face gaskets, ANSI B16.1. Reference
spec Section 15085.
N/A
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
(All sizes)
Pipe:
(4" and less)
Valves:
(5" and larger)
Valves:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
PVC; ASTM D1784, Class 12454-B, NSF certified, ASTM D1785,
Sch. 80. Pipe and fittings exposed to sunlight shall be painted.
Ref. spec Section 15064.
Conn; plain end, solvent weld, flanged for valves 3 inch and
larger.
Ftgs; PVC, Sch. 80, solvent weld.
Ball; PVC Chemtrol Tru Bloc TU Series, Asahi/America Duo Bloc
TU Series, GSR TU Series, or equal, with PTFE seats and EPDM
0-rings.
Diaphragm; PVC body, Chemtrol Series PD, Posacon 677,
Asahi/America, or equal with EPDM or PTFE diaphragm.
Ball check; PVC body, Chemtrol Series BC, Asahi/America, or
equal with EPDM or PTFE seats/seals.
Diaphragm; ITT Dia-Flo 2558-2-M, Hills-McCanna 0649-1-38, or
equal.
Swing or ball check; fully lined valve body; fully coated swing
check flapper or ball check ball; lining and coating shall be
Hypalon or fluorinated ethylene propylene. Valve and Primer
Co. APCO Series 100R, Peabody Dore Model 770, or equal.
15050-32
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
19 (continued)
Buried and Encased Pipe and Valves:
(See drawings for pipe size and valve type)
(All sizes)
Pipe:
(2" and less)
Valves:
(2 1/2" and larger)
Valves:
PVC; same as exposed. Provide magnetic tracer tape.
Conn; same as exposed.
Ftgs; same as exposed.
Ball; same as exposed with extension stem and valve box.
Diaphragm; same as exposed with extension stem and valve
box.
Remarks:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-33
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
FA--Foul Air
Test Requirements:
Medium:
Pressure:
Duration:
Air; ref. spec paragraph 15050-3.04 B.
30” w.c.
60 minutes
Gasket Requirements:
Push-on/Mech Cpl:
System--22
Flange: Gylon gasketing, Garlock style 3504. Reference spec
Section 15085.
PTFE, reference spec Section 15085.
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
(16" and smaller)
Pipe:
Reinforced thermosetting resin (RTRP); Type 4, ref. spec Section
15058.
Conn; bonded bell and spigot or flanged.
Ftgs; RTRP to match pipe, glass filament wound reinforcing only.
Or FRP Ductwork; ref. spec Section 13234.
Valves:
Butterfly style damper ref. spec Section 13234.
(18" and larger)
Pipe:
FRP Ductwork; ref. spec Section 13234.
Valves:
Butterfly style damper ref. spec Section 13234.
Buried and Encased Pipe and Valves: (See drawings for pipe size and valve type)
(4" and greater)
Pipe:
HDPE: Reference spec Section 15065. SDR = 32.
Fittings and joints: Reference spec Section 15065.
Provide flanges at valves and equipment
Valves:
Butterfly style damper; same as exposed with extension stem
and valve box
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-34
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
Test Requirements:
Medium:
RWP--Rainwater Pipe
SD--Sanitary Drain
V--Vent
In accordance with Uniform Plumbing Code.
Pressure:
In accordance with Uniform Plumbing Code.
Duration:
In accordance with Uniform Plumbing Code.
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
System—24
Nitrile or Neoprene. Reference spec Section 15085.
Nitrile or neoprene. Reference spec Section 15085.
Exposed Pipe and Valves:
(See drawings for pipe size.)
(3-1/2" and smaller)
Pipe:
Valves:
(4" and greater)
Pipe:
Valves:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 40. Ref.
spec Section 15064. Provide magnetic tracer tape.
Conn; plain end, solvent weld.
Ftgs; PVC, socket type, DWV, ASTM D2665.
None
Ductile iron; Flanged or grooved end, ceramic epoxy lining,
primer coated. Ref. spec Section 15062.
Ftgs; ductile iron per spec Section 15062; coating, lining, and
ends to match pipe.
None
15050-35
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
24 (continued)
Buried and Encased Pipe and Valves Under and 5 Feet Outside Building
(See drawings for pipe size.)
(All sizes)
Pipe:
Valves:
PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 40. Ref.
spec Section 15064. Provide magnetic tracer tape.
Conn; plain end, solvent weld.
Ftgs; PVC, socket type, DWV, ASTM D2665.
None
Buried and Encased Pipe and Valves Beyond 5 Feet Outside Building
(See drawings for pipe size.)
(All sizes)
Pipe:
Valves:
PVC; ASTM D3034, SDR 35. Provide magnetic tracer tape.
Conn; Push-on with nitrile gasket.
Ftgs; PVC or dictile iron per Section 15062; ends to match pipe.
None
Remarks:
1.
Sanitary drains shall be continuously sloped to drain with minimum slope of ¼” per foot in
the direction of flow.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-36
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
CD--Chemical Drain
VC--Chemical Vent
System--25
Test Requirements:
Medium:
Pressure:
Duration:
In accordance with the Uniform Plumbing Code.
In accordance with the Uniform Plumbing Code.
In accordance with the Uniform Plumbing Code.
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
N/A
N/A
Exposed Pipe and Valves:
(See drawings for pipe size and valve type)
(All sizes)
Pipe:
Valves:
PP; ASTM D4101, Sch. 40, flame retardant. Ref. spec Section
15064.
Conn; ref. spec Section 15064.
Ftgs; PP, socket type coil fused DWV. Ref. spec Section 15064.
None
Buried and Encased Pipe and Valves:
(See drawings for pipe size and valve type)
Pipe:
PP; same as exposed. Provide magnetic tracer tape.
Conn; ref. spec Section 15064.
Ftgs; same as exposed.
Valves:
None
Remarks:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-37
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service:
PDR—Process Drain
STD—Storm Drain
System—27
Test Requirements:
Medium:
Pressure:
Duration:
Water; ref. spec paragraph 15050-3.04 C.
30 psig
120 minutes
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
Nitrile or Neoprene. Reference spec Section 15085.
Nitrile or neoprene. Reference spec Section 15085.
Exposed Pipe and Valves:
(See drawings for pipe size.)
(3-1/2" and smaller)
Pipe:
Valves:
(4" and greater)
Pipe:
Valves:
PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 40.
Ref. spec Section 15064. Provide magnetic tracer tape.
Conn; plain end, solvent weld.
Ftgs; PVC, socket type, DWV, ASTM D2665.
None
Ductile iron; Flanged or grooved end, ceramic epoxy lining,
primer coated. Ref. spec Section 15062.
Ftgs; ductile iron per spec Section 15062; coating, lining, and
ends to match pipe.
None
Buried and Encased Pipe and Valves Under and 5 Feet Outside Building
(See drawings for pipe size.)
(3-1/2" and smaller)
Pipe:
Valves:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 40.
Ref. spec Section 15064. Provide magnetic tracer tape.
Conn; plain end, solvent weld.
Ftgs; PVC, socket type, DWV, ASTM D2665.
None
15050-38
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping System:
(4" thru 16")
Pipe:
Valves:
(18" and greater)
Pipe:
Valves:
27 (continued)
PVC; ASTM D3034, SDR 35. Provide magnetic tracer tape.
Conn; Push-on with nitrile gasket.
Ftgs; PVC or ductile iron per Section 15062; ends to match
pipe.
None
PVC; ASTM F679, PS46. Provide magnetic tracer tape.
Conn; Push-on with nitrile gasket.
Ftgs; PVC or dictile iron per Section 15062; ends to match pipe.
None
Remarks:
1.
Process Drains shall be continuously sloped to drain with minimum slope of ¼” per foot in
the direction of flow.
2.
Provide long radius 90 degree and 45 degree fittings for all buried pipe.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-39
ADDENDUM NO. 3
PIPING SYSTEMS
3.07
PIPING SPECIFICATION SHEETS--PIPESPEC
Piping Symbol/Service
EE--Engine Exhaust
Test Requirements:
Medium:
Pressure:
Duration:
None
None
None
Gasket Requirements:
Flange:
Push-on/Mech Cpl:
See Remarks
N/A
System--31
Exposed Pipe and Valves:
(See drawings for pipe size)
All Pipe:
Stainless Steel; ASTM A312, Type 321 or 316L seamless,
Schedule 10S, welded.
Conn; butt weld, flanged for equipment connections.
Ftgs; ASTM A403, material, thickness, and end connections to
match pipe.
Remarks:
1.
Pipe, fittings and exhaust silencer shall be insulated as specified with removable blanket type
insulation per Section 15250.
2.
Flange gasket shall be flat, full-face, graphoil suitable for temperatures to 1200 degrees F.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-40
ADDENDUM NO. 3
PIPING SYSTEMS
3.08
MEASUREMENT AND PAYMENT
A.
Piping systems shall not be paid for directly, but shall be considered incidental and
included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15050-41
ADDENDUM NO. 3
PIPING SYSTEMS
SECTION 15085
PIPING CONNECTIONS
PART 1--GENERAL
1.01
SUMMARY
A.
1.02
SCOPE: This Section specifies the following methods of connecting metallic piping:
flanges, threading, mechanical couplings, dielectric unions, and welding.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this Section shall prevail. Unless
otherwise specified, references to documents shall mean the documents in effect on
the effective date of the Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replacement documents issued or otherwise identified by that organization or, if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
Title
ANSI B1.1
Unified Inch Screw Threads (UN and UNR Thread Form)
ANSI B1.20.1
Pipe Threads, General Purpose (Inch)
ANSI B16.1
Cast Iron Pipe Flanges and Flanged Fittings
ANSI B16.5
Pipe Flanges and Flanged Fittings
ANSI B18.2.1
Square and Hex Bolts and Screws Inch Series
ANSI B18.2.2
Square and Hex Nuts (Inch Series)
ANSI B31.1
Power Piping
ANSI B31.3
Chemical Plant and Petroleum Refinery Piping
ASME Section IX
Boiler and Pressure Vessel Code; Welding and Brazing Procedures,
Welders, Brazers, and Welding and Brazing Operators Qualifications
ASTM B98
Copper-Silicon Alloy Rod, Bar and Shapes
ASTM A 183
Carbon Steel Track Bolts and Nuts
ASTM A 449
Hex Cap Screws, Bolts and Studs, Steel, Heat Treated, 120/105/90 ksi
Minimum Tensile Strength, General Use
ASTM F37
Standard Test Methods for Sealability of Gasket Materials
ASTM F104
Standard Classification System for Nonmetallic Gasket Materials
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-1
ADDENDUM NO. 3
PIPING CONNECTIONS
Reference
Title
ASTM F152
Standard Test Methods for Tension Testing of Nonmetallic Gasket
Materials
ASTM F593
Stainless Steel Bolts, Hex Cap Screws, and Studs
ASTM F594
Stainless Steel Nuts
AWWA C111
Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings
AWWA C206
Field Welding of Steel Water Pipe
AWWA C207
Steel Pipe Flanges for Waterworks Service-Size 4 in. through 144 in.
AWWA C219
Bolted, Sleeve-Type Couplings for Plain-End Pipe
AWWA C550
Protective Epoxy Coatings for Valves and Hydrants
AWWA C606
Grooved and Shouldered Joints
AWWA M11
Steel Pipe-A Guide for Design and Installation
NSF 61
Drinking Water System Components - Health Effects
1.03
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
Manufacturer's catalog data showing piping connection details for each piping
system.
2.
Details for installation for each type of piping connection.
3.
A welder qualification certificate for each welder indicating the welder is
certified for pipe welding in accordance with ASME Boiler and Pressure Vessel,
Section IX. Each welder's certificate shall be provided to the City prior to that
welder working on the job.
4.
For Equipment Connection Fittings used in pumping applications submit thrust
rod stretch calculations in accordance with paragraph 15085-2.01D and
dimensional layout data.
PART 2--PRODUCTS
2.01
GENERAL
A.
Pipe connections (joint and fitting) options for a particular piping system shall be as
specified on the particular system PIPESPEC sheet in Section 15050.
B.
TAKEDOWN COUPLINGS: To be provided for all piping systems in accordance with this
Section. To be provided both around equipment, at valves and where otherwise
specified.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-2
ADDENDUM NO. 3
PIPING CONNECTIONS
2.02
C.
Continuous welding for straight runs of pipe is acceptable only where the individual
PIPESPEC sheet allows welding as a connection option.
D.
Where connections are shown, then the connections shall be specifically where shown,
however, if several connection options are allowed for the particular piping system on
the PIPESPEC sheet, then any option may be consistently used, i.e., if flanged or
grooved connections are acceptable and grooved are shown, then flanged may be
substituted. Integrity of rigid, non-rotating connections must be maintained at all valves
and other equipment.
FLANGE ASSEMBLIES
A.
FLANGES:
1.
General: Flanges shall either be flat flanges or convoluted ring flanges. Flange
rating shall always exceed test pressure requirement for the piping system as
listed in Section 15050 PIPESPEC.
2.
Flat Flanges:
3.
a.
Cast iron flanges: Faced in accordance with ANSI B16.1. Where
companion flanges are used, the flanges on pipe shall be refaced to be
flush with the companion flange face.
b.
Class 150 and Class 300 forged steel flanges: Raised face conforming
to ANSI B16.5.
c.
Lightweight slip-on flanges: Plain face conforming to AWWA C207,
Class B and ANSI B16.5.
d.
Steel flanges: Unless otherwise specified, ANSI B16.5, Class 150 or
AWWA C207, Class D. Class E AWWA flanges shall be provided where
test pressure exceeds 175 psi. Plain faced flanges shall not be bolted
to raised face flanges.
Convoluted Ring Flanges:
a.
Ductile iron, forged steel or cast stainless steel, designed to bear on
hubs welded to the pipe.
b.
Flange joints: Rated for not less than 150 percent of the test pressures
listed in Section 15050 and in conformance with the requirements of
ANSI B 16.5 and AWWA C207.
c.
The flange manufacturer shall be prepared to demonstrate, by certified
pressure test that the flanges will meet these requirements.
d.
Acceptable manufacturer:
1)
2)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Improved Piping Products.
Or approved substitute.
15085-3
ADDENDUM NO. 3
PIPING CONNECTIONS
B.
GASKETS:
1.
Material: As specified in Section 15050 and this Section.
2.
For plain faced flanges:
a.
Full face type.
b.
Thickness:
1)
2)
3.
For raised face flanges:
a.
Unless otherwise indicated, shall match the raised face.
b.
Thickness:
1)
2)
C.
2.03
Pipe 10 inches and less in diameter: 1/16 inch.
Pipe 12 inches and larger in diameter: 1/8 inch.
Pipe 3-1/2 inches and less in diameter: 1/16 inch,
Pipe 4 inches and larger: 1/8 inch
BOLTS:
1.
Bolts and nuts shall be Type 316 stainless steel in conformance with ASTM
F593 for bolts and ASTM F594 for nuts. Bolts shall be threaded to conform to
ANSI B 18.2.1, page C-1 for finished hex bolts. Nuts shall conform to ANSI
B18.2.2, page D-1. Bolts and nuts shall be fully passivated. Nuts shall be
finished with Tripac 2000 coating system, or approved substitute. All bolt heads
and nuts shall be hexagonal. Identification on the head of the bolt shall be T316, 316, F593G or F593H.
2.
Where washers are required, they shall be of the same material as the
associated bolts.
MECHANICAL COUPLINGS
A.
SLEEVE-TYPE COUPLINGS:
1.
Acceptable manufacturer:
a.
Sleeve-type mechanical pipe couplings:
1)
2)
3)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
SmithSmith-Blair Type 411.
Dresser Style 38.
Or approved substitute, with the stop removed from the middle
ring.
15085-4
ADDENDUM NO. 3
PIPING CONNECTIONS
b.
Reducing couplings:
1)
2)
3)
c.
Sleeve-type flanged coupling adapters:
1)
2)
3)
d.
3.
B.
SmithSmith-Blair Type 913.
Dresser Style 128.
Or approved substitute.
Insulating couplings:
1)
2)
3)
2.
SmithSmith-Blair Type 415.
Dresser Style 62.
Or approved substitute.
SmithSmith-Blair Type 416.
Dresser Style 39.
Or approved substitute.
Bolts and nuts:
a.
Bolts and nuts shall be Type 316 stainless steel in conformance with
ASTM F593 for bolts and ASTM F594 for nuts. Bolts shall be threaded
to conform to ANSI B 18.2.1, page C-1 for finished hex bolts. Nuts shall
conform to ANSI B18.2.2, page D-1. Bolts and nuts shall be fully
passivated. Nuts shall be finished with Tripac 2000 coating system, or
approved substitute. All bolt heads and nuts shall be hexagonal.
Identification on the head of the bolt shall be T-316, 316, F593G or
F593H. Substitute Tripac 2000 Blue coated steel bolts and nuts where
316 stainless components are not available as manufacturer’s
standard option.
d.
Where washers are required, they shall be of the same material as the
associated bolts.
Gaskets: As specified in this Section and AWWA C111.
PLAIN END COUPLINGS:
1.
Acceptable manufacturer:
a.
Pipe sizes 6 inches and smaller (Schedule 80):
1)
2)
3)
b.
Anvil Gruvlock Figure 7005.
7005
Victaulic Style 99.
Or approved substitute.
Pipe sizes 6 inches and smaller (lighter weight):
1)
2)
3)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Anvil Gruvlock Figure 7005.
7005
Victaulic Style 90.
Or approved substitute.
15085-5
ADDENDUM NO. 3
PIPING CONNECTIONS
c.
Pipe sizes 8 inches and larger:
1)
2)
3)
C.
Anvil Gruvlock Figure 7005.
7005
Victaulic Style 99.
Or approved substitute.
2.
Bolts and nuts: Unless otherwise specified, shall comply with AWWA C606.
Provide Type 316 stainless steel bolts and nuts. Bolts and nuts shall be fully
passivated. Nuts shall be finished with Tripac 2000 coating system, or
approved substitute. Substitute Tripac 2000 Blue coated standard steel bolts
and nuts where 316 stainless components are not available as manufacturer’s
standard option.
3.
Gaskets: As specified in this Section and AWWA C606.
GROOVED END COUPLINGS:
1.
Acceptable manufacturer:
a.
Grooved end flexible-type couplings:
1)
2)
3)
b.
Grooved end rigid-type couplings:
1)
2)
3)
c.
Anvil Gruvlok Figure 7401 Rigidlok (thru 24-inch)
Victaulic Style 07 Zero-Flex (thru 24-inch).
Or approved substitute.
Grooved end flanged coupling adapters:
1)
2)
3)
d.
Anvil Gruvlok Figure 7001.
Victaulic Style 77/770.
Or approved substitute.
Anvil Gruvlok Figure 7012.
Victaulic Style 741.
Or approved substitute.
Snap-joint grooved end couplings:
1)
2)
3)
Anvil Gruvlok Figure 7003.
Victaulic Style 78.
Or approved substitute.
2.
Unless noted otherwise, flexible-type couplings shall be used for all piping
greater than 12 inches in diameter and for grooved joints adjacent to pump or
blower suction and discharge where grooved couplings are used for noise and
vibration control. All other applications for piping 12 inches in diameter and
less shall utilize rigid-type couplings.
3.
Cut grooves are not permitted on fabricated or light wall pipe with non-standard
outside diameters or surface imperfections that may affect joint integrity.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-6
ADDENDUM NO. 3
PIPING CONNECTIONS
Minimum thickness shall be SCH 40 through 6-inch and SCH 30 for larger
sizes).
D.
4.
Minimum thickness for roll grooved pipe shall be SCH 5 or coupling
manufacturer’s standard, whichever is greater.
5.
Bolts and nuts:
a.
Unless otherwise specified, shall comply with AWWA C606.
b.
Provide Type 316 stainless steel bolts and nuts. Bolts and nuts shall be
fully passivated. Nuts shall be finished with Tripac 2000 coating
system, or approved substitute. Substitute Tripac 2000 Blue coated
steel bolts and nuts where 316 stainless components are not available
as manufacturer’s standard option.
c.
Where washers are required, they shall be of the same material as the
associated bolts.
6.
Gaskets: As specified in this Section and AWWA C 606.
7.
To assure uniformity and compatibility of piping components in grooved end
piping systems, all grooved products utilized shall be supplied by the same
manufacturer. Grooving tools shall be supplied by the same manufacturer as
the grooved components. A factory trained representative (direct employee of
grooved coupling manufacturer) shall provide on-site and periodically visit the
job site to review installation, as specified in Part 3.
EQUIPMENT CONNECTION FITTINGS:
1.
Equipment connection fittings shall provide both lateral and angular
misalignment adjustment between equipment connection flanges and the
connection to field piping systems by providing individually adjustable flexible
joints at each connection. In addition, equipment connection fittings shall
provide full pressure thrust restraint between the field piping connection and
equipment connection flanges.
a.
Equipment connection fittings shall consist of two flanged coupling
adapters, a plain end section of pipe and thrust restraint rods and
associated fittings designed to transmit thrust without transmitting
shear to the thrust restraint rods and without compromising
provisions for accommodating angular and parallel misalignment.
b.
Materials and features shall conform to the requirements established
in this Section. Standard “dismantling joints” incorporate only one
flanged coupling adapter and are not acceptable substitutes.
c.
Equipment connection fittings shall be:
1)
2)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Romac ECF Series,
Baker Coupling Company, Los Angeles
15085-7
ADDENDUM NO. 3
PIPING CONNECTIONS
3)
Or approved substitute, modified as specified to provide the
required features.
2.
Shall each consist of a single sleeve of plain end piping conforming to the
requirements of the specified piping system of sufficient length to span the
gap between the connection at the equipment and the connection at the field
piping with gasketed flange adapters at each end.
3.
Thrust restraint shall be provided by means of all threaded rod spanning
between flanges and male rod nuts and female washers that are rounded to
provide a ball-joint type self aligning feature. All threaded restraint rod shall
project through flange and mating flange coupling adapter bolt holes or
through holes in restraint lug plates that extend above the flanges and are
secured to the flanges with a minimum of two flange bolts.
4.
Where the all threaded rods project through flange bolt holes, ball joint type
nut and washer combinations and lock washers shall be provided at each
face, each end. Where restraint lug plates are employed, ball joint type nuts
and washers shall be provided only on the outside faces of the plates and the
nuts shall have a self locking feature that prevents nut movement due to
vibration or other operational or environmental causes.
5.
Double nutting with non-locking nuts shall not be an acceptable method of
providing the self locking feature.
6.
Thrust rod diameter and material shall be selected to provide sufficient
freedom of movement through all bolt holes to allow unrestricted maximum
adjustment of equipment connection fittings to accommodate piping
misalignment without transmitting any shear to the thrust rods and also to
permit full development of thrust restraint at all thrust rod tension take-ups.
7.
Design of equipment connection fittings shall conform to AWWA C219.
8.
Thrust rods, restraint lug plates, nuts, washers and lock washers shall be
Type 316 stainless steel, all selected to develop full rated piping system
pressure thrust forces. Bolts and nuts shall be fully passivated. Nuts shall be
finished with Tripac 2000 coating system, or approved substitute. Equipment
connection fittings for pump applications shall have thrust rod number and
diameter selected such that thrust rod stretch under piping system operating
pressure does not exceed 2 mils.
9.
Factory apply dry film molybdenum di-sulfide anti-galling compound to ends
of thrust rods, covering all threads subject to nut travel and tightening.
10.
Gaskets shall be as specified in this Section. Flange gaskets shall be full
face type. Follower gaskets shall be compression wedge type.
11.
Sleeves shall be carbon steel or as specified for the specific piping system.
Pressure rating of flange adapters shall equal or exceed the pressure rating
of mating flanges. All metal portions of equipment connection fittings, with
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-8
ADDENDUM NO. 3
PIPING CONNECTIONS
the exception of 316 stainless steel components, shall be coated and lined
with fusion bonded epoxy conforming to AWWA C550 and NSF 61.
E.
DISMANTLING JOINTS:
1.
Dismantling joints may be used as takedown couplings in accordance with this
Specification.
a.
Dismantling joints shall fully restrained double flange fittings consisting
of a flange coupling adapter and flanged spool piece that allows for
longitudinal adjustment.
b.
Provide thrust restraint by means of all threaded rod spanning
between flanges and secured to the flanges with a minimum of two
flange bolts.
c.
Design of equipment connection fittings shall conform to AWWA
C219.
d.
Sleeves shall be carbon steel or as specified for the specific piping
system. Pressure rating of flange adapters shall equal or exceed the
pressure rating of mating flanges.
e.
All metal portions of dismantling joints, with the exception of 316
stainless steel components, shall be coated and lined with fusion
bonded epoxy conforming to AWWA C550 and NSF 61.
f.
Provide Type 316 stainless steel bolts and nuts. The stainless steel
nuts shall be provided with Tripac 2000 Blue coating, or approved
substitute. Substitute Tripac 2000 Blue coated steel bolts and nuts
where 316 stainless components are not available as manufacturer’s
standard option.
g.
Dismantling joints:
1)
2)
3)
4)
F.
Romac DJ-400,
Smith Blair 975,
Crane-Viking Johnson Dismantling Joint
Or approved substitute.
SLEEVE BAND COUPLINGS: Sleeve band couplings shall be Victaulic Depend-O-Lock.
Unless otherwise noted, couplings for liquid service shall be Model F x F Type 2 fully
restrained, shouldered high deflection couplings with standard width band.
Couplings shall comply with AWWA C-219. Couplings for use with air systems shall
be Airmaster restrained Depend-O-Lock couplings in conformance with AWWA C-606.
Sleeve band couplings are acceptable wherever sleeve type couplings are used
(paragraph 15085-2.03 A.). Provide Type 316 stainless steel bolts and nuts. The
stainless steel nuts shall be provided with Tripac 2000 Blue coating, or approved
substitute. Substitute Tripac 2000 Blue coated steel bolts and nuts where 316
stainless components are not available as manufacturer’s standard option.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-9
ADDENDUM NO. 3
PIPING CONNECTIONS
G.
2.04
FLEXIJOINT:
1.
Where specified Flexijoint couplings shall be Flanged Romac Flexijoint
couplings or approved substitute.
2.
The Flexijoint is a flexible, ductile iron joint that can accommodate expansion,
contraction, rotation and bending and is rated at 350 psi working pressure.
3.
The joint can accommodate 15 to 20 degree deflection depending on size.
4.
Body shall be ductile iron, lock rings Type 410 stainless steel, and ring
gasket, casing, ball and cover shall be EPDM molded watertight construction.
5.
All metal portions of Flexijoint coupling including the stainless steel lock rings
shall be coated and lined with fusion bonded epoxy conforming to AWWA
C550 and NSF 61.
6.
For buried installations, install with polyethylene baggy cover in accordance
with the manufacturer’s instructions.
GASKETS
A.
Gaskets designated in Section 15050 shall be as follows:
1.
EPDM: Ethylene-propylene-diene-terpolymer.
2.
Neoprene: Neoprene.
3.
Nitrile: Nitrile (Buna N).
4.
Viton
5.
Compressed gasketing consisting of organic fibers (Kevlar) and neoprene
binder:
a.
b.
c.
6.
Compressed gasketing consisting of organic fibers (Kevlar) and nitrile binder:
a.
b.
c.
7.
Classification, ASTM F104 (F712400)
Tensile Strength, 2500 psi (ASTM F152)
Leakage, 0.2 ML/HR LEAKAGE FUEL A (ASTM F37), 0.2 ml/hr Fuel A.
Classification, ASTM F104 (F712400)
Tensile Strength, 2500 PSI (ASTM F152)
Leakage, 0.1 ml/hr leakage Fuel A (ASTM F37).
Gylon gasketing, Garlock Style 3500:
a.
b.
Tensile Strength, 2000 psi (ASTM F152)
Leakage, 0.22 ml/hr Fuel A (ASTM F37).
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-10
ADDENDUM NO. 3
PIPING CONNECTIONS
8.
Gylon gasketing, Garlock Style 3504:
a.
b.
9.
Gylon gasketing, Garlock Style 3510
a.
b.
2.05
2.07
Tensile Strength, 2000 psi (ASTM F152)
Leakage, 0.04 ml/hr Fuel A (ASTM F37).
10.
TFE: Noncreeping tetrafluoroethylene (TFE) with insert filler.
11.
PTFE bonded EPDM: PTFE bonded to EPDM in full-face gasket having
concentric-convex molded rings.
THREAD
A.
2.06
Tensile Strength, 2000 psi (ASTM F152)
Leakage, 0.12 ml/hr Fuel A (ASTM F37).
Pipe thread dimensions and size limits shall conform to ANSI B1.20.1.
UNIONS
A.
2 INCHES AND SMALLER: Ground joint screwed pattern unions. 2-1/2 inches larger:
Ground joint flange unions.
B.
DIELECTRIC UNIONS: Match the pipe material except bronze may be used with copper
piping. Dielectric unions shall be EPCO, Capitol Manufacturing, or approved substitute.
C.
Hydraulic power and petroleum conveying piping shall use flat-faced O-ring style unions,
for both regular and dielectric unions. O-ring material shall be suitable for piped fluid.
COATINGS
A.
Unless otherwise specified, flange assemblies and mechanical type couplings for buried
installation shall be field coated with System E-9 as specified in Section 09900.
PART 3--EXECUTION
3.01
PIPE CUTTING, THREADING AND JOINTING
A.
3.02
Pipe cutting, threading and jointing shall conform to the requirements of ANSI B31.1.
PIPE WELDING
A.
Pipe shall be welded by ASME-certified welders using shielded metal arc, gas shielded
arc or submerged arc welding methods. Provide welding certification for each welder
working on piping fabrication.
B.
Make welds in accordance with the requirements of ANSI B31.1 for piping System 18
specified in Section 15050.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-11
ADDENDUM NO. 3
PIPING CONNECTIONS
C.
3.03
GROOVED END COUPLINGS
A.
3.04
3.05
3.06
3.07
Make welds for piping systems not specified above in accordance with AWWA C206.
A factory trained representative (direct employee of grooved coupling manufacturer)
shall provide on-site training for contractor’s field personnel in the use of grooving tools,
application of groove, and product installation. A factory-trained representative shall
periodically visit the job site and review installation. Contractor shall promptly remove
and replace any improperly installed products or piping distorted or damaged by
incorrect preparation.
TAKEDOWN COUPLINGS
A.
Screw unions, flanged or grooved end mechanical coupling type joints and provided as
specified.
B.
Employ flanged or grooved end joints on pipelines 2-1/2 inches in diameter and larger.
C.
Where piping passes through walls, unless otherwise indicated, provide takedown
couplings within 3 feet of the wall.
D.
Provide a union or flanged connection within 2 feet of each threaded end valve.
FLEXIBILITY
A.
Unless otherwise specified, piping passing from concrete to earth shall be provided with
two pipe couplings or flexible joints (or a single Flexijoint) as specified on the buried pipe
within 2 feet of the structure for 2-inch through 6-inch diameter pipe; within 3 feet of the
structure for 8-inch through 24-inch diameter pipe; and within one and one-half pipe
diameters of the structure for larger pipe. Where required for resistance to pressure,
mechanical couplings shall be restrained in accordance with Chapter 13 of AWWA M11,
including Tables 13-4, 13-5 and 13-5A, and Figure 13-20.
B.
Restrain all flexible joints for pressurized ductile iron joints. Lugs for restraint on ductile
iron pipe shall be factory installed.
DIELECTRIC CONNECTIONS
A.
Provide an insulating section of rubber or plastic pipe where a copper pipe is connected
to steel or cast iron pipe. The insulating section shall have a minimum length of 12 pipe
diameters.
B.
Dielectric unions as specified in this Section may be used instead of the specified
insulating sections. Where copper pipe is supported from hangers, insulate it from the
hangers, or use copper-plated hangers.
EQUIPMENT CONNECTION FITTINGS
A.
Where shown, equipment connection fittings shall be provided between field piping
systems and equipment inlet and outlet connections.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-12
ADDENDUM NO. 3
PIPING CONNECTIONS
3.08
MEASUREMENT AND PAYMENT
A.
Piping connections shall not be paid for directly, but shall be considered incidental and
included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15085-13
ADDENDUM NO. 3
PIPING CONNECTIONS
SECTION 15095
PIPING APPURTENANCES
PART 1--GENERAL
1.01
1.02
SUMMARY
A.
SCOPE: This Section specifies general connection information for pipeline
instrumentation, strainers, sight glasses, vents, drains, and other devices specified
herein and elsewhere.
B.
EXCLUSIONS:
Primary process measurement devices for temperature, pressure and flow
used for communication with the process control system (PCS) are specified
in Sections 17212, and 17216.
2.
Process control auxiliary devices including chemical seals, gages, rotameters
and similar devices are specified in Sections 17000 and 17211, and are
identified in the instrument index in Section 17901.
QUALITY ASSURANCE
A.
1.03
1.
REFERENCE STANDARDS: Not used.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
Appurtenances shall be located on the piping layout Drawings by plant area
and submitted in accordance with Section 15050.
2.
Manufacturer's product data, measurement ranges, materials of
construction, dimensions, typical installation and application information.
PART 2--PRODUCTS
2.01
GENERAL
A.
Unless otherwise specified:
1.
Body material of equipment shall match pipeline material.
2.
Pressure rating of equipment shall be no less than 150 psi.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15095-1
ADDENDUM NO. 3
PIPING APPURTENANCES
2.02
B.
All units shall have the name of the manufacturer and the size of the unit cast on the
body or shown on a permanently attached plate in raised letters.
C.
All equipment provided shall be equipped with flanges, integral unions, or other
functional take-aparts.
PIPELINE CONNECTIONS
A.
B.
2.03
GENERAL:
1.
Pipeline connections for instrumentation, not otherwise specified, shall be
fabricated with a 3-inch FNPT branch outlet on the process pipe, a 3-inch
male NPT by ¾-inch female NPT reducing bushing, a ¾-inch by 3 inch long
threaded nipple, and a threaded ball valve with lock open provisions.
2.
Materials and methods of connections, not otherwise specified, shall be the
same as the process piping system per Section 15050.
CONNECTION TYPES:
1.
Connection types and details are specified with the instrumentation in
Section 17901.
2.
Connection types shall protect the integrity of the process pipe and the lining
and shall be, as a minimum:
a.
Glass-lined ductile iron and steel pipe – factory installed threaded
half-coupling, installed prior to lining, or tee with tapped blind flange
or tap.
b.
Unlined steel and stainless steel pipe – reducing tee or threaded half
coupling.
c.
HDPE pipe – reducing tee or electro-fusion welded saddle by butt
end.
d.
PVC/CPVC pipe – solvent welded tee with branch socket adapted with
solvent welded pipe or SCH 80 threaded fitting to suit use. Transition
to metal pipe or fittings shall be PVC male NPT to threaded metal or
flange by flange.
FLOW AND LEVEL INDICATORS
A.
FLOW INDICATORS:
1.
Flow indicators shall be provided where specified.
2.
Fabrication: Bronze body with threaded ends and a sight glass with rotary
wheel.
3.
Pressure ratings for flow indicators shall match pipe pressure ratings.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15095-2
ADDENDUM NO. 3
PIPING APPURTENANCES
4.
Candidate manufacturer:
a.
b.
c.
d.
B.
Jacoby-Tarbox.
Schutte & Koerting.
Eugene Ernst Products.
Or approved equal.
ROTAMETERS:
1.
Purge rotameters with differential pressure regulator (seal water):
a.
General:
1)
2)
3)
4)
5)
b.
Constant differential pressure regulator to maintain set flow rate with
constant downstream pressure if upstream pressure varies.
c.
Materials:
1)
2)
3)
d.
Meter tube: Glass/acrylic
Body and frame: 316 stainless steel
Regulator: Epoxy coated
Acceptable manufacturers:
1)
2)
2.
Variable area type with constant differential pressure
regulator.
Field or factory assembled with integral needle valve, flow
switch, and pressure regulator.
Range: See Section 15130 for flow ranges.
200 psi working pressure
Includes an integral proximity flow switch set at a minimum
flow of 0.25 gph. Flow switch will be rated at 120 VAC, 0.5A.
Kytola Model E
Approved equal.
Rotameters for highhigh-capacity service:
a.
Glass tube variable area type with 55-inch scale and stainless steel
body and frame. Flow range shall be as specified and scales shall
indicate the units of flow.
b.
Acceptable manufacturer:
1)
2)
3)
4)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Brooks.
Wallace & Tiernan.
Schutte & Koerting.
Approved equal.
15095-3
ADDENDUM NO. 3
PIPING APPURTENANCES
C.
2.04
DIGESTER U-TUBE ASSEMBLY SIGHT WINDOW:
1.
Digester U-Tube Assembly sight windows shall be provided where specified
on the Drawings.
2.
Glass section shall be able to withstand 20 psig.
3.
Dimensions shall be as specified on the Drawings.
4.
The body of the sight window shall isolate the glass section from all pipe
strain, thrust, and vibration such that no load is transferred to the glass.
5.
Sight windows shall be welded to schedule 40 Stainless Steel, Type 316L
pipe spool with end connections to match adjacent piping.
6.
Sight windows shall be welded flush to the inside of the pipe wall such that
no component of the sight glass window shall protrude into the pipe inner
diameter.
7.
Sight windows shall be Jacoby-Tarbox Style 5300 Obround.
STRAINERS
A.
AIR AND GAS STRAINERS:
1.
Unless otherwise specified, air and gas line strainers shall be Y-pattern with
40 mesh Monel screens packed with Everdur wool.
2.
Bronze bodies shall be provided with copper piping. Cast iron bodies shall be
provided with steel piping.
3.
Air line strainers shall be fitted with a brass blowoff ball valve.
4.
Candidate manufacturer:
a.
b.
c.
B.
Mueller.
Armstrong.
Or approved equal.
WATER STRAINERS:
1.
Unless otherwise specified, water strainers shall be Y-pattern.
2.
Bronze bodies shall be provided with copper piping. Cast iron bodies shall be
provided with steel piping.
3.
Strainers shall have 316 stainless steel screens and tapped and plugged
blowoff connections.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15095-4
ADDENDUM NO. 3
PIPING APPURTENANCES
4.
5.
Screen perforations shall be:
a.
General service - 0.045 inch.
b.
Seal water control service– as specified in Section 15130, Seal Water
Control Unit Schedule.
Schedule
Candidate manufacturer:
a.
b.
c.
C.
FUEL OIL STRAINERS:
1.
Fuel oil strainers shall be of the basket type and shall have cast iron body
with 316 stainless steel screens.
2.
Screen perforation shall be 3/64 inch.
3.
Candidate manufacturer:
a.
b.
c.
D.
Bailey No. 1.
Mueller.
Or approved equal.
METHANOL STRAINERS:
1.
Y-pattern, cast type 316 Stainless steel (CF8M)
2.
Class 150, NPT connections
3.
Screen perforation shall be 3/64 inch.
4.
Candidate manufacturer:
a.
b.
E.
Mueller.
Armstrong.
Or approved equal.
Armstrong E-series.
Or approved equal.
BASKET STRAINER:
1.
Strainer shall be of the basket type and have a CPVC body and Viton-A O-rings
and seals.
2.
Screen perforations shall be 1/8 inch.
3.
Strainer shall have NPT threaded inlet and outlet and strainer cover shall be
removable without the use of tools.
4.
100 psi pressure rating.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15095-5
ADDENDUM NO. 3
PIPING APPURTENANCES
5.
One spare basket for each basket strainer.
6.
Strainer shall be equipped with NPT threaded drain.
7.
Candidate manufacturer:
a.
b.
2.05
Plast-O-Matic, Series KST.
Or approved equal.
QUICK CONNECT FITTINGS
A.
QUICK CONNECT FITTINGS:
1.
Type: Coupler type, with cam arms. Capable of connecting to a hose adapter
without the use of tools.
2.
Size: Same size as the pipeline.
3.
Materials: PVDF with teflon gaskets.
4.
Candidate manufacturer:
a.
b.
Kamlock.
Or approved equal.
PART 3--EXECUTION
3.01
3.02
INSTALLATION
A.
Install piping appurtenances in accordance with submitted layout drawings,
applicable details and manufacturer’s written recommendations.
B.
Repair linings damaged during installation. Damaged glass-lined pipe and/or fittings
shall be replaced.
C.
Appurtenances shall be installed in such a manner as to free of pipe strain in either
the installed or operating conditions. Adjust pipe support systems, as required.
VENTS AND DRAINS
A.
VENTS:
1.
Provide manual air vents at the high points of each reach of pipeline where
specified.
2.
Air vents shall consist of full port ball valve and pipe return routed per
standard details as specified in the Drawings.
3.
Air vents shall be taken to the nearest floor with valve mounted as specified
in the Drawings.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15095-6
ADDENDUM NO. 3
PIPING APPURTENANCES
4.
B.
3.03
DRAINS:
1.
Pipe each drain to a sump, gutter, floor drain or other collection point with
valve mounted as specified in the Drawings.
2.
Drain valves in piping systems for fluids containing solids shall be threaded
end full port ball valves of the size specified, fitted with NPT male threaded
nipple
3.
When a drain cannot be run to a collection point, route the drain to a point of
easy access and install a valve, of the type and size specified, fitted with a
male threaded nipple suitable for connection to a hose.
COMPONENT TEST PHASE
A.
3.04
Fit vents in piping systems for fluids containing solids with NPT male
threaded nipple.
Demonstrate successful performance of devices in conjunction with connected
piping system, pump or other equipment.
MEASUREMENT AND PAYMENT
A.
Piping appurtenances shall not be paid for directly, but shall be considered incidental
and included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15095-7
ADDENDUM NO. 3
PIPING APPURTENANCES
SECTION 15097
SEISMIC RESTRAINTS FOR PIPING
PART 1--GENERAL
1.01
SUMMARY
A.
B.
1.02
SCOPE:
1.
This Section, in conjunction with Section 01900, specifies requirements for
design and installation of seismic restraints for bracing piping less than 20-inch
diameter, specified in Section 15050, and interior (indoor) foul air (FA) duct
specified in Section 15050. Seismic restraints for piping 20-inch diameter and
larger and outdoor foul air duct are specified on the Drawings.
2.
This Section does not specify design and installation requirements for seismic
restraints for fire sprinkler systems or other piping systems that are not
specified in Section 15050.
3.
Pipe anchors and pipe guides for pipe expansion control are specified on the
drawings. Requirements for design of piping supports are specified in
Section 15096.
4.
Inspection requirements are specified in Sections 15096 and 01900.
DEFINITIONS:
1.
Longitudinal Direction: parallel to the pipe axis.
2.
Lateral Direction: perpendicular to the pipe axis.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this Section shall prevail. Unless
otherwise specified, references to documents shall mean the documents in effect on
the effective date of the Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replacement documents issued or otherwise identified by that organization or, if
there are no replacement documents, the last version of the document before it was
discontinued.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-1
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
Reference
1.03
1.04
Title
ANSI A58.12
Minimum Design Loads for Buildings and Other Structures
AISC Manual of Steel
Construction
American Institute of Steel Construction, Manual of Steel
Construction, Allowable Stress Design
FEDSPEC WW-H-171e
Hangers and Supports, Pipe
MFMA-3
Metal Framing Standards Publication
MFMA-102
Guidelines for the Use of Metal Framing
MSS SP-58
Pipe Hangers and Supports – Materials, Design and
Manufacture
MSS SP-69
Pipe Hangers and Supports – Selection and Application
SMACNA, PPIC
Guidelines for Seismic Restraints of Mechanical Systems and
Plumbing Piping Systems
SUBMITTALS
A.
PROCEDURES: 01300.
B.
SUBMITTAL ITEMS:
1.
Seismic restraint locations and components indicated on the piping layout
drawings required by specification Sections 15050 and 01900.
2.
A legend (to the piping layout drawings required by this Section) that gives load
information and restraint component selection at each restraint location.
3.
Fabrication Drawings for fabricated components.
4.
Manufacturer's catalog data on structural and pipe attachments, restraints,
braces, fittings, and accessories.
5.
For each seismic restraint location, provide calculations substantiating the
loads, in all directions, that the seismic restraint system must withstand.
Calculations must be stamped, dated, and sealed by a registered engineer
licensed in the state of Hawaii as specified in Sections 15050 and 01900.
SERVICE REQUIREMENTS
A.
The seismic restraints specified in this Section are provided to resist pipe movements
and loads occurring as a result of an earthquake or other seismic event.
B.
Unless otherwise specified, all piping shall have bracing to resist seismic loading
caused by forces applied at the individual pipe's center of gravity. Seismic loading
shall be as specified in Section 01900. Seismic loading shall be assumed to be
acting in the lateral, longitudinal and vertical directions simultaneously.
C.
Expansion control provisions are specified in Drawings and Specifications as
necessary to accommodate expansion and/or contraction of pipe materials as a
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-2
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
result of temperature changes between ambient temperature conditions and
operating temperature conditions. The Contractor’s seismic restraint selection shall
accommodate expansion/contraction without interfering with expansion control
functions. Following commissioning of piping systems, the Contractor shall adjust
seismic restraints as necessary for proper installation at operating temperatures.
1.05
D.
Section 15098 specifies minimum operating temperatures for piping services that
have been designed to operate at temperatures below ambient temperature
conditions and specifies maximum operating temperatures for piping services that
have been designed to operate at temperatures above ambient temperature
conditions. All piping services that are not listed in Section 15098 are assumed to
have operating temperature conditions within the range of ambient temperature
conditions. For the purposes of installing pipe hangers, supports, seismic, bracing,
and expansion control components of piping systems, ambient temperature
conditions are defined as 60 to 120 degrees Fahrenheit.
E.
Until commissioning is completed, the Contractor is responsible for protecting piping
systems against damage resulting from expansion or contraction of pipe materials
exposed to temperatures outside the temperature range between ambient
temperature conditions and operating temperature conditions.
RESTRAINT SELECTION
A.
DESIGN:
1.
The Contractor’s Design Professional, specified in Section 15050, shall be
responsible for design of seismic restraints for piping in conjunction with the
Design Professional’s design of pipe hangers and supports and the expansion
control systems specified on the drawings. Applicable design criteria include,
but are not limited to, those design standards specified in Section 01900 and
Section 15050.
2.
The pipe system drawings specified in Section 15050 shall show the seismic
restraint locations as well as the details of the hangers, supports, and
expansion control systems. The pipe system design Drawings and calculations
shall be prepared and signed by the design professional and shall bear the
design professional’s registration seal in the state of Hawaii.
3.
Supports, seismic bracing, and other piping system mounting elements for
piping less than 2020-inch diameter are generally not shown on the Drawings.
Hangers, supports, seismic restraints, and other piping system mounting
elements for pipe and foul
foul air ductwork 20
20-inch diameter and greater are
shown on the Drawings.
4.
Where piping that is less than 20-inch diameter is shown on a common support
with piping that is 20-inch or greater diameter, the pipe support, seismic
restraint, or other piping system mounting element shown on the Drawings may
be used for the piping less than 20-inch diameter.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-3
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
5.
Where a specific support, hanger, guide, structural attachment, anchor, joint, or
seismic restraint detail for pipe less than 20-inch diameter is shown, it shall be
to indicate the required configuration or general arrangement to be developed
by the Contractor’s Design Professional.
6.
Design, select, locate, and provide piping supports, pipe guides, and seismic
restraint required for final piping layout.
B.
Review the piping layout in relation to the surrounding structure and adjacent piping
and equipment before selecting the restraint to be used at each point.
C.
Seismic restraints may be omitted from the following installations:
1.
Gas piping less than 1-inch inside diameter.
2.
Piping in boiler and mechanical rooms less than 1 1/4-inch inside diameter.
3.
All other piping less than 2 1/2-inch inside diameter.
4.
All piping suspended by individual hangers 12 inches or less in length from the
top of the pipe to the bottom of the structural attachment for the hanger.
D.
Piping systems shall not be braced to dissimilar parts of a building or to dissimilar
building systems that may respond in a different mode during an earthquake.
Examples: wall and a roof; solid concrete wall and a metal deck with lightweight
concrete fill.
E.
Restraints shall be sized to fit the outside diameter of the pipe, tubing or, where
specified, the outside diameter of insulation.
F.
There shall be no contact between a pipe and restraint component of dissimilar
metals. Prevent contact between dissimilar metals when restraining copper tubing
by the use of copper-plated, rubber, plastic or vinyl-coated, or stainless steel restraint
components.
G.
Branch lines shall not be used to brace main lines.
H.
Seismic bracing shall not limit the expansion and contraction of the piping system.
PART 2--PRODUCTS
2.01
GENERAL
A.
ACCEPTABLE MANUFACTURERS:
1.
2.
3.
4.
Carpenter & Patterson
Cooper B-Line
Cooper Kin-Line.
ITT Grinnell
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-4
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
5.
6.
7.
8.
9.
B.
2.02
Pipe restraint material design, manufacture, installation, and application shall
conform to the requirements of MSS SP-58, MSS-SP-69, MSS-SP-89, MFMA-1, and
MFMA-101.
MATERIALS
A.
2.03
Michigan Hanger, Co.
Pipe Shields Incorporated
Thomas & Betts Superstrut
Unistrut
Or approved equal
Unless otherwise specified, materials for seismic restraints shall be as specified in
Section 15096.
THERMAL PIPE HANGER SHIELD
A.
Thermal shields shall be provided at seismic restraint locations on pipe requiring
insulation. Thermal pipe hanger shields shall be as specified in Section 15096.
Stainless steel band clamps shall be provided on thermal shields at longitudinal pipe
restraint locations.
PART 3--EXECUTION
3.01
PIPE RESTRAINT LOCATIONS
A.
Locate the first seismic restraint on a piping system not more than 10 feet from the
main riser, from an entrance to a building, or from a piece of equipment.
B.
Brace cast iron soil pipe on each side of a change in direction of 90 degrees or more.
Brace or stabilize joints in risers between floors.
C.
Brace no-hub and bell and spigot cast iron soil pipe longitudinally every 20 feet and
laterally every 10 feet.
D.
Lateral bracing for one pipe section may also act as longitudinal bracing for the pipe
section connected perpendicular to it, by an elbow, if the bracing is installed within
24 inches of the elbow.
E.
Seismic restraint locations and components shall be indicated on the piping layout
drawings required by Section 15050. The Contractor shall provide a legend giving load
information and restraint component selection at each restraint location.
Piping systems with thermal expansion control anchors shown on the Drawings shall
utilize those anchors for longitudinal seismic bracing.
F.
Seismic bracing shall not hinder the functioning of thermal expansion control systems,
but shall accommodate longitudinal movement of piping due to temperature changes.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-5
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
3.02
3.03
G.
Where pipe guides are specified on the drawings, the expansion control anchors are
designed to resist longitudinal seismic loads. Longitudinal seismic bracing is not
permitted at any point along the pipe section between anchors where pipe guides are
indicated on the piping. Longitudinal movement of the pipe shall be unrestricted by
pipe hangers, supports, seismic restraints or other appurtenances installed by the
Contractor where pipe guides are indicated on a pipe section.
H.
Where pipe guides are specified on the Drawings, they shall be placed as specified and
braced/restrained for the maximum lateral load capacity of the specified pipe guides.
INSTALLATION
A.
Use rod stiffener assemblies at seismic restraints for hanger rods over 6 inches in
length. Use a minimum of two rod stiffener clamps on any rod stiffener assembly.
B.
Install lateral and longitudinal bracing between 45 degrees above and 45 degrees
below horizontal, inclusive, relative to the horizontal centerline of the pipe.
C.
Welded and bolted attachments to the building structural steel shall be in accordance
with the requirements of AISC. Do not drill or burn holes in the building structural steel
without approval of the City.
D.
Use embedded anchor bolts instead of concrete inserts for seismic brace installations in
areas below water surface or normally subject to submerging.
E.
Install thermal pipe hanger shields on insulated piping at required locations during
restraint installation. Make butt joint connections to pipe insulation at the time of
insulation installation in accordance with the manufacturer's recommendations.
F.
Restraint components in contact with plastic pipe shall be free of burrs and sharp edges
and shall be lined between the pipe and restraint with a layer of rubber sheet.
G.
Rollers shall roll freely without binding.
H.
Provide plastic or rubber end caps at the exposed ends of all framing channels that are
located up to 7 feet above the floor.
INSPECTION AND CERTIFICATION
A.
The Design Professional retained by the Contractor under the provisions of Section
15050 shall provide inspection and written certification of construction conformance in
accordance with Section 15096 requirements.
B.
The City will provide special inspection in accordance with Section 01900 for piping
seismic restraint and bracing systems.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-6
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
3.04
MEASUREMENT AND PAYMENT
A.
Seismic restraints for piping shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15097-7
ADDENDUM NO. 3
SEISMIC RESTRAINTS FOR PIPING
SECTION 15118
SPRING-LOADED SWING CHECK VALVES
PART 1--GENERAL
1.01
DESCRIPTION
A.
1.02
This Section specifies spring-loaded swing check valves.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this Section shall prevail. Unless
otherwise specified, references to documents shall mean the documents in effect on
the effective date of the Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replacement documents issued or otherwise identified by that organization or, if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
1.03
Title
ASTM A126
Gray Iron Castings for Valves, Flanges, and Pipe Fittings
ASTM A276
Stainless and Heat-Resisting Steel Bars and Shapes
ASTM A536
Ductile Iron Castings
ASTM B148
Aluminum-Bronze Sand Castings
AWWA C508
Swing-Check Valves for Waterworks Service, 2 In. Through 24 In.
NPS
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations.
2.
Manufacturer's catalog information including dimensions, cross sectional views,
details of construction.
3.
Affidavits of compliance with AWWA C508 shall be provided.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15118-1
ADDENDUM NO. 3
SPRING-LOADED CHECK VALVES
1.04
PERFORMANCE REQUIREMENTS
A.
DESIGN REQUIREMENTS: Disc, disc arm, shaft, keyways, lever and spring shall be
heavily reinforced and designed for resistant to impact forces resulting from hydraulic
transients. The design of the keyways, shafts, keys, lever arms, springs, spring anchors
and all related parts shall be designed to withstand the forces associated with a spring
tension that requires not less than a 5 psig differential pressure across the valve leaf to
open the valve. Spring tension shall be adjustable and initially set for a 2 psig
differential to open the valve. The valve design shall permit mounting levers and springs
on either side of the valve. The design of the spring attachment shall permit adjustment
of closing force by tensioning the spring or replacement with different active length
springs.
PART 2--PRODUCTS
2.01
CANDIDATE MANUFACTURERS/ PRODUCTS/ MATERIALS
A.
Candidate manufacturers are specified by valve type within this Section. The
manufacturer’s standard models or products may require modification to conform to
specified requirements. Candidate manufacturers include:
1.
2.
3.
2.02
APCO. Series 6000
Flomatic, Series 92 LS
Or approved equal.
MATERIALS
A.
Materials of construction shall be as follows:
Component
2.03
Material
Body, cover, Disc
Cast iron, ASTM A126, Class B
Disc arm
Ductile iron, ASTM A536
Seat rings
Aluminum bronze, ASTM B148 or Stainless steel,
ASTM A276, Type 316
Hinge shafts and hinge pins
Stainless steel, ASTM A276, Type 301, 303 or
304
Shaft bushings
Bronze, AWWA C508
All fastening hardware
Stainless steel, ASTM A276, Type 316
FEATURES
A.
PIVOT ARM:
1.
Valve design shall permit mounting pivot arm and springs on either side of the
valve.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15118-2
ADDENDUM NO. 3
SPRING-LOADED CHECK VALVES
B.
C.
2.
The design of the spring attachment shall permit adjustment of closing force by
tensioning the spring or replacement with different active length springs.
3.
The pivot arm shall be secured to the pivot shaft with either twin bolted
connections with lockwashers or a pinned nut.
4.
Disc and pivot arms shall be keyed to the pivot shaft and retained by bushings
or pins.
SEAT:
1.
Valves shall be provided with a clear opening equal to or greater than the
connecting piping, with no raised seating surface.
2.
Seats shall be threaded onto the body or fitted with an O-ring seal and locked in
place with stainless steel screws or pins and shall be replaceable.
PIVOT SHAFT:
1.
Shafts shall be provided with stuffing box and packing or O-ring seals at each
end.
2.
Shaft seals shall be externally replaceable.
3.
Shaft bearings shall extend the entire length of the shaft other than the section
required for the disc arm attachment.
4.
Minimum shaft diameters shall be as follows:
Valve Inlet Connection
Size, inches
Shaft diameter,
inches
3
0.75
4
0.825
6
1.0
8
1.75
10
2.0
12
2.5
14
2.75
16
3.25
18
3.5
20
3.75
24
3.75
30
3.75
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15118-3
ADDENDUM NO. 3
SPRING-LOADED CHECK VALVES
D.
Unless otherwise specified, valves shall, as a minimum, conform to the following
pressure ratings:
Size, inches
Working pressure,
pressure, psig
Hydrostatic test
2 through 12
175
350
14 through 30
150
300
E.
Ferrous metal wetted parts shall be coated with fusion bonded epoxy.
F.
POSITION MONITORING.
1.
Check valve manufacturer shall supply position monitoring limit switches and
associated mounting hardware as required. Provide limit switches per Section
17216.
PART 3--EXECUTION
3.01
INSTALLATION
A.
3.02
GENERAL: Install valves in accordance with the manufacturer's written
recommendations.
COATINGS
A.
PROCEDURES: Section 09900.
B.
PRIMER COATING:
1.
2.
C.
FINISH COATING:
1.
2.
3.03
Per Section 09900.
Shop applied
Per Section 09900.
Field applied
COMPONENT TEST PHASE
A.
OPERATION TEST: Demonstrate successful performance of devices in conjunction with
connected piping system and pump.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15118-4
ADDENDUM NO. 3
SPRING-LOADED CHECK VALVES
3.04
MEASUREMENT AND PAYMENT
A.
Spring-loaded check valves shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15118-5
ADDENDUM NO. 3
SPRING-LOADED CHECK VALVES
SECTION 15121
PRESSURE REGULATING VALVES
PART 1--GENERAL
1.01
1.02
DESCRIPTION
A.
SCOPE: This Section specifies direct acting and pilot controlled pressure control valves
for air, water and gas service. Pressure relief valves for boilers, expansion tanks,
hydropneumatic tanks, pressure vessels, and other equipment are specified with the
equipment that they serve/protect.
B.
EQUIPMENT LIST: Pressure regulating valves used in seal water control units are
scheduled in Section 15130. All other pressure regulating valves are scheduled here in
paragraph 15121-1.03.
C.
DEFINITIONS: Terminology used in this Section conforms to the following definitions:
1.
Pressure regulating/reducing valve: maintains a consistent pressure
downstream of the valve.
2.
Back pressure sustaining valve: maintains a consistent pressure upstream of
the valve.
3.
Pressure relief valve: Opens to relieve pressure in excess of a set pressure
value.
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this Section shall prevail. Unless
otherwise specified, references to documents shall mean the documents in effect on
the effective date of the Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replacement documents issued or otherwise identified by that organization or, if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
ANSI B16.5
B.
Title
Pipe Flanges and Flanged Fittings
FACTORY TESTS:
1.
Hydrostatic tests shall be conducted by the manufacturer for one valve of each
type supplied for a particular service.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15121-1
ADDENDUM NO. 3
PRESSURE REGULATING VALVES
1.03
2.
Steel-bodied valves shall be hydrostatically tested in accordance with the
requirements of ANSI B16.5.
3.
Aluminum-, bronze-, and brass-bodied valves shall be hydrostatically tested at
double the maximum pressure specified for the piping service in the PIPESPEC
(Section 15050).
4.
Leakage, sweating or visible deformation at any point on the valve shall be
cause for rejection of valves of that type and manufacture.
PERFORMANCE REQUIREMENTS
A.
OPERATING CONDITIONS
Valve number
Valve
type
Service
Valve size,
inches
Maximum flow,
scfm or gpma
Maximum inlet
pressure, psig
Pressure control
set pointb, psig
PRV 200,410
V815
1W
2
30
80
60
PRV 200,419
V815
RW2
6
500
500
110
80
PRV 200,086
V820
SA
1-1/2
150
175
115
PRV 300,431
V811
1W
1
5
80
60
PRV 200,424
V815
RW2
4
300
80
70
PRV 400,412
V811
1W
1
5
80
60
PRV 800,413
V811
1W
1
20
80
60
a Values
b
in units of scfm for Type 820, otherwise values in units of gpm.
Equal to Maximum Inlet Pressure for back pressure sustaining valves
B.
1.04
DESIGN REQUIREMENTS:
1.
Direct acting type pressure regulating/reducing control valves shall control
pressure within ±5 percent of the pressure control set point.
2.
Pilot controlled type pressure regulating/reducing valves and back pressure
sustaining valves shall maintain the pressure control set point regardless of
fluctuations in flow and pressure.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations.
2.
Manufacturer’s data including product literature, materials of construction,
construction details of equipment, wiring diagrams, and weight of equipment.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15121-2
ADDENDUM NO. 3
PRESSURE REGULATING VALVES
3.
Hydrostatic test results.
PART 2--PRODUCTS
2.01
2.02
CANDIDATE MANUFACTURERS/PRODUCTS/MATERIALS
A.
Candidate manufacturers are specified by valve type within this Section. The
manufacturer’s standard models or products may require modification to conform to
specified requirements.
B.
Valves shall be provided by type, as specified, and constructed of the following
materials, unless otherwise specified.
MATERIALS
A.
Type V811, Pressure Regulating/Reducing, Direct Acting, Water Service, less than 1-1/4
inches:
1.
Materials:
Component
2.
Seat
Stainless Steel
Diaphragm
Buna-N
Spring
Stainless Steel
Body
Lead free Bronze
All fastening
hardware
Stainless steel, ASTM A276, Type 316
Manufacturers and Products:
a.
b.
c.
3.
B.
Material
Cash-Acme E-41
Watts 223
Or approved equal
Furnish with separate Y-pattern strainer per 15095.
Type V815, Pressure Regulating/Reducing, Pilot Controlled, Water Service, 1-1/4 inches
and larger:
1.
Materials:
Component
Material
Diaphragm
Nylon reinforced Buna-N
Disc
Buna-N
Stem, Nut, and Spring
Stainless steel, ASTM A276, Type 316
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15121-3
ADDENDUM NO. 3
PRESSURE REGULATING VALVES
Component
2.
Trim
Stainless steel, ASTM A276, Type 316
Body and Cover
Ductile iron, ASTM A536
All fastening hardware
Stainless steel, ASTM A276, Type 316
Manufacturers and Products:
a.
b.
c.
C.
Material
Cla-Val Co., Model 90-01
Ames, 910 Series
Or approved equal
Type V816, Back Pressure Sustaining, Pilot Controlled, Water Service, 1-1/2 inches and
larger:
1.
Materials:
Component
2.
Diaphragm
Nylon reinforced Buna-N
Disc
Buna-N
Stem, Nut, and Spring
Stainless steel, ASTM A276, Type 316
Trim
Stainless steel, ASTM A276, Type 316
Body and Cover
Ductile iron, ASTM A536
All fastening hardware
Stainless steel, ASTM A276, Type 316
Manufacturers and Products:
a.
b.
c.
D.
Material
Cla-Val Co., Model 50-AE
Watts, F116/F1116
Or approved equal
Type V820, Pressure Regulating/Reducing, Direct Acting, Air Service:
1.
Materials:
Component
Material
Seat
Stainless Steel
Diaphragm
Buna-N
Spring
Stainless Steel
Body
Lead free Bronze
All fastening
hardware
Stainless steel, ASTM A276, Type 316
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15121-4
ADDENDUM NO. 3
PRESSURE REGULATING VALVES
2.
Manufacturers and Products:
a.
b.
c.
3.
E.
Watts, Series 152A
Spirax_Sarco, Models 25MP, BRV 71/73
Or approved equal
Furnish with separate Y-pattern strainer per 15095
Type V825, Pressure Regulating/Reducing, Pilot Controlled, Natural Gas Service, AGA
Approved:
1.
Materials:
Component
2.
Orifice
Brass
Diaphragm cases
Die Cast Aluminum Alloy
Diaphragm
Buna-N with nylon fabric insert
Seat sealing surface
Neoprene, EPDM or Buna N
Body
Cast iron, ASTM A126, Class B
All fastening
hardware
Stainless steel, ASTM A276, Type 316
Manufacturers and Products:
a.
b.
c.
2.03
Material
Fisher, Model 1098-EGR
Sensus, Model 243 RPC
Or approved equal
FEATURES:
A.
GENERAL: Pressure control valves shall be flanged or threaded connections as
specified. Moving parts requiring lubrication shall have means provided for lubrication
and shall be lubricated prior to delivery.
B.
GAS SERVICE: Valves for gas service shall conform to all AGA regulations and criteria.
Valves shall be sized as recommended by the manufacturer for the intended use.
PART 3--EXECUTION
3.01
GENERAL
A.
Pressure control valves shall be installed in accordance with the manufacturer's
recommendations.
B.
Install take-aparts on both ends of the pressure control valves and the strainers.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15121-5
ADDENDUM NO. 3
PRESSURE REGULATING VALVES
3.02
MEASUREMENT AND PAYMENT
A.
Pressure regulating valves shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15121-6
ADDENDUM NO. 3
PRESSURE REGULATING VALVES
SECTION 15130
SEAL WATER CONTROL UNIT SCHEDULE
PART 1 GENERAL
1.01
SUMMARY
A.
1.02
QUALITY ASSURANCE
A.
1.03
1.04
1.05
GENERAL: This section contains the schedule of control units for this Work.
Control units shall be supplied to control the flow of seal water to pumps and other
specified devices. Rotameters shall be as specified in Section 15095. Solenoid valves
shall be as specified in Section 15147. Control unit configuration shall be in
accordance with Detail A/M-012.
REFERENCED STANDARDS: Not Used.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A layout Drawing of the control units.
2.
Catalog data for equipment.
VALVE SIZING
A.
Where the specific valve is smaller than the connected pipe, the Contractor shall
provide reducers.
B.
Pressure drop across each valve for the purpose of actuator sizing shall be the
"maximum" pressure for the service as listed on the PIPESPEC sheets in Section 15050.
SCHEDULES
A.
The following table contains the schedule of control units.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15130-1
ADDENDUM NO. 3
SEAL WATER
CONTROL UNIT SCHEDULE
Control Unit Tablea
Control unit
number and
type
CU 200,001
Solenoid valve
numbersb
Flow switch
numbers
Supply
piping to
control unit
1" 2W
Piping to
equipmentc
1/2" 2W
1/2” 2W
1/2” 2W
Type 811
PRV setting
(psi)
65
Solenoid valve flow
range/initial
setting (gpm)
0-1/0.5
0-1/0.5
0-1/0.5
P 200,110
P 200,120
P 200,130
Gland seal
Equipment
served
Control unit
usage
SV 200,110
SV 200,120
SV 200,130
FSL 200,110
FSL 200,120
FSL 200,130
CU 200,002
SV 200,210
SV 200,220
SV 200,230
FSL 200,210
FSL 200,220
FSL 200,230
1” 2W
1/2” 2W
1/2" 2W
1/2" 2W
65
0-1/0.5
0-1/0.5
0-1/0.5
P 200,210
P 200,220
P 200,230
Gland seal
CU 300,003
SV 300,220
SV 300,320
FSL 300,220
FSL 300,320
1” 2W
1/2” 2W
1/2” 2W
50
0-1/0.5
0-1/0.5
P 300,220
P 300,320
Gland seal
aControl
units shall be in accordance with Detail A/M-012.
flow switch shall be provided with each solenoid valve. The flow switch shall be located in accordance with Detail A/M-012.
cWhere control unit pipe size differs from equipment connection, the Contractor shall provide reducers.
bA
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15130-2
ADDENDUM NO. 3
SEAL WATER
CONTROL UNIT SCHEDULE
PART 2 PRODUCTS
Not used.
PART 3 EXECUTION
3.01
MEASUREMENT AND PAYMENT
A.
Seal water control units shall not be paid for directly, but shall be considered incidental
and included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15130-3
ADDENDUM NO. 3
SEAL WATER
CONTROL UNIT SCHEDULE
SECTION 15185
MOTORIZED ACTUATORS AND SCHEDULE FOR VALVES AND GATES
PART 1--GENERAL
1.01
SUMMARY
A.
SCOPE: This Section specifies motorized actuators for valves and gates.
B.
DEFINITIONS: For purposes of this Section, the word “valve” refers to both valves and
gates. Motorized actuators are defined as follows:
Type
1.02
Definition
EMTT
Electric Motor, Multi-Turn, Throttling
EQTT
Electric Motor, Quarter-Turn, Throttling
EMTI
Electric Motor, Multi-Turn, Isolating
EQTI
Electric Motor, Quarter-Turn, Isolating
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this Section shall prevail. Unless
otherwise specified, references to documents shall mean the documents in effect on
the effective date of the Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replacement documents issued or otherwise identified by that organization or, if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
Title
NEMA ICS
Industrial Control Devices, Controllers and Assemblies
FM 3615
Approval Standard for Explosion Proof Electrical Equipment
General Requirements
UL 429
Electrically Operated Valves
UL 1002
Electrically Operated Valves for Use in Hazardous Locations,
Class I, Groups A, B, C, and D, and Class II, Groups E, F, and G
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-1
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
1.03
1.04
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations from
Section requirements.
2.
Manufacturer's catalog information and other data confirming conformance to
specified requirements. Information to include description of actuator and valve
conditions that activate TROUBLE alarm contacts.
3.
Application sheets and schedules for each actuator showing required mounting,
operating torque for driven equipment, torque capacity of actuator, and
electrical connection requirements for actuator’s specified service. Actuator
identification (tag) number shall be based on the associated valve or gate and
shall be clearly tagged.
4.
List of components provided for each actuator.
5.
Installation and training forms.
6.
Operating and maintenance data in accordance with Section 01730.
7.
Devicenet configuration file, Electronic Data Sheet (EDS).
SCHEDULES
A.
The following schedule includes powered valves and gates on the project. Control valves
or HVAC valves with operators are covered elsewhere.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-2
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
Valve and Gate Schedule
SG
100,001
Gate/11109
RS
101
Valve/
gate
size
(in)
48 x 48
EMTI
Diff/
design
press
(psig)a
1.1
NEMA 4X
Last
SG
100,002
Gate/11109
RS
101
48 x 48
EMTI
1.1
1 fpm
NEMA 4X
Last
SG
100,101
Gate/11109
RS
102
42 x 80
EMTI
2.5
1 fpm
NEMA 4X
Last
SG
100,109
Gate/11109
RS
102
42 x 80
EMTI
2.4
1 fpm
NEMA 4X
Last
SG
100,182
Gate/11109
RS
111
48 x 48
EMTI
2.6
1 fpm
NEMA 4X
Last
55 x 55
EMTTb
29
1 fpm
NEMA 4X
Last
Equip Number
Type/Spec
Service
PID
Line
size
(in)
Oper
type
Open
close
time
(sec)
1 fpm
Enclosure
DeviceNet
Remote
control
station
Fail
SG
200,101
Gate/11109
RS
201
CV
200,111
Plug/15110
RS
201
20
20
EQTI
50
30
NEMA 4X
Last
CV
200,121
Plug/15110
RS
201
20
20
EQTI
50
30
NEMA 4X
Last
20
CV
200,131
Plug/15110
RS
201
SG
200,201
Gate/11109
RS
202
20
EQTI
50
30
NEMA 4X
Last
55 x 55
EMTTb
29
1 fpm
NEMA 4X
Last
CV
200,211
Plug/15110
RS
202
20
20
EQTI
50
30
NEMA 4X
Last
CV
200,221
Plug/15110
RS
202
20
20
EQTI
50
30
NEMA 4X
Last
CV
200,231
Plug/15110
RS
202
20
20
EQTI
50
30
NEMA 4X
Last
CV
200,113
Plug/15110
RS
204
14
14
EQTI
100
15
NEMA 4X
Last
CV
200,123
Plug/15110
RS
204
14
14
EQTI
100
15
NEMA 4X
Last
CV
200,133
Plug/15110
RS
204
14
14
EQTI
100
15
NEMA 4X
Last
CV
200,213
Plug/15110
RS
205
14
14
EQTI
100
15
NEMA 4X
Last
CV
200,223
Plug/15110
RS
205
14
14
EQTI
100
15
NEMA 4X
Last
CV
200,233
Plug/15110
RS
205
14
14
EQTI
100
15
Last
CV
200,312
Plug/15110
RS
206
10
10
EQTI
75
15
CV
200,322
Plug/15110
RS
206
10
10
EQTI
75
15
CV
200,332
Plug/15110
RS
206
10
10
EQTI
75
15
CV
200,103
Plug/15110
RS
208
30
30
EQTI
75
20
NEMA 4X
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
NEMA 4X
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-3
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES AND GATES
Last
Last
Last
Last
CV
200,203
Plug/15110
RS
208
30
Valve/
gate
size
(in)
30
CV
200,002
Plug/15110
RS
208
30
30
EQTI
75
CV
200,003
Plug/15110
RS
208
30
30
EQTI
SG
300,113
Gate/11109
RS
311
30 x 30
SG
300,123
Gate/11109
RS
311
SG
300,133
Gate/11109
RS
SG
300,111
Gate/11109
SG
300,121
SG
Equip Number
Type/Spec
Service
PID
Line
size
(in)
EQTI
Diff/
design
press
(psig)a
75
Open
close
time
(sec)
20
Oper
type
Enclosure
DeviceNet
Remote
control
station
Fail
NEMA 4X
Last
20
NEMA 4X
Last
75
20
Last
EMTI
4.3
1 fpm
20 x 20
EMTI
4.3
1 fpm
311
30 x 30
EMTI
4.3
1 fpm
RS
311
36 x 98
EMTI
1.9
1 fpm
Gate/11109
RS
311
36 x 98
EMTI
1.9
1 fpm
300,131
Gate/11109
RS
311
36 x 98
EMTI
1.9
1 fpm
SG
300,112
Gate/11109
RS
311
36 x 71
EMTI
1.1
1 fpm
SG
300,122
Gate/11109
RS
311
36 x 71
EMTI
1.1
1 fpm
SG
300,132
Gate/11109
RS
311
36 x 71
EMTI
1.1
1 fpm
SG
300,171
Screenings
312
12
EMTI
NA c
1 fpm
SG
300,172
Screenings
313
12
EMTI
NA c
1 fpm
SG
300,211
Gate/11109
RS
321
60 x 100
EMTI
1.5
1 fpm
SG
300,311
Gate/11109
RS
321
60 x 100
EMTI
1.5
1 fpm
SG
300,161
Gate/11109
RS
321
48 x 48
EMTI
2.4
1 fpm
CV
300,225
Plug/15110
Grit
322
6
6
EQTI
50
15
CV
300,251
Plug/15110
Grit
322
6
6
EQTI
50
15
NEMA 4X
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
Knife
Gate/15102
Knife
Gate/15102
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-4
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES AND GATES
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Last
Equip Number
Type/Spec
Service
PID
Line
size
(in)
6
Valve/
gate
size
(in)
Oper
type
Diff/
design
press
(psig)a
Open
close
time
(sec)
6
EQTI
50
15
Enclosure
DeviceNet
Remote
control
station
Fail
CV
300,325
Plug/15110
Grit
323
SG
300,413
Gate/14553
Scr/Grit
326
13 x 17
EMTI
NA d
1 fpm
SG
300,414
Gate/14553
Scr/Grit
326
13 x 17
EMTI
NA d
1 fpm
SG
300,415
Gate/14553
Scr/Grit
326
13 x 17
EMTI
NA d
1 fpm
SG
300,423
Gate/14553
Scr/Grit
326
13 x 17
EMTI
NA d
1 fpm
SG
300,424
Gate/14553
Scr/Grit
326
13 x 17
EMTI
NA d
1 fpm
SG
300,425
Gate/14553
Scr/Grit
326
13 x 17
EMTI
NA d
1 fpm
SG
600,001
Gate/11109
RS
601
36 x 36
EMTI
1.3
1 fpm
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
FM Class I,
Gr D, Div 1
NEMA 4X
SG
600,002
Gate/11109
RS
601
36 x 36
EMTI
1.3
1 fpm
NEMA 4X
Last
SG
600,003
Gate/11109
RS
601
48 x 48
EMTI
1.3
1 fpm
NEMA 4X
Last
SG
700,101
Gate/11109
RS
701
42 x 110
EMTI
3.5
1 fpm
NEMA 4X
Last
SG
700,201
Gate/11109
RS
701
42 x 110
EMTI
3.5
1 fpm
NEMA 4X
Last
See Section 11109 for slide gate design conditions
Throttling actuators for gates SG 200, 101 and SG 200, 201 shall be capable of at least 300 starts per hour
c Knife gates and actuators for isolation of sluiceway at screenings washer/compactor will be supplied as part of the headworks screen and sluiceway package
(see Sections 11129, 15102, and 15185).
d Gates and actuators for discharge points at screenings/grit screw conveyors will be supplied as part of the conveyor package (see Section 14553 and 15185).
a
b
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-5
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES AND GATES
Last
Last
Last
Last
Last
Last
Last
Last
PART 2--PRODUCTS
2.01
ACCEPTABLE MANUFACTURERS/PRODUCTS
A.
2.02
Candidate manufacturers are listed for each actuator type. The manufacturer’s
standard models or products may require modification to conform the specified
requirements.
FEATURES
A.
B.
GENERAL: Provide actuators in accordance with the actuator specification sheets
(ACTUSPEC) located at the end of this Section, and provide the following features:
1.
Factory mount actuator on the valve, and provide as a unit. Each valve body or
actuator shall have cast thereon the word “OPEN,” and arrows indicating the
direction to open and flow direction.
2.
Size actuators to produce an operating torque equal to twice the maximum
torque required at the specified flow conditions.
3.
Provide actuators capable of operating at a minimum temperature of -20
degrees Celsius.
4.
Power supply: 480 V, 3 phase, 60Hz with a +/-10 percent voltage fluctuation.
5.
Provide actuator listed for intended use by an independent testing laboratory.
Four such organizations are Underwriters Laboratories (UL), Canadian
Standards Association (CSA), Factory Mutual (FM), and Electrical Testing
Laboratories (ETL). The independent testing laboratory to be acceptable to
the inspection authority having jurisdiction.
6.
Actuators shall be equipped with a heater to alleviate internal condensation.
MOTOR: Motor shall be heavy duty, designed specifically for valve actuator service, with
the following features:
1.
The motor shall be an integral part of the actuator, designed specifically for
valve actuator applications. It shall be a low inertia high torque design.
2.
NEMA Class F insulation.
3.
Three thermostats embedded in motor end windings integrated into controls for
thermal protection.
4.
Automatic motor thermostat reset once the motor has cooled sufficiently after
an overload.
5.
De-energize within 8 seconds in the event of a stall when attempting to unseat a
jammed valve.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-6
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
C.
6.
De-energize upon loss of a single phase of three phase power supply.
7.
Automatic detection and correction of three-phase power supply to proper
open/close directions.
ENCLOSURE: Provide NEMA 4, NEMA 4X, NEMA 6, or Factory Mutual Certified NEMA 7
Explosion Proof in accordance with the schedules.
1.
Actuators shall be double O-ring sealed, watertight to IP66/IP68 6m for 72
hours, NEMA 4, 4X, 6. The motor and all other internal electrical elements of the
actuator shall be protected from ingress of moisture and dust when the terminal
cover is removed for site for cabling, the terminal compartment having the same
ingress protection rating as the actuator with the terminal cover removed.
2.
Enclosure must allow for temporary site storage without the need for electrical
supply connection. All external fasteners shall be plated stainless steel. The use
of un-plated stainless steel or steel fasteners is not permitted.
D.
MOTOR STARTER: Provide a three phase full voltage reversing starter rated at 30amperes both mechanically and electrically interlocked with overload protection or
elements in each of the three poles.
E.
CONTROL TRANSFORMER:
1.
Epoxy encapsulated and impregnated with short circuit and overload protection.
2.
Rated, at a minimum, to handle 80 percent of the connected load with 120
VAC secondary or other secondary voltage of 24 VDC as required.
3.
Adequately rated to provide power for the following functions:
a.
b.
c.
F.
DISCONNECT SWITCH: Provide a lockable, heavy-duty, non-fused, UL listed disconnect
switch for mounting near actuator. Where actuated valve is out-of-reach, locate the
disconnect switch on an adjacent wall at an accessible level.
1.
G.
Energizing of the contactor coils.
24 VDC output for remote controls.
Internal electrical circuits.
Where depicted on the electrical drawings provide Suitable Use for Service
Entrance (SUSE) rated disconnected switch.
GEARING:
1.
Totally enclosed in a oil-filled gearcase suitable for operation at any angle.
Grease lubrication is not permissible.
2.
All drive gearing and components must be of metal construction and
incorporate a lost-motion hammerblow feature.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-7
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
H.
3.
For rising stem valves, the output shaft shall be hollow to accept a rising stem,
and incorporate thrust bearings of the ball or roller type at the base of the
actuator. The design should be such as to permit the opening of the gearcase
for inspection or disassembled without releasing the stem thrust or taking the
valve out of service.
4.
For quarter turn valves, drive gearing shall be self locking to prevent the valve
back-driving the actuator.
TORQUE AND LIMITS:
1.
I.
Torque and turns limitation to be adjustable as follows:
a.
Position setting range for multi-turn actuators: 2.5 to 8,000 turns, with
resolution to 7.5 degrees of actuator output.
b.
Position setting range for direct drive quarter turn actuators: 80 to 100
degrees, with resolution to 0.1 degree of actuator output.
c.
Torque setting: 40 to 100 percent rated torque.
2.
Position measurement: Absolute position measurement shall be incorporated
within the actuator. The technology shall be capable of reliably measuring
position with power interruptions. The design shall be simple with no more
than five moving parts. Technologies using LEDs or potentiometers for
position measurement are not acceptable.
3.
Measurement of torque shall be from direct measurement of force at the
output of the actuator. Methods of determining torque-using data derived
from the motor such as motor speed, current, flux, etc. are not acceptable.
4.
A means for automatic “torque switch bypass” to inhibit torque off during
valve unseating and “latching” to prevent torque switch hammer under
maintained or repeated control signals shall be provided.
5.
The electrical circuit diagram of the actuator should not vary with valve type,
remaining identical regardless of whether the valve is to open or close on
torque or position limit.
OPERATION:
1.
MANUAL OPERATOR: Provide a hand wheel for manual operation. The hand
wheel shall not rotate during motor operation nor shall a locked motor prevent
manual operation. Motor or manual selection shall be accomplished by a
positive declutching knob or lever which disengages the motor and motor
gearing mechanically but not electrically. Prohibit simultaneous manual and
motor operation. Hand operation shall not require more than 80 pounds of rim
effort at maximum torque.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-8
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
2.
CONTROL STATION: Provide a control station for each motorized gate and
valve. Control station to include:
a.
LOCAL, REMOTE, STOP, OPEN, and CLOSE controls through selector
switches and/or pushbuttons.
1)
In LOCAL, use the controls station’s momentary operation of
OPEN and CLOSE to position the valve or gate to full open or
full close. Configure for inching action in either travel
direction.
2)
In REMOTE, use momentary operation of the external OPEN or
CLOSE to cause the actuator to drive the valve or gate to the
appropriate limit for isolating service; use the external
position input signal for throttling service; or use the
DeviceNet bus communication when specified for isolating
and throttling services. Prevent the controls station’s OPEN
and CLOSE from operating the valve or gate.
3)
In STOP, prevent travel in either open or close direction in
both LOCAL and REMOTE.
b.
OPEN and CLOSE status lights as shown in interconnection diagrams.
c.
Provide remote mounted control station or remote mount the entire
motor control package including control power transformers and motor
reversing contactor when specified. Reference Contract Drawings.
3.
ACTUATOR DISPLAY: Provide a dedicated digital numeric display for indicating
the position in 1 percent increments. Provide a separate text display element,
with a minimum of 32 characters, to display position, torque, full open, full
close, power on, and communication okay. Provide amber, green, and white
lights to indicate open, closed, and intermediate valve positions, respectively.
The digital display shall be maintained and updated during handwheel
operation when power to the actuator is isolated.
4.
INDICATION CONTACTS: Provide single-pole, single-throw dry contacts rated a
minimum of 5 amps at 24VDC. Provide a minimum of four contacts
individually configurable as normally open or normally closed for valve
position, control status, valve trouble alarm, or actuator trouble alarm.
Configure contacts as specified on Contract Drawings.
5.
ACTUATOR COMMUNICATIONS: Provide DeviceNet when specified in addition
to external OPEN and CLOSE momentary control, and use for REMOTE
operation through the plant’s process control system as specified in Sections
17315 and 17850.
a.
Configuration: Provide Electronic Data Sheet (EDS).
b.
Compliance: ODVA.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-9
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
c.
Connection: Thick or thin cable as specified.
d.
Baud Rates: 125, 250 and 500 Kbit/sec (automatic baud rate
detection along with manual selection).
Current Draw: 30 mA or less.
e.
6.
f.
Node Address: Change default address (64 or 63) by coordinating
node address with System Integrator specified in Section 17000.
g.
Programmable failure of actuator on loss of Communication.
h.
Bus Access: Polling or explicit messaging.
i.
Supported Functions: Explicit connection, I/O poll connection,
Fragmentation, device heartbeat message, device shutdown
message, and offline connection set.
j.
Termination Resistor: Default in the off position.
k.
I/O Data Exchange Requirements: Program requirements per
Section 17315, PROGSPEC DN.
CONFIGURATION TOOL: Provide a configuration tool that can be used in
classified and non-classified area installations. Provide configuration tool as
non-intrusive device to view and setup the actuator parameters. Additionally,
provide a diagnostic data logger that can transfer actuator data to a personal
computer (PC) via wireless communications. Provide PC graphical user
interface software allowing actuator set-up configuration and data logger
information to be reviewed, analyzed and reconfigured. Provide wireless
communication link between PC and actuator allowing direct communication
without the use of a configuration tool. Provide one configuration tool with
software per every ten actuators.
J.
HAMMER BLOW DEVICE: Provide a built-in lost-motion device that allows sufficient
travel of the worm gear, prior to engaging the stem nut, for the motor to reach full
speed. This action shall impart a “hammer blow” to start the valve or gate in motion in
either direction. The load shall be shared equally by two lugs cast integrally on the drive
sleeve.
K.
CONDUIT OPENINGS: Provide three conduit openings: power, control, and instrument.
L.
IDENTIFICATION TAG: Provide a 16-gage stainless steel identification tag that bears the
equipment description and tag number of the actuator. Characters shall be 1/4 inch,
die-stamped. Identification tags shall be securely attached to the actuator in a readily
visible location using stainless steel screws or wire.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-10
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
PART 3--EXECUTION
3.01
INSTALLATION
A.
3.02
EQUIPMENT MOUNTING: Locate actuators with unobstructed access for operation and
maintenance.
1.
Do not obstruct walkways.
2.
Do not attach to handrails, process piping, or mechanical equipment.
3.
Do not locate where shock or vibration impairs their operation.
4.
Locate the remote mounted control station such that the controls and displays
have unobstructed access.
5.
Actuators shall have their manual operating accessory located between 48
inches and 60 inches above the finished floor.
6.
Identification tags shall be located in a clearly visible location on the valves. If
necessary, reposition and reattachment with stainless steel screws or wire.
7.
Power wiring and signal wiring shall comply with Division 16.
TESTING:
A.
Testing and commissioning shall be performed in accordance with Section 01660.
Each gate and valve shall be tested for each modes of operation including but not
limited to, open, close, modulation, Auto, Manual, and Network as well as the travel
rates, limit switches, jam and torque settings.
B.
Provide a factory-trained manufacturer’s representative at the site for the following
activities.
1.
COMPONENT TESTING:
a.
Inspect actuator’s electrical power, control, signal, communication
and grounding wiring for proper termination.
b.
Configure actuator and include:
c.
1)
DeviceNet settings: Address, transmission rate, bus loss
action, heartbeat interval, consumed path, and production
path.
2)
Actuator Settings: Limit switch, torque position, travel speed,
emergency function, and relay functions.
Test actuator DeviceNet in compliance with Sections 17030, 17315
and 17850. Provide DeviceNet testing collaboration with Section
17030 – Testing Manager.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-11
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
2.
3.03
3.04
SYSTEM AND OPERATIONAL TESTING: Assist and supervise local, remote and
network control testing of the valves and gates in compliance with Section
17030. Provide testing collaboration for operation through the plant’s
process control system with Section 17030 – Testing Manager.
TRAINING:
A.
Provide two 4-hour instructional sessions, on separate days, conforming to the
requirements specified in Section 01664 and taught by a factory-trained
manufacturer’s representative.
B.
Include in training sessions preventive maintenance requirements, overhaul and
troubleshooting instructions, normal operating practices, actuator parameter
configuration set-up, changing actuator parameter settings, and DeviceNet
configuration. The factory-trained representative shall provide instruction
certification on Form 11000-B specified in Section 01999.
ACTUATOR SPECIFICATION SHEETS (ACTUSPEC)
A.
The following ACTUSPEC sheets are included in this section:
Type
3.05
Definition
EMTT
Electric Motor, Multi-Turn, Throttling
EQTT
Electric Motor, Quarter-Turn, Throttling
EMTI
Electric Motor, Multi-Turn, Isolating
EQTI
Electric Motor, Quarter-Turn, Isolating
MEASUREMENT AND PAYMENT
A.
Motorized actuators for valves and gates shall not be paid for directly, but shall be
considered incidental and included in the lump sum bids for the respective items in the
Proposal Schedule.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-12
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
3.04
ACTUATOR SPECIFICATION SHEETS (ACTUSPEC)
Type:
EMTT
Definition:
Electric Motor, Multi-Turn, Throttling Actuator
Features:
Rotork IQM, AUMA SAR or approved substitute
Controller shall consist of a solid-state electronic, servoamplifier comparator and an electro-mechanical reversing
starter. The controller shall accept an external 4 to 20 mA DC
isolated position input signal into a maximum load of 250
ohms.
Provide a current position transmitter providing an internally
fed 4-20 mA signal proportional to the valve position. The
current position transmitter shall be selectable for minimum
signal corresponding to fully closed or fully open position with
automatic zero and span setting. The maximum external
impedance that may be connected to the signal shall be 500
ohms at nominal supply voltage. Repeatability shall be within
+/- 1 percent and linearity shall be within +/- 1 percent of
total valve travel.
Capable of 900 starts per hour unless otherwise noted on the
Valve and Gate Schedule.
Controller shall compare the commanded position with the
actual position to produce an error signal. The controller shall
cause the motor to move the valve or gate in a direction so as
to reduce the magnitude of the error signal. The controller
positioning accuracy shall be plus or minus 1.0 percent of
travel, or better.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-13
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
3.04
ACTUATOR SPECIFICATION SHEETS (ACTUSPEC)
Type:
EQTT
Definition:
Electric Motor, Quarter-Turn, Throttling Actuator
Features:
Rotork IQM, AUMA SGR or approved substitute
Controller shall consist of a solid-state electronic, servoamplifier comparator and an electro-mechanical reversing
starter. The controller shall accept an external 4 to 20 mA DC
isolated position input signal into a maximum load of 250
ohms.
Provide a current position transmitter providing an internally
fed 4-20 mA signal proportional to the valve position. The
current position transmitter shall be selectable for minimum
signal corresponding to fully closed or fully open position with
automatic zero and span setting. The maximum external
impedance that may be connected to the signal shall be 500
ohms at nominal supply voltage. Repeatability shall be within
+/- 1 percent and linearity shall be within +/- 1 percent of
total valve travel.
Capable of 900 starts per hour.
Controller shall compare the commanded position with the
actual position to produce an error signal. The controller shall
cause the motor to move the valve or gate in a direction so as
to reduce the magnitude of the error signal. The controller
positioning accuracy shall be plus or minus 1.0 percent of
travel, or better.
Provide 90 degree gear box for actuators without internal
quadrant gear, if required to accommodate valve torque
requirement.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-14
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
3.04
ACTUATOR SPECIFICATION SHEETS (ACTUSPEC)
Type:
EMTI
Definition:
Electric Motor, Multi-Turn, Isolation Actuator
Features:
Rotork IQ, AUMA SA or approved substitute
Provide reversing starter, control transformer, and control station with
the actuator.
Capable of 60 starts per hour.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-15
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
3.04
ACTUATOR SPECIFICATION SHEETS (ACTUSPEC)
Type:
EQTI
Definition:
Electric Motor, Quarter-Turn, Isolation Actuator
Features:
Rotork IQ, AUMA SG or approved substitute
Provide reversing starter, control transformer, and control station with
the actuator.
Capable of 60 starts per hour.
Provide 90 degree gear box for actuators without internal quadrant
gear, if required to accommodate valve torque requirement
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15185-16
ADDENDUM NO. 3
MOTORIZED ACTUATORS AND
SCHEDULE FOR VALVES
AND GATES
SECTION 15400
PLUMBING
PART 1--GENERAL
1.01
DESCRIPTION
A.
1.02
This section specifies drains, piping, appurtenances and general requirements for
plumbing systems.
QUALITY ASSURANCE
A.
REFERENCES:
1.
This section contains references to the following documents. They are a part of
this section as specified and modified. Where a referenced document contains
references to other standards, those documents are included as references
under this section as if referenced directly. In the event of conflict between the
requirements of this section and those of the listed documents, the
requirements of this section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the
documents in effect at the time of Advertisement for Bids or Invitation to Bid
(or on the effective date of the Agreement if there were no Bids). If
referenced documents have been discontinued by the issuing organization,
references to those documents shall mean the replacement documents
issued or otherwise identified by that organization or, if there are no
replacement documents, the last version of the document before it was
discontinued. Where document dates are given in the following listing,
references to those documents shall mean the specific document version
associated with that date, regardless of whether the document has been
superseded by a version with a later date, discontinued or replaced.
Reference
1.03
UPC
Uniform Plumbing Code
SPC
State Plumbing Code (Hawaii)
ENVIRONMENTAL CONDITIONS
A.
1.04
Title
Plumbing shall be suitable for installation and service at a wastewater treatment
plant, under the environmental conditions specified in Section 01800.
SUBMITTALS
A.
PROCEDURES: Section 01300.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15400-1
ADDENDUM NO. 3
PLUMBING
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph checkmarked to indicate compliance or marked to indicate requested deviations.
2.
Brochures of plumbing equipment, including catalog data and installation
information.
PART 2--PRODUCTS
2.01
2.02
CLEANOUTS
A.
GENERAL: Unless otherwise specified, cleanouts shall be the same size as the pipe
connected. Cleanouts shall be provided with clamping collars where waterproofing
membranes are located in the floor. Cleanouts located inside buildings shall be
provided with bronze covers. Bronze plug with tapered thread shall be provided for
cleanouts on pressurized systems. Cleanouts on chemical waste or drain lines shall be
of the same material and type of joint as the pipe.
B.
TYPE I CLEANOUT: Unless otherwise specified, Type I cleanouts shall be Josam series
56010, J. R. Smith series 9760, or approved substitute.
C.
TYPE II CLEANOUT: Unless otherwise specified, Type II cleanouts shall be MIFAB series
P7040/P7060, J. R. Smith series 9760, or approved substitute.
D.
TYPE III CLEANOUT: Unless otherwise specified, Type III cleanouts shall be
StainlessDrains SDcDO-R42060, Wade series 8190-SS, or approved substitute.
E.
TYPE IV CLEANOUT: Unless otherwise specified, Type IV cleanouts shall be NIBCO series
4816 with bronze plug, Zurn series CO2410, or approved substitute.
F.
TYPE V CLEANOUT: Unless otherwise specified, Type V cleanouts shall be Josam series
58600-PLG, J. R. Smith series 4472, or approved substitute.
DRAINS
A.
FLOOR DRAINS:
1.
GENERAL: Floor drains shall be provided with clamping collars where
waterproofing membranes are located in the floor.
2.
TYPE I FLOOR DRAIN: Unless otherwise specified, Type I floor drains shall be
Kusel Equipment series KE-100 with side outlet, sediment bucket, and
perforated grate, Watts FD-100 (-SO) series with sediment bucket, 6” diameter
nickel bronze strainer, or approved substitute.
3.
TYPE II, III, AND IV FLOOR DRAINS: Unless otherwise specified, Type II, III, and IV
floor drains shall be Kusel Equipment series KE-100 with drilled grate,
perforated and perforated basket, Zurn series Z1726, or approved substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15400-2
ADDENDUM NO. 3
PLUMBING
4.
TYPE V FLOOR DRAIN: Unless otherwise specified, Type V floor drains shall be J.
R. Smith series 9725 with clamp ring and weep holes, Zurn series Z1726 with
10” diameter nickel bronze strainer, clamp ring, and seepage holes, or
approved substitute.
5.
TYPE VI FLOOR DRAIN: Unless otherwise specified, Type VI floor drains shall be
J. R. Smith series 9755, or approved substitute.
6.
TYPE VII FLOOR DRAIN: Unless otherwise specified, Type VII floor drains shall be
J. R. Smith series 9745-316, Mifab series F1100-RS-3-28, Zurn series Z1723,
or approved substitute.
6.
TYPE VIII FLOOR DRAIN: Unless otherwise specified, Type VIII floor drains shall
be J. R. Smith series 9700, Mifab series P3080-FL-HD, Zurn series Z1800-8BSGH, or approved substitute.
B.
ROOF DRAINS: Unless otherwise specified, roof drains shall be J. R. Smith series 1330
(-G-RBD), Josam series 21500-6 (-1-20-23-), or approved substitute.
C.
CONDENSATE DRAINS: Unless otherwise specified, condensate drains shall be as
specified for piping system 24 in Section 15050.
D.
TRENCH DRAINS:
1.
2.
2.03
Manufactured trench drain shall utilize a manufactured trench drain system.
Trench drain systems shall be pre-engineered, manufactured systems that
conform to the design loading listed below and with the following minimum
requirements:
a.
A method of forming around or V-bottom channel pre-sloped to a
minimum of 0.5 percent (1/16-inch per foot) installed in sections.
See drawings for channel cross section or size. If not shown, assume
6 inches wide and 6 inches deep (nominal) and confirm with the Officerin-Charge.
b.
Ductile Iron slotted grate designed for 450 psi load and minimum 19.8
square inches per linear foot open area. Grate shall be slotted stainless
steel.
Candidate manufacturers include: Polycast 600 series, J. R. Smith series 9814,
or approved substitute.
COUPLINGS, NIPPLES AND UNIONS
A.
Couplings and nipples shall be of the same material as the pipe on which they are used.
B.
Unions 2 inches and smaller shall be ground joint screwed pattern unions. Unions
larger than 2 inches shall be flanged. Unions shall be packed with 1/16-inch thick
rubber packing. Dielectric unions shall be as specified in paragraph 15085-2.05.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15400-3
ADDENDUM NO. 3
PLUMBING
2.04
HOSE BIBBS
A.
2.05
WATER HAMMER ARRESTERS
A.
2.06
Water hammer arresters shall be Josam, J. R. Smith, Wade, or approved substitute.
SLEEVES
A.
2.07
Hose bibbs located within restrooms or janitors rooms shall be Acorn No. 8126, Chicago
387-LF, or approved substitute.
Sleeves shall be as specified on the drawings.
ESCUTCHEONS
A.
Escutcheons shall be chrome-plated cold rolled steel or stainless steel.
PART 3--EXECUTION
3.01
INSTALLATION
A.
B.
GENERAL:
1.
Work shall be in accordance with the Uniform Plumbing Code as amended by
the State Plumbing code as adopted by the State of Hawaii.
2.
Plumbing shall be provided to avoid obstructions, allow 7.5-foot minimum
headroom, and keep openings and passageways clear.
3.
No holes shall be made in structural members.
4.
Torn and pierced waterproofing shall be repaired.
5.
Fixtures, fittings, valves, and copper and brass items shall be wrapped with
burlap or building paper. Wrapping shall be removed at completion of the work.
VALVES AND ACCESSORIES:
1.
Valves shall be provided upstream of branches, apparatus and fixtures and as
indicated on the drawings.
2.
Valves on branch lines and at distribution points shall be provided with a 2-inch
heavy brass disc, stamped and stenciled with 1/4-inch high letters, stating
portion of system controlled by valve. Valve locations shall be shown on record
drawings. The Contractor shall provide a chart of location and use of main
valves.
3.
Adjustable shaft valve boxes shall be provided for underground valves.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15400-4
ADDENDUM NO. 3
PLUMBING
3.02
C.
DIELECTRIC UNIONS: Dielectric unions shall be provided at connections between pipe
or fittings of different material.
D.
ESCUTCHEONS: Escutcheons shall be provided where pipes penetrate finished walls,
ceilings or floors. Escutcheons shall be securely mounted allowing clearance for
expansion.
E.
PIPING:
Piping shall be carried in chases or recesses where provided in walls, through
floors and partitions, and over ceilings. Unless otherwise specified, piping shall
not be run in floor slabs.
2.
Pipes shall not be supported by plumbing fixtures or equipment. Changes in
pipe size shall be made with reducing fittings. The use of bushings is not
acceptable.
3.
Where galvanized steel pipe is calked into a cast iron hub, a soil pipe adapter
shall be provided on the calked end of the steel pipe.
4.
Unless otherwise specified, underground piping outside buildings shall have a
minimum cover of 24 inches. Piping under buildings shall have a minimum
clearance from structure of 12 inches.
5.
Hot and cold water piping shall be separated by at least 6 inches.
CLEANING AND FLUSHING
A.
3.03
1.
Piping and equipment shall be cleaned and flushed in accordance with paragraph
15050-3.06.
MEASUREMENT AND PAYMENT
A.
Plumbing shall not be paid for directly, but shall be considered incidental and included
in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15400-5
ADDENDUM NO. 3
PLUMBING
SECTION 15782
PACKAGED ROOFTOP AIR CONDITIONING EQUIPMENT
PART 1–GENERAL
1.01
DESCRIPTION
A.
SCOPE: This Section includes provisions for the materials, installation and testing of
packaged HVAC equipment, including:
1.
B.
Packaged Rooftop Air Conditioning Equipment
EQUIPMENT LIST:
ID
C.
1.02
Name
AC 400,711
Generator Electrical Room Air Conditioner
AC 400,712
MV Distribution Room Air Conditioner
AC 800,701
KAN-GEN Building Air Conditioner
Air conditioner and coil capacities, electrical characteristics, special features and
accessories shall be per the Drawings.
QUALITY ASSURANCE
A.
REFERENCES:
1.
This section contains references to the following documents. They are a part of
this section as specified and modified. Where a referenced document contains
references to other standards, those documents are included as references
under this section as if referenced directly. In the event of conflict between the
requirements of this section and those of the listed documents, the
requirements of this section shall prevail.
2.
Unless otherwise specified, references to documents shall mean the documents
in effect at the time of Advertisement for Bids or Invitation to Bid (or on the
effective date of the Agreement if there were no Bids). If referenced documents
have been discontinued by the issuing organization, references to those
documents shall mean the replacement documents issued or otherwise
identified by that organization or, if there are no replacement documents, the
last version of the document before it was discontinued. Where document
dates are given in the following listing, references to those documents shall
mean the specific document version associated with that date, regardless of
whether the document has been superseded by a version with a later date,
discontinued or replaced.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-1
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
Reference
ANSI/AHRI 210/240
Performance Rating of Unitary Air-Conditioning & AirSource Heat Pump Equipment
ANSI/AHRI 340/360
Performance Rating of Commercial and Industrial
Unitary Air-Conditioning and Heat Pump Equipment
B.
1.03
Title
UNIT RESPONSIBILITY: Unit responsibility shall be assigned to the air conditioning
unit equipment vender. The air conditioning unit equipment includes all
components, services, and warrantees stated or referenced in this Section.
SUBMITTALS
A.
The following submittals shall be provided as specified in Section 01300:
1.
A copy of this specification section, with addendum updates included, and all
referenced and applicable sections, with addendum updates included, with
each paragraph check-marked to indicate specification compliance or
marked to indicate requested deviations from specification requirements.
Check marks shall denote full compliance with a paragraph as a whole. If
deviations from the specifications are indicated, and therefore requested by
the Contractor, each deviation shall be underlined and denoted by a number
in the margin to the right of the identified paragraph, referenced to a detailed
written explanation of the reasons for requesting the deviation. The Officer in
Charge shall be the final authority for determining acceptability of requested
deviations. The remaining portions of the paragraph not underlined will
signify compliance on the part of the Contractor with the specifications.
Failure to include a copy of the marked-up specification sections, along with
justification(s) for any requested deviations to the specification requirements,
with the submittal shall be sufficient cause for rejection of the entire
submittal with no further consideration.
2.
Certificate of Unit Responsibility attesting that the Contractor has assigned,
and that the manufacturer accepts, unit responsibility in accordance with the
requirements of this Section and paragraph 11000-1.02 C. No other
submittal material will be reviewed until the certificate has been received and
found to be in conformance with these requirements
3.
Fan performance curves for the specified operation conditions.
4.
The motor data required under Section 11060.
5.
Manufacturer's catalog and/or other data confirming conformance to
specified design, material and equipment requirements.
6.
Predicted performance data and/or curves as applicable developed for the
specific application, confirming conformance to specified design and
operating requirements and characteristics.
7.
Electrical and control diagrams.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-2
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
1.04
Installation requirements, showing clearance required for maintenance
purposes.
9.
Operations and maintenance data specified in Section 01730.
ENVIRONMENTAL CONDITIONS
A.
1.05
8.
Equipment shall be suitable for installation and service at a wastewater treatment
plant, under the environmental conditions specified in Section 01800.
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. Contractor shall design the structural components,
seismic attachment, braces, and anchors to the structure for all parts or elements of the
mechanical and electrical systems in accordance with Section 01900.
PART 2–PRODUCTS
2.01
MANUFACTURERS
A.
2.02
The City and Officer in Charge believe the following candidate manufacturers are
capable of producing equipment and/or products that will satisfy the requirements of
the Section. This statement, however, shall not be construed as an endorsement of
a particular manufacturer’s products, nor shall it be construed that a named
manufacture’s standard equipment or products will comply with the requirement of
this Section. Candidate manufacturers include Carrier, Trane, York, or approved
substitute.
BLOWER/COIL UNIT
A.
CABINET: Cabinet shall be a one-piece welded assembly of 18 gauge or heavier
galvanized steel. Exterior surfaces shall be cleaned and coated with a corrosion
resistant, factory applied coating as specified in this section.
B.
FAN: The fan shall be a belt-driven, forward curved centrifugal fan with adjustable
drive pulleys for motor speed adjustment. Blower motor shall be as specified in
Section 11060 and shall be thermally overload protected. The blower wheel shall be
statically and dynamically balanced and sized to operate at no more than 30 percent
of the maximum recommended speed for that fan.
C.
EVAPORATOR COIL: The evaporator coil shall consist of seamless copper tubing
mechanically bonded to aluminum fins. The coil shall be factory pressure and leak
tested to 300 psig.
D.
PROTECTIVE COATINGS: Coat entire assembly, including roof curb. Corrosionresistant, factory applied coatings shall be Heresite, Hi-Pro Polyester, or epoxy
applied in strict conformance with the paint manufacturer's instructions. Coils shall
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-3
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
be treated after manufacture with Blygold PoluAl XT corrosion protection system or
approved substitute.
2.03
E.
FILTERS: The filter shall be the 2-inch thick disposal carbon filter with a minimum
MERV rating of 8. See Section 15887. Each filter will be provided with a 0 to 1 inch
WC manometer located near the room thermostat and connected by tubing to the
filter pressure taps.
F.
CONTROLS: The controls shall be factory wired and shall be located in a readily
accessible space.
G.
SAFETY DISCONNECTS: The unit shall be provided with local safety disconnect
provided by the unit vendor. Safety disconnect shall be suitable for installation
outdoors in conditions described in Section 01800.
COMPRESSOR/CONDENSER
A.
COMPRESSOR:
1.
The unit shall have one, two-speed hermetic reciprocating compressor with
centrifugal oil pump and lubrication system.
2.
The unit shall be provided with crankcase heater and well and high-strength,
ring type suction and discharge valves. The compressor shall have overload
protection, internal pressure relief, vibration isolation mountings, and sound
absorbing blanket.
B.
CONDENSER COIL: The condenser coil shall consist of 3/8-inch OD seamless copper
tubing mechanically bonded to aluminum fins. Subcooling circuits provided as
standard for each refrigeration circuit. Condensor coil shall be factory pressure and
leak tested to 425 psig. Condenser coil shall be coated as specified for evaporator
coil.
C.
CONDENSER FAN: Condenser fan shall be direct driven propeller fans with aluminum
blades and zinc plated steel hubs. The fans shall be driven by 1100 rpm totally
enclosed motors with permanently lubricated bearings and built-in thermal overload
protection. Low noise fans shall be provided if available.
D.
CONTROLS:
1.
Provide complete, integrated packaged control systems for packaged air
conditioning equipment. Control systems shall include all necessary
components, transformers, accessories, wiring and conduits to provide
complete and automatic systems ready for full time operation.
2.
System shall include air conditioning controls to automatically start and stop
equipment. The system shall provide space cooling sensing to maintain
space temperatures as indicated. Each system shall be provided with a
programmable thermostat for remote mounting.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-4
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
3.
THERMOSTATS: Provide thermostats where specified, and for all equipment
identified as thermostat-controlled. Thermostats shall be wall-mounted and
have a minimum 40 to 104°F temperature range. Multi-stage thermostats
shall be provided whenever more than one temperature setpoint is indicated.
Provide thermostats meeting the following requirements unless noted
otherwise on the Drawings or in the Specifications.
a.
Digital automatic-setback thermostats shall be provided in finished
areas. Thermostats shall be digital programmable with 7 different day
types and capable of night setback. Thermostats shall have fan AutoOn switch and system Off-Heat-Auto-Cool and manual temperature
settings. Thermostats shall be capable of a 5 degree minimum
deadband.
b.
Low-voltage or line-voltage thermostats shall be provided in
unfinished areas. Thermostats shall include an integral room
thermometer.
4.
Smoke Detector: Where specified, provide return air smoke detector. Smoke
detector shall be ionization type, mounted in the return air stream inside the
unit, factory wired and tested per NFPA, IBC, and UL. Provide indication of
status including, but not limited to, power, alarm, trouble, on, reset, and test
in a visible location outside the unit. Indicator panel shall be suitable for
outdoor, wet exposure. Smoke detector shall be provided with two auxiliary
form C dry contacts suitable for remote detection of alarm condition.
Contacts shall be rated for at least 1A at 24Vdc.
5.
ACCESSORIES: Accessories shall include:
a.
b.
c.
d.
e.
f.
g.
E.
Magnetic contactors for the compressors and fans.
High and low pressure cutouts and reset relays.
All control circuitry transformers and fusing.
Thermostat and subbase.
Conduit and cable between thermostat and control system.
One form C dry contact for remote detection of general trouble alarm
condition. Contacts shall be rated for at least 0.5A at 24Vdc.
As listed in Drawings.
ACOUSTICS:
ACOUSTICS:
1.
Octave Band Center
Frequencies (Hz)
Sound Power Level
(dB)
The rooftop unit shall not exceed the following noise limits at a horizontal
distance of 20 feet.
Rooftop
Rooftop Unit Maximum Radiated Sound Power Levels
63
125
250
500 1000 2000 4000
8000
90.1
66.7
82.6
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
81
79.4
77
15782-5
ADDENDUM NO. 3
73
70.4
A-Weighted
Total
82
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
Octave Band Center
Frequencies (Hz)
Sound Power Level
(dB)
Octave Band Center
Frequencies (Hz)
Sound Power Level
(dB)
Rooftop Unit Maximum Discharge Sound Power Levels
63
125
250
500 1000 2000 4000
8000
111.3
89.3
92.2
Rooftop Unit Maximum Inlet Sound Power Levels
63
125 250 500 1000 2000
2000 4000
8000
106.2
93.9
94.8
93.2
86
86.7
75.6
85
74.3
87.1
77.1
83.9
85.9
A-Weighted
Total
96.3
A-Weighted
Total
89.8
2.04 VIBRATION ISOLATION
A.
SPRING CURB:
1.
Curb type isolator with integral spring isolators, designed to provide a
complete roof curb installation. The vibration
vibration isolation curbs shall be
complete assemblies designed to resiliently support equipment at the
specified elevation and shall constitute a fully enclosed airair- and weatherweather-tight
system.
2.
The isolation curb shall consist of an upper support rail with supply
supply and
return duct supports on which the equipment and duct openings rest and a
lower support curb which is attached to the roof structure, separated by freefreestanding, unun-housed, laterally stable steel springs.
a.
The upper support rail shall provide continuous
continuous structural support for
the rooftop equipment and shall be designed to provide isolation
against casing radiated vibration in the rooftop equipment housing
and structure borne vibration from rotating and mechanical
equipment in the rooftop package. The
The upper support rail shall
consist of a structural channel with sufficient elevation above the
spring to preclude interference with the rooftop equipment and
permit access to inspect the isolation system after placement of the
rooftop equipment. Attachment
Attachment to the equipment by weather seal
attachment bolt heads is not permitted.
b.
The lower support curb shall be a formed channel fabricated of heavy
gauge galvanized steel with a continuous 11-1/2 inch x 11-1/2 inch (38
mm x 38 mm) nominal wood nailer attached to the isolation support
pedestals. The isolation support pedestal, which includes the seismic
and wind load restraints, shall be bolted or welded to the building
support steel to suitably transfer seismic and wind load forces to the
building structure. The lower support curb shall have a minimum
elevation of 14 inches (356 mm) from the top of the wood nailer to
the base of the curb.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-6
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
c.
Spring components shall be 2 inch deflection, freefree-standing, ununhoused, laterally stable steel springs. Springs shall have a lateral
stiffness greater than 1.2 times the rated vertical stiffness and shall
be designed for a typical 50% overload to solid. All springs shall have
a polyester powder coated finish and be color coded to indicate load
capacity. Spring coils shall
shall rest on minimum 0.25 inch neoprene
noise pads.
3.
The isolation curb system shall be complete with crosscross-bracing as required as
a part of the upper and lower assemblies. Supply air and return duct shall be
flexibly attached by the contractor to prevent transmission of vibration to the
building structure.
4.
Vibration isolators shall be selected by the manufacturer for each specific
application to comply with deflection requirements.
requirements.
PART 3–EXECUTION
3.01
INSTALLATION
A.
The air conditioning unit shall be installed as shown in the Drawings and in
accordance with manufacturer’s recommendations. Install conduit and cable
between thermostat and control system. Conduit and cable shall be per Division 16
requirements.
B.
EQUIPMENT MOUNTING:
1.
3.02
TESTING AND BALANCING
A.
3.03
Testing, adjusting, and balancing shall be as specified in Section 15990. Each fan shall
be completely field tested to guarantee compliance with the project manual.
COMMISSIONING AND TRAINING
A.
3.04
PROCEDURES: Section 11002.
Commissioning and training shall be as specified in Section 01660.
SEQUENCE OF OPERATION
A.
SYSTEM DESCRIPTION: The air conditioning system consists of a packaged rooftop
air conditioning unit. The air conditioner provides conditioned air to electrical rooms.
B.
OPERATION:
1.
The air conditioner is composed of a supply fan, condensing unit section,
filter section, and on-board control system. The air conditioner operates
through its “Hand/Off/Auto” selector switch in manual or automatic
operation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-7
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
C.
2.
MANUAL: With its “Hand/Off/Auto” selector switch in the “Hand” position, the
fan operates continuously. The condenser shall operate as described in this
section. With its “Hand/Off/Auto” selector switch in the “Off” position, the air
conditioner and all of its components are inoperative.
3.
AUTOMATIC: With its “Hand/Off/Auto” selector switch in the “Auto” position,
the air conditioner shall operate through the on-board Controller as described
in this section.
4.
The on-board Controller utilizes the local thermostat to provide temperature
input. The on-board controller controls the supply fan and the condenser to
maintain room temperature between 55 and 75 degrees F (adjustable).
5.
The air conditioner operates through its internal safety and capacity controls
as specified in this Section. Provide the relays, contacts, and wiring required
to achieve the specified control.
6.
COOLING MODE: The indoor fan runs continuously. On temperature rise, the
condensing unit starts with one cooling stage active for minimum cooling. As
the room temperature increases, the condensing unit activates the second
cooling stage for maximum cooling. The system continues in this mode until
the set temperature is reached. When the set temperature is reached, the
condensing unit deactivates all active cooling stages and the fan continues to
run.
7.
HEATING MODE: Heating mode is not provided
ALARMS:
1.
SMOKE DETECTORS (where specified): On sensing smoke, shut down AC
800,701 , display a fault condition at ICP 800,160, and send a signal to the
SCADA system.
2.
TROUBLE. When the on-board Controller produces a trouble condition, a
signal shall be sent to the SCADA system.
a.
Trouble condition includes the following conditions:
•
•
•
•
•
•
•
•
•
•
•
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Sensor signal loss
Compressor failure
Compressor reverse rotation
Compressor stuck on
Loss of refrigerant charge
Low compressor suction temperature
High compressor suction temperature
High compressor head pressure
High compressor discharge temperature
Supply fan status fail
Condenser fan fail
15782-8
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
•
•
3.05
Control system failure
Unit in emergency stop
MEASUREMENT AND PAYMENT
A.
Packaged rooftop air conditioning equipment shall not be paid for directly, but shall be
considered incidental and included in the lump sum bids for the respective items in the
Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15782-9
ADDENDUM NO. 3
PACKAGED ROOFTOP
AIR CONDITIONING EQUIPMENT
SECTION 15783
SPLIT SYSTEM AIR CONDITIONING UNITS
PART 1--GENERAL
1.01
DESCRIPTION
A.
B.
SCOPE: This Section includes provisions for the materials, installation and testing of
unitary HVAC equipment, including:
1.
Ductless Split System Air Conditioning Equipment
2.
Split System Air Conditioning Equipment: 5 Tons and greater
EQUIPMENT LIST:
ID
C.
1.02
Name
AC 200,701
TIPS Electrical Room Air Conditioning Unit
AHU 200,711
TIPS Electrical Room Air Handler
AC 200,702
TIPS East Control Room Air Conditioning Unit
AHU 200,712
TIPS East Control Room Air Handler
AC 200,703
TIPS West Elevator Closet Air Conditioning Unit
AHU 200,713
TIPS West Elevator Closet Air Handler
AC 200,704
TIPS East Elevator Closet Air Conditioning Unit
AHU 200,714
TIPS East Elevator Closet Air Handler
AC 200,705
TIPS West Control Room Air Conditioning Unit
AHU 200,715
TIIPS West Control Room Air Handler
AC 300,701
Headworks Electrical Room Air Conditioning Unit
AHU 300,711
Headworks Electrical Room Air Handler
AC 300,702
Headworks Control Room Air Conditioning Unit
AHU 300,712
Headworks Control Room Air Handler
Air conditioner and coil capacities, electrical characteristics, special features and
accessories shall be per the Drawings.
QUALITY ASSURANCE
A.
REFERENCES:
1.
This section contains references to the following documents. They are a part of
this section as specified and modified. Where a referenced document contains
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-1
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
references to other standards, those documents are included as references
under this section as if referenced directly. In the event of conflict between the
requirements of this section and those of the listed documents, the
requirements of this section shall prevail.
2.
1.03
Unless otherwise specified, references to documents shall mean the documents
in effect at the time of Advertisement for Bids or Invitation to Bid (or on the
effective date of the Agreement if there were no Bids). If referenced documents
have been discontinued by the issuing organization, references to those
documents shall mean the replacement documents issued or otherwise
identified by that organization or, if there are no replacement documents, the
last version of the document before it was discontinued. Where document
dates are given in the following listing, references to those documents shall
mean the specific document version associated with that date, regardless of
whether the document has been superseded by a version with a later date,
discontinued or replaced.
Reference
Title
ANSI/AHRI 210/240
Performance Rating of Unitary Air-Conditioning & AirSource Heat Pump Equipment
ANSI/AHRI 340/360
Performance Rating of Commercial and Industrial
Unitary Air-Conditioning and Heat Pump Equipment
B.
STANDARDS: The air conditioning unit shall be tested and certified in accordance with
and shall be UL labeled.
C.
UNIT RESPONSIBILITY: Unit responsibility shall be assigned to the air conditioning unit
equipment vender. The air conditioning unit equipment includes the following
equipment:
SUBMITTALS
A.
The following submittals shall be provided as specified in Section 01300:
1.
A copy of this specification section, with addendum updates included, and all
referenced and applicable sections, with addendum updates included, with
each paragraph check-marked to indicate specification compliance or marked
to indicate requested deviations from specification requirements. Check marks
shall denote full compliance with a paragraph as a whole. If deviations from the
specifications are indicated, and therefore requested by the Contractor, each
deviation shall be underlined and denoted by a number in the margin to the
right of the identified paragraph, referenced to a detailed written explanation of
the reasons for requesting the deviation. The Officer in Charge shall be the final
authority for determining acceptability of requested deviations. The remaining
portions of the paragraph not underlined will signify compliance on the part of
the Contractor with the specifications. Failure to include a copy of the markedup specification sections, along with justification(s) for any requested deviations
to the specification requirements, with the submittal shall be sufficient cause
for rejection of the entire submittal with no further consideration.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-2
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
1.04
Certificate of Unit Responsibility attesting that the Contractor has assigned, and
that the manufacturer accepts, unit responsibility in accordance with the
requirements of this Section and paragraph 11000-1.02 C. No other submittal
material will be reviewed until the certificate has been received and found to be
in conformance with these requirements.
3.
Fan performance curves for the specified operation conditions.
4.
The motor data required under Section 11060.
5.
Manufacturer's catalog and/or other data confirming conformance to specified
design, material and equipment requirements.
6.
Predicted performance data and/or curves as applicable developed for the
specific application, confirming conformance to specified design and operating
requirements and characteristics.
7.
Electrical and control diagrams.
8.
Installation requirements, showing clearance required for maintenance
purposes.
9.
Sound power levels in dB for each octave band.
10.
In addition to the standard warranty, an additional four years parts and labor
warranty shall apply to the compressor, interconnecting tubing and coils. See
Section 01740.
11.
Provide operation and maintenance data specified in Section 01730.
ENVIRONMENTAL CONDITIONS
A.
1.05
2.
Equipment shall be suitable for installation and service at a wastewater treatment plant,
under the environmental conditions specified in Section 01800.
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. Contractor shall design the structural components,
seismic attachment, braces, and anchors to the structure for all parts or elements of the
mechanical and electrical systems in accordance with Section 01900.
PART 2--PRODUCTS
2.01
MANUFACTURERS
A.
The City and Officer in Charge believe the following candidate manufacturers are
capable of producing equipment and/or products that will satisfy the requirements of
the Section. This statement, however, shall not be construed as an endorsement of a
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-3
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
particular manufacturer’s products, nor shall it be construed that a named
manufacture’s standard equipment or products will comply with the requirement of this
Section. Candidate manufacturers include Carrier, Trane, York, or approved substitute.
2.02
AIR CONDITIONING SYSTEMS 5 TONS AND GREATER:
A.
GENERAL: The complete equipment unit shall consist of the outdoor and indoor units
and required accessories for a complete installation. A full refrigerant charge for field
installation shall be provided. Provide refrigerant piping between the indoor and
outdoor units; piping shall be sized and insulated as recommended by the
manufacturer.
1.
Interior surfaces of units to meet erosion and growth resistance requirements
as well as construction requirements for equipment of ASHRAE 62.1.
2.
Electrical Components, Devices, and Accessories: Listed and labeled as defined
in NFPA 70, Article 100, by a testing agency acceptable to authorities having
jurisdiction, and marked for intended use.
3.
ARI Certification: Provide ARI certified and listed units.
4.
Energy-Efficient Ratio (EER): Meet the minimum (S)EER requirement as
specified.
5.
ARI Compliance for Units with Capacities Less Than 135,000 Btu/hr: Rate airconditioner capacity according to ARI 210/240.
6.
ARI Compliance for Units with Capacities 135,000 Btu/hr and Greater: Rate airconditioner capacity according to ARI 340/360.
7.
Sound Power Level Ratings: Comply with ARI 270.
B.
PROTECTIVE COATINGS: Coat entire assembly, including roof curb. Corrosion-resistant,
factory applied coatings shall be Heresite, Hi-Pro Polyester, or epoxy applied in strict
conformance with the paint manufacturer's instructions. Coils shall be treated after
manufacture with Blygold PoluAl XT corrosion protection system or approved substitute.
C.
ELECTRICAL: 120-volt, 1-phase equipment shall be provided with factory installed,
internally mounted, and UL approved non-fused disconnect switch. Non-fused switch
shall provide unit power shutoff and shall be accessible from outside the unit and shall
provide power off lockout capability. 480-volt, 3-phase equipment shall be provided
with factory installed and UL approved fused disconnect switch. Fused switch shall
provide unit power shutoff and shall be accessible from outside the unit and shall
provide power off lockout capability.
D.
CONTROLS: Provide complete, integrated packaged control systems for unitary air
conditioning equipment. Control systems shall include all necessary components,
transformers, accessories, wiring and conduits to provide complete and automatic
systems ready for full time operation.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-4
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
E.
1.
System shall include air conditioning controls to automatically start and stop
equipment. The system shall provide space cooling sensing to maintain space
temperatures as indicated. Each split system shall be provided with a
programmable thermostat for remote mounting.
2.
Thermostats: Provide thermostats where specified, and for all equipment
identified as thermostat-controlled. Thermostats shall be wall-mounted and
have a minimum 40 to 104°F temperature range. Multi-stage thermostats
shall be provided whenever more than one temperature setpoint is indicated.
Provide thermostats meeting the following requirements unless noted
otherwise on the Drawings or in the Specifications.
a.
Digital automatic-setback thermostats shall be provided in finished
areas. Thermostats shall be digital programmable with 7 different day
types and capable of night setback. Thermostats shall have fan AutoOn switch and system Off-Heat-Auto-Cool and manual temperature
settings. Thermostats shall be capable of a 5 degree minimum
deadband.
b.
Low-voltage or line-voltage thermostats shall be provided in
unfinished areas. Thermostats shall include an integral room
thermometer.
INDOOR UNIT:
1.
GENERAL:
a.
Indoor unit shall be factory assembled, single piece unit consisting of
refrigerant evaporator coil, fan section, filter section, wiring, piping,
controls, and accessories.
b.
Indoor
Indoor unit shall be Type A floor mounted as indicated and per
requirements of Section 11021.
2.
CABINET: Cabinet material shall be galvanized steel, coated with a baked
enamel finish. All materials shall be capable of withstanding 500-hour salt spray
exposure per ASTM B117 (scribed specimen).
3.
FAN: The fan shall be a forward curved, belt driven, centrifugal type. Fan, drive
and motor assembly shall be isolated from the cabinet to reduce the
transmission of vibration from the fan/drive assembly to the cabinet. The fan
shall be statically and dynamically balanced at the factory. Fan motor shall be
permanently lubricated, shall have internal overload protection and shall be
resiliently mounted to the cabinet.
4.
COIL: The coil shall the direct expansion cooling type with refrigerant metering
device, refrigerant line fittings, and non-corroding condensate pan.
5.
FILTER: The filter shall be the 2-inch thick disposal carbon filter with a minimum
MERV rating of 8. See Section 15887. Each filter will be provided with a 0 to 1
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-5
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
inch WC manometer located near the room thermostat and connected by tubing
to the filter pressure taps.
6.
ACOUSTICS:
ACOUSTICS: The indoor unit shall not exceed the following noise limits at a
horizontal distance of 20 feet.
Octave Band Center
Frequencies (Hz)
Sound Power Level (dB)
Octave Band Center
Frequencies (Hz)
Sound Power Level (dB)
F.
Indoor Unit Maximum Radiated Sound Power Levels
63
125
250
500 1000 2000
4000
95.3
91.3
87.3
86.3
82.3
80.3
76.3
Indoor Unit Maximum Duct Sound Power Levels
63
125
250
500
1000 2000
104.7
100.7
96.7
91.7
89.7
A-Weighted
Total
Total
88.4
89.7
4000
Total
85.7
107.4
OUTDOOR UNIT:
1.
GENERAL:
a.
The outdoor unit shall be an air cooled condensing unit, sized to match
indoor unit specified in this section, complete with refrigerant charge,
service valves, compressor, controls, condenser coil and fan, and
specified accessories.
b.
Outdoor unit shall be mounted on spring isolation curb.
2.
COMPRESSOR: The compressor shall be the welded hermetic type with internal
vibration isolation. It shall have thermal and current overload protection.
3.
CONTROLS: The controls shall be factory wired and shall be located in a readily
accessible space.
4.
CONDENSER: The condenser shall be a refrigerant coil for heat rejection. The
fan shall be direct drive propeller type. The fan motor shall be permanently
lubricated, totally enclosed and have thermal and current overload protection.
5.
ACCESSORIES: Accessories shall include:
a.
b.
c.
d.
e.
f.
g.
h.
Start capacitor and relay.
Indoor fan relay.
Thermostat and subbase.
Conduit and cable between thermostat and control system.
Conduit and cable between outdoor and indoor units.
Low voltage transformer.
Liquid-line filter drier.
Low noise compressor with sound absorbing blanket and low noise
condenser fans.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-6
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
j.
k.
l.
One form C dry contact for remote detection of general trouble alarm
condition. Contacts shall be rated for at least 0.5A at 24Vdc.
Refrigerant piping between indoor and outdoor units.
As listed on drawings.
G.
CONTROLS: Provide room thermostat for two stage cooling operation as a minimum.
Complete system controls shall be stand alone, vendor supplied for each split system.
H
SPRING CURB:
1.
Curb type isolator with integral spring isolators, designed to provide a complete
roof curb installation. The vibration isolation curbs shall be complete
assemblies designed to resiliently
resiliently support equipment at the specified elevation
and shall constitute a fully enclosed airair- and weatherweather-tight system.
2.
The isolation curb shall consist of an upper support rail with supply and return
duct supports on which the equipment and duct openings
openings rest and a lower
support curb which is attached to the roof structure, separated by freefree-standing,
unun-housed, laterally stable steel springs.
a.
The upper support rail shall provide continuous structural support for
the rooftop equipment and shall be designed
designed to provide isolation
against casing radiated vibration in the rooftop equipment housing and
structure borne vibration from rotating and mechanical equipment in
the rooftop package. The upper support rail shall consist of a structural
channel with sufficient
sufficient elevation above the spring to preclude
interference with the rooftop equipment and permit access to inspect
the isolation system after placement of the rooftop equipment.
Attachment to the equipment by weather seal attachment bolt heads is
not permitted.
permitted.
b.
The lower support curb shall be a formed channel fabricated of heavy
gauge galvanized steel with a continuous 11-1/2 inch x 11-1/2 inch (38
mm x 38 mm) nominal wood nailer attached to the isolation support
pedestals. The isolation support pedestal, which includes the seismic
and wind load restraints, shall be bolted or welded to the building
support steel to suitably transfer seismic and wind load forces to the
building structure. The lower support curb shall have a minimum
elevation of 14 inches (356
(356 mm) from the top of the wood nailer
nailer to the
base of the curb.
c.
Spring components shall be 2 inch deflection, freefree-standing, unun-housed,
laterally stable steel springs. Springs shall have a lateral stiffness
greater than 1.2 times the rated vertical stiffness
stiffness and shall be designed
for a typical 50% overload to solid. All springs shall have a polyester
powder coated finish and be color coded to indicate load capacity.
Spring coils shall rest on minimum 0.25 inch neoprene noise pads.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-7
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
I.
3.
The isolation curb system
system shall be complete with crosscross-bracing as required as a
part of the upper and lower assemblies. Supply air and return duct shall be
flexibly attached by the contractor to prevent transmission of vibration
vibration to the
building structure.
4.
Vibration isolators
isolators shall be selected by the manufacturer for each specific
application to comply with deflection requirements.
ACOUSTICS: The outdoor unit shall not exceed the following noise limits at a horizontal
distance of 20 feet.
Octave Band Center
Frequencies (Hz)
Sound Power Level (dB)
2.03
Outdoor Unit Maximum Radiated Sound
Sound Power Levels
63
125
250
500 1000 2000
4000
89.3
85
82
82.7
80.2
75.2
71
A-Weighted
Total
84.6
DUCTLESS SPLIT SYSTEM AIR CONDITIONER AND FAN COIL
A.
GENERAL: Air conditioning systems shall be split, ductless systems. The indoor fan coil
units shall be designed for mounting below the ceiling or mounting on the wall as
specified on the Drawings. The air conditioner shall be designed for outdoor service.
Refrigerant piping between the fan-coil unit and air conditioner shall be as
recommended by the manufacturer.
1.
Condensing Units:
a.
Unit cabinet shall be constructed of galvanized steel with a powder
coated finish.
b.
Fan shall be direct-drive propeller type with horizontal discharge, and
corrosion resistant shaft. Fan shall be statically and dynamically
balanced. Fan motor shall be totally-enclosed with permanently
lubricated ball bearings, and shall be provided with internal thermal
overload protection where specified.
c.
Compressor shall be hermetically sealed scroll type, mounted on
rubber vibration isolators, and covered with sound absorbing blanket.
Motor shall be NEMA rated and provided with internal overload to
protect against over-current and over-temperature.
d.
Outdoor coil shall consist of seamless copper tubes with mechanically
bonded aluminum fins. Outdoor coil shall be treated after
manufacture as indicated in this section.
e.
Electrical power shall be a single point connection. Starters, step
down transformers and other elements required for the control of the
indoor and outdoor units shall be provided by the supplier of this
section. Control voltage to the indoor fan coil shall be 24 VDC.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-8
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
2.
3.
4.
Fan Coil Unit:
a.
Unit cabinet shall be constructed of galvanized steel with a baked
enamel paint.
b.
Indoor fan shall be 3-speed centrifugal type motor suitable for multispeed operation unless noted otherwise. Fan shall be statically and
dynamically balanced. Fan motor shall be totally-enclosed with
permanently lubricated ball bearings, and shall be provided with
internal thermal overload protection.
c.
Indoor coil shall consist of seamless copper tubes with mechanically
bonded aluminum fins and galvanized steel tube sheet. Unit shall
include a drain sump under the coil with a drain connection.
d.
Electrical power shall be a single point connection. Starters, step
down transformers and other elements required for the control of the
indoor and outdoor units shall be provided by the supplier of this
section. Control voltage shall be 24 VDC.
Accessories shall include:
a.
Integral condensate pump, fresh air intake and power ventilation kit
shall be provided on the fan coil unit where specified.
b.
Wired remote controller.
c.
Freeze-up, high discharge temperature, and self-diagnostics on the
fan coil unit.
d.
High and low pressure safety switches, low voltage startup capability,
and fluid line filter drier on the condenser unit. Refrigerant charge
shall be R-410A.
Manufacturers:
a.
2.04
Air Conditioning Systems:
1)
Ceiling suspended fan coil units shall be Carrier 40QAC with
Carrier 38HDR condensing unit; Mitsubishi PCA with
Mitsubishi PUY condensing unit; or Approved substitute.
2)
Wall mounted fan coil units shall be Mitsubishi PKA with
Mitsubishi PUY condensing unit; Carrier 40QNC with Carrier
38HDF heat pump; or Approved substitute.
STANDBY COMPONENTS
A.
Provide a new set of filters for each indoor section for final balancing and furnish an
additional set of filters for the City.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-9
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
PART 3--EXECUTION
3.01
INSTALLATION
A.
Install the condenser and coil per the Drawings and as recommended by the
manufacturer. Set the condenser on a concrete equipment pad. Floor mount or hang
the indoor unit from the structure and provide a drain pipe from the drip pan to a
disposal point. Install the refrigerant piping between the units per manufacturer’s
recommendations. Install conduit and cable between thermostat and control system.
Install conduit for power (where indicated) and control cable between outdoor and
indoor units. Conduit and cables shall be per Division 16 requirements.
B.
EQUIPMENT MOUNTING:
1.
3.02
TESTING AND BALANCING
A.
3.03
Testing, adjusting, and balancing shall be as specified in Section 15990. Each fan shall
be completely field tested to guarantee compliance with the project manual.
COMMISSIONING AND TRAINING
A.
3.04
PROCEDURES: Section 11002.
Commissioning and training shall be as specified in Section 01660.
SEQUENCE OF OPERATION
A.
SYSTEM DESCRIPTION: The split system air conditioning system consists of an indoor
air handler and a matched outdoor air conditioning unit. The split system provides
conditioned air to electrical rooms, elevator control closets, and control rooms.
B.
OPERATION:
1.
The split system indoor air handler is composed of a supply fan, evaporator
coil(s), filter section, and mixing box section. The outdoor air conditioning unit
consists of a condensing coil(s), compressor(s), expansion valve(s), and onboard control system. The split system operates through its “Hand/Off/Auto”
selector switch in manual or automatic operation.
2.
MANUAL: With its “Hand/Off/Auto” selector switch in the “Hand” position, the
indoor fan operates continuously. The air conditioner shall operate as
described in this section. With its “Hand/Off/Auto” selector switch in the “Off”
position, the split system and all of its components are inoperative.
3.
AUTOMATIC: With its “Hand/Off/Auto” selector switch in the “Auto” position, the
split system shall operate through the on-board Controller as described in this
section.
4.
The on-board Controller utilizes the local thermostat to provide temperature
input. The on-board controller controls the indoor fan, compressor(s), and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-10
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
expansion valve(s) to maintain room temperature between 55 and 75 degrees F
(adjustable).
D.
5.
The split system operates through its internal safety and capacity controls as
specified in this Section. Provide the relays, contacts, and wiring required to
achieve the specified control.
7.
COOLING MODE (2-stage systems): The indoor fan runs continuously. On
temperature rise, the outdoor air conditioning unit starts with one cooling stage
active for minimum cooling. As the room temperature increases, the
condensing unit activates the second cooling stage for maximum cooling. The
system continues in this mode until the set temperature is reached. When the
set temperature is reached, the condensing unit deactivates all active cooling
stages and the fan continues to run.
7.
COOLING MODE (1-stage systems): The indoor fan runs continuously. On
temperature rise, the outdoor air conditioning unit starts. The system continues
in this mode until the set temperature is reached. When the set temperature is
reached, the condensing unit deactivates the outdoor air conditioning unit and
the indoor fan continues to run.
7.
COOLING MODE (ductless systems): The indoor fan runs only when cooling is
required. On temperature rise, the indoor fan starts and modulates per the
factory controls, the outdoor air conditioning unit starts. The system continues
in this mode until the set temperature is reached. When the set temperature is
reached, the condensing unit deactivates the outdoor air conditioning unit and
the indoor fan.
8.
HEATING MODE: Heating mode is not provided.
ALARMS:
1.
TROUBLE. When the on-board Controller produces a trouble condition, a signal
shall be sent to the SCADA system.
a.
Trouble condition includes the following conditions:
•
•
•
•
•
•
•
•
•
•
•
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Sensor signal loss
Compressor failure
Compressor reverse rotation
Compressor stuck on
Loss of refrigerant charge
Low compressor suction temperature
High compressor suction temperature
High compressor head pressure
High compressor discharge temperature
Supply fan status fail
Condenser fan fail
15783-11
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
•
•
3.05
Control system failure
Unit in emergency stop
MEASUREMENT AND PAYMENT
A.
Split system air conditioning units shall not be paid for directly, but shall be considered
incidental and included in the lump sum bids for the respective items in the Proposal
Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15783-12
ADDENDUM NO. 3
SPLIT SYSTEM AIR CONDITIONING UNITS
SECTION 15828
CENTRIFUGAL FIBERGLASS REINFORCED PLASTIC (FRP) FANS
PART 1--GENERAL
1.01
SUMMARY
A.
SCOPE: This Section specifies centrifugal belt-driven, fiberglass reinforced plastic
(FRP) fans for service of saturated foul air with high concentrations of hydrogen
sulfide and organic sulfides, and at times containing dilute sulfuric acid, methane,
and gasoline vapors. Fans shall be medium or high pressure, backward inclined or
backward curved impeller type.
B.
EQUIPMENT LIST:
Description
1.02
Equipment No.
KAI-ODOR, TIPS Foul Air Fan 1
F 500,110
KAI-ODOR, TIPS Foul Air Fan 2
F 500,120
KAI-ODOR, HDWKS Foul Air Fan 1
F 550,110
KAI-ODOR, HDWKS Foul Air Fan 2
F 550,120
KAN-ODOR, Foul Air Fan 1
F 900,110
KAN-ODOR, Foul Air Fan 2
F 900,120
QUALITY ASSURANCE
A.
REFERENCE STANDARDS: This Section incorporates by reference the latest revisions
of the following documents. They are part of this Section insofar as specified and
modified herein. In the event of conflict between the requirements of this Section
and those of the listed documents, the requirements of this Section shall prevail.
Unless otherwise specified, references to documents shall mean the documents in
effect on the effective date of Agreement. If referenced documents have been
discontinued by the issuing organization, references to those documents shall mean
the replaced documents issued or otherwise identified by that organization, or if
there are no replacement documents, the last version of the document before it was
discontinued.
Reference
Title
AMCA Standard 210
Air Movement and Control Association Test Code and
Certified Ratings Program
AMCA Standard 211
Certified Rating Program for Air Moving Devices
AMCA Standard 300
Test Code for Sound Rating
AMCA Standard 301
Methods for Calculating Fan Sound Ratings from Laboratory
Test Data
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-1
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
Reference
ASTM D4167
Standard Specification for Fiber-Reinforced Plastic Fans and
Blowers
ASTM E84
Standard Method of Test for Surface Burning Characteristics
of Building Materials
B.
UNIT RESPONSIBILITY: Assign unit responsibility, as specified in Section 11000, to
the centrifugal FRP fan Manufacturer for the engineering, design, selection, and
operation of fans, motors, vibration isolation systems, and all appurtenances
specified in this Section. This Manufacturer is the unit responsibility Manufacturer
and has unit responsibility, as defined in Section 11000, for equipment specified in
this Section. Provide a completed and signed Unit Responsibility Certification Form
(Form 11000-C, Section 01999).
C.
FACTORY TESTS:
D.
1.03
Title
1.
The Manufacturer shall allow for one factory visit by the City or Officer-inCharge to witness factory testing. The Contractor shall pay for transportation
and accommodation costs of two people for the visit. Contractor shall
coordinate factory visits with the Officer-in-Charge a minimum of 20 business
days in advance of the factory test.
2.
The following factory tests shall be performed:
a.
DYNAMIC BALANCING: Each fan shall be dynamically balanced in
accordance with ASTM D4167 at the operating speeds specified in
this Section.
b.
AMCA AIR TEST: One of each size fan shall be tested in an AMCA
accredited air and sound laboratory for air performance at the
operating conditions specified in this Section. Testing shall be
performed in accordance with AMCA 210 with the project motor.
SHIPMENT AND STORAGE: As specified in Section 01605 and Section 13230.
SUBMITTALS
A.
PROCEDURES: Section 01300.
B.
SUBMITTAL ITEMS:
1.
A copy of this Section, addendum updates included, with each paragraph
check-marked to indicate compliance or marked to indicate requested
deviations.
2.
A copy of the process and instrumentation diagrams, addendum updates
included, that apply to the equipment listed in the Section. Each diagram
shall check-marked to indicate compliance or marked to indicate requested
deviations.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-2
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
3.
Unit Responsibility Certification Form (Form 11000-C, Section 01999)
attesting that unit responsibility has been assigned in accordance with the
Contract Documents. No other submittal material will be reviewed until the
certificate has been found in conformance with this requirement.
4.
Performance curves for the operating conditions specified in this section.
5.
Motor Data Form (Form 11060-A, Section 01999) plus any information
required for coordination with the variable frequency drives manufacturer
specified under Section 16158.
6.
Dimensioned drawings including motor V-belt drive and base.
7.
Sound power level ratings of the fan and motor at the specified operating
conditions in eight octave bands, in accordance with AMCA Standards 300
and 301.
8.
Octave band sound power levels generated by the fan with motor at the
operating conditions specified in this Section.
9.
Estimated sound pressure level outside the fan measured at 5 feet when
both the inlet and outlet are ducted.
10.
A statement as to whether the fan inlet and outlet ductwork will cause any
adverse system effects on the fan.
11.
Certification that the units have been tested and rated in accordance with the
applicable AMCA Standard Test Code and Certified Ratings Program for air
movement and sound and that they bear the AMCA seal for air movement.
12.
A letter signed by both the manufacturer of the acoustic enclosures specified
in Section 13123 and the manufacturer of the fans specified in this Section
stating that they have coordinated the sizes of the acoustic enclosures to
accommodate the fans.
13.
Operations and maintenance information as specified in Section 01730.
14.
Manufacturer’s Installation Certification Form (Form 11000-A, Section
01999).
15.
Manufacturer’s Instruction Certification Form (Form 11000-B, Section
01999).
16.
Results of the factory testing specified in this Section.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-3
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
1.04
PERFORMANCE REQUIREMENTS
A.
SERVICE CONDITIONS: Equipment shall be suitable for installation and service at a
wastewater treatment plant, under the environmental conditions specified in Section
01800.
B.
OPERATING CONDITIONS:
Equipment
No.
Air Volume,
scfm
F 500,110
Static Pressure, inches w.c.
Maximum Fan Speed, rpm
Design
Emergency
Design
Emergency
20,000
10
13
1615
1750
F 500,120
20,000
10
13
1615
1750
F 550,110
30,400
6
7
1135
1180
F 550,120
30,400
6
7
1135
1180
F 900,110
5,400
8
4
1950
1550
F 900,120
5,400
8
4
1950
1550
C.
DESIGN REQUIREMENTS:
1.
FAN:
Octave Band Total Sound Power Level, dB (reference 10-12 Watts)
Equipment No.
Octave band center frequency, hertz
63
125
250
500
1000
2000
4000
8000
Overall
F 500,110
105.4
108.2
104.4
99.4
94.4
92.4
89.4
86.4
111.5
F 500,120
105.4
108.2
104.4
99.4
94.4
92.4
89.4
86.4
111.5
F 550,110
106.0
108.0
103.0
101.3
96.3
96.3
90.3
83.0
111.6
F 550,120
106.0
108.0
103.0
101.3
96.3
96.3
90.3
83.0
111.6
F 900,110
101.0
100.6
107.6
102.6
98.6
95.6
95.6
88.6
110.6
F 900,120
101.0
100.6
107.6
102.6
98.6
95.6
95.6
88.6
110.6
Sound Pressure Level Outside the Fan
Equipment No.
Housing Radiated Noise, dBA
F 500,110
79.4
F 500,120
79.4
F 550,110
80.8
F 550,120
80.8
F 900,110
84.6
F 900,120
84.6
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-4
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
2.
1.05
MOTOR:
Equipment
No.
HP
Motor
Voltage/phase
Type
F 500,110
75
480/3
TEFC
F 500,120
75
480/3
TEFC
F 550,110
75
480/3
TEFC
F 550,120
75
480/3
TEFC
F 900,110
15
480/3
TEFC
F 900,120
15
480/3
TEFC
SEISMIC ANCHORAGE AND STRUCTURAL DATA
A.
Mechanical, instrumentation and control, electrical, nonstructural systems,
components, and elements permanently attached to the structure shall be anchored
and braced to resist seismic forces. The structural components, seismic
attachments, braces, and anchors to the structure for all parts or elements of the
mechanical and electrical systems shall be designed in accordance with Section
01900.
PART 2 – PRODUCTS
2.01
CANDIDATE MANUFACTURERS/PRODUCTS
A.
Candidate manufacturers and models are listed below. To conform with specified
requirements, the manufacturer’s standard product may require modification.
1.
2.
4.
2.02
New York Blower
Hartzell
Or Approved substitute
MATERIALS
A.
MATERIALS OF CONSTRUCTION:
Component
Material
Housing
Fiberglass reinforced plastic
Wheel
Fiberglass reinforced plastic
Door gasket and shaft seal
Neoprene or Teflon
Hub
Aluminum encapsulated in FRP
Bolts
Type 316L stainless steel
Base
Epoxy coated steel
Shaft
Type 316L stainless steel
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-5
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
Component
Fasteners
B.
2.03
Material
Type 316L stainless steel
FRP FABRICATION:
1.
GENERAL: FRP fabrication shall be in accordance with the National Bureau of
Standard Voluntary Product Standards PS-15-69. FRP construction quality
shall be as specified in Section 13230.
2.
RESIN: Resin shall be premium grade vinyl ester resin, Vipel K0, Derakane
510-A, Dion 9300 or approved substitute. Resin shall achieve ASTM Class I
fire retardance per ASTM E84 with a fire retardance of 25 or less without the
use of antimony.
3.
HOUSING: Fan housings shall be ultraviolet light stabilized. Housings shall be
built up with laminate construction using vinyl ester resin. Outer layers shall
be a 100 percent less carbon impregnation content resin coat. The next layer
shall be a C glass or Nexus corrosion resistant veil followed by another resin
rich coat layer and another C-glass or Nexus veil. The structural core layer
shall be comprised of resin and chopped strand fiberglass. Total glass
content shall be 30 to 40 percent. Wheel and housing shall have a carbonrich resin coating on air stream contact surfaces and shall be grounded
through the base to prevent static buildup.
4.
WHEEL: Fan wheel shall be built up with laminate construction using vinyl
ester resin. The first layer of the wheel laminate shall be a 100 percent resin.
The next layer shall be a C-glass or Nexus corrosion resistant veil followed by
another resin rich coat and another C glass or Nexus veil. The structural core
consisting of chopped strand fiberglass and resin shall be laid next, followed
by a C-glass or Nexus veil, a resin rich coat, another C-glass or Nexus veil, and
a final 100 percent less carbon impregnation content resin coat. Total glass
content shall be 30 to 40 percent. Wheel shall be graphite impregnated and
grounded to prevent static buildup.
5.
TYPE: Construction type and material thicknesses shall be in accordance with
ASTM D4167.
FEATURES
A.
GENERAL: Fans, motors, and accessories shall be suitable for use in a Class I,
Division 1, Group D environment.
B.
FAN:
1.
Fan shall bear the AMCA rating seal for air movement and be listed on the
AMCA website as being approved for air movement prior to bid.
2.
Fans shall be selected to achieve the design requirements specified in this
Section at no greater than 90 percent of the maximum recommended RPM.
Fans shall be non-overloading at all points on their curve. Capacity shall be
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-6
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
determined in accordance with AMCA Standard 210, cataloged performance
licensed to bare the AMCA Rating Seal prior to bid.
C.
3.
Fans shall be medium or high pressure, V-belt driven, centrifugal design with
backward inclined or backward curved impellers. The fan wheel shall be
overhung type with at least two pillow block bearings located away from the
air stream. Fan and motor configuration shall conform to the design
requirements specified in this Section.
4.
Bearings shall be rated for a minimum AFBMA L-10 bearing life of 50,000
hours of operation. The shaft hub and bushings shall be completely
encapsulated in a reinforced plastic laminate. Shaft and wheel are to be
permanently affixed as one unit. An FRP sleeve extending from the back plate
of the wheel through the fan housing shall be provided for protection of the
fan shaft. The rotor shall be dynamically balanced after fabrication.
5.
Fan shall be provided with a 1-1/2 inch FRP drain with plug at the lowest
point of the scroll housing. Unless shown otherwise on the Drawings, plain
round inlets and outlets shall be provided suitable for use with flexible
connections. All flanges shall be factory drilled. The base shall be adequately
braced and equipped with lifting eyes. Housing shall be provided with an
access door and a minimum 6 inch diameter inspection port cleanout.
6.
Fans shall be balanced at the factory to operate without vibration throughout
the full range of operating conditions specified in this Section.
7.
Octave band sound power levels, measured in accordance with ANSI S1-21,
ASHRAE 36, AMCA 300, and subsequent revisions of these standards, shall
not exceed the design levels specified in this Section at any operating
condition.
8.
Fans shall be rated for sound power levels in accordance with AMCA
Standards. Sound power rating shall be decibels (reference 10-12 watts) in
eight octave bands. Sound dBA levels only are not acceptable.
MOTOR AND DRIVE:
1.
Fans shall be operated by variable frequency drives as specified in Section
16158.
2.
Fans shall be V-belt driven by an electric motor mounted to an adjustable
motor slide base located on the exterior side of the fan's bearing pedestal.
Configuration shall be in accordance with AMCA arrangement 9, 9E, or 9F.
3.
The electric motors shall be as specified in Section 11060 and shall be
explosion proof. Electric motors shall have low noise characteristics. Motor
sound levels shall not exceed 80 dBA when measured in accordance with
IEEE No. 85 "Test Procedures for Air Borne Noise Measurements on Rotating
Machinery" over the specified motor speed range.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-7
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
2.04
D.
DIFFERENTIAL PRESSURE INDICATOR: One differential pressure indicator gauge shall
be provided for each fan unit to measure the air pressure drop across the fan. The
gauge shall be provided by the Manufacturer in accordance with Section 17211.
E.
VIBRATION SWITCHES: Provide one vibration switch per fan unit, mounted on the
bearing housing, for measuring vibration at pillow block bearings. Exact installation
location and method to be per manufacturer’s recommendations. Switch set point to
be field adjustable, initially set to close contacts at 1.5 mils peak-to-peak vibration
amplitude. The switch shall mechanically latch the vibration alarm and have a reset
button on the switch. The switch shall not require external power. The switch contacts
configuration and voltage rating shall be as depicted on the Drawings.
F.
SOUND ENCLOSURES: Sound enclosures and sound traps shall be as specified in
Section 13123.
SPARE PARTS
A.
PROCEDURES: Section 11000.
B.
Provide the following spare parts:
1.
2.
3.
4.
2.05
One set of matched belts per fan size and horse-power requirement.
One shaft seal for each fan size.
One set of bearings for each fan size.
One spare differential pressure gauge for each fan size.
EQUIPMENT AND SYSTEM CONTROLS:
A.
Fan controls are provided under Division 17.
PART 3 – EXECUTION
3.01
INSTALLATION
A.
B.
EQUIPMENT MOUNTING:
1.
PROCEDURES: Section 11021.
2.
Install on Type I base with Type B mounting and seismic restraints as
specified in Section 11021.
3.
Vibration isolation mountings shall be of the height-saving type and have a
minimum certifiable deflection of 2.5 inches.
4.
Seismic restraints shall be designed for a 4g lateral acceleration.
ALIGNMENT:
1.
PROCEDURES: Section 11005.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-8
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
3.02
3.03
COMPONENT TEST PHASE
A.
PROCEDURES: Section 01660 and Section 01662.
B.
TESTING: Each fan shall be completely field tested in accordance with Section 15990
to guarantee compliance with the Contract Documents.
MANUFACTURER’S SERVICES
A.
3.04
ON-SITE INSPECTIONS AND TRAINING:
1.
GENERAL: Contractor shall have the responsible equipment Manufacturer to
supply qualified installation technicians to supervise the unloading, erection,
placement, installation, adjustment, testing, and initial start-up of the
equipment specified in this Section. Nothing in the provision, however, shall
be construed as relieving the Contractor of the responsibility of the overall
quality and completeness of the work.
2.
TRAINING SESSIONS: A minimum of 4 hours of training shall be provided by
the Manufacturer’s service representative. Training shall conform to Section
01664 and be certified on Form 11000-B as specified in Section 01999.
MEASUREMENT AND PAYMENT
A.
Centrifugal FRP fans shall not be paid for directly, but shall be considered incidental
and included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15828-9
ADDENDUM NO. 3
CENTRIFUGAL FIBERGLASS
REINFORCED PLASTIC (FRP) FANS
SECTION 15925
DUCT SILENCERS (SOUND TRAPS)
PART 1--GENERAL
1.01
DESCRIPTION
A.
SCOPE: This section includes provisions for the materials, and installation of
rectangular duct silencers (sound traps) for heating, ventilation, and air conditioning
service.
B.
EQUIPMENT LIST:.
ID
Name
ST 200,779
TIPS N Mech Room 2-203
ST 200,780
TIPS N Mech Room 2-203
ST 200,781
TIPS N Mech Room 2-203
ST 200,782
TIPS N Mech Room 2-203
ST 200,783
TIPS East Control Room 2-104
ST 200,784
TIPS West Control Room 2-109
ST 200,785
TIPS West Control Room 2-109
ST 300,770
Headworks Mech Room C 3-102
ST 300,771
Headworks Mech Room C 3-102
ST 300,772
Headworks Mech Room B 3-205
ST 300,773
Headworks Mech Room B 3-205
ST 300,774
Headworks Mech Room A 3-204
ST 300,775
Headworks Mech Room A 3-204
ST 300,776
Headworks Elect Room 3-203
ST 300,777
Headworks Elect Room 3-203
ST 400,770
Generator Room 4-104 Intake
ST 400,771
Generator Room 4-104 Intake
ST 400,772
Generator Room 4-104 Intake
ST 400,773
Generator Room 4-104 Discharge
ST 400,774
Generator Room 4-104 Discharge
ST 400,775
Generator Room 4-104 Discharge
ST 400,776
Generator Room 4-104 Exhaust
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15925-1
ADDENDUM NO. 3
DUCT SILENCERS
(SOUND TRAPS)
ID
C.
1.02
Name
ST 400,777
Generator Room 4-104 Exhaust
ST 400,778
KAN-GEN HVAC Room 4-107 Intake
ST 400,779
KAN-GEN HVAC Room 4-107 Intake
ST 400,780
KAN-GEN HVAC Room 4-107 Intake
ST 400,781
KAN-GEN HVAC Room 4-107 Relief
ST 400,782
KAN-GEN HVAC Room 4-107 Relief
ST 400,783
KAN-GEN HVAC Room 4-107 Relief
ST 800,770
KAN Generator Room 8-105 Exhaust
ST 800,771
KAN Generator Room 8-105 Discharge
ST 800,772
KAN Generator Room 8-105 Intake
Duct silencers size, capacities, attenuation characteristics, special features and
accessories shall be per the Drawings.
QUALITY ASSURANCE
A.
GENERAL: All duct silencers shall be of a single manufacturer to assure compatibility
and ease of installation.
B.
PERFORMANCE AND DESIGN REQUIREMENTS: Silencer ratings shall be determined by
the duct-to-reverberant room method.
C.
OPERATING REQUIREMENTS: Silencers shall be designed to meet the operating
requirements provided in the equipment schedules.
D.
REFERENCES: This section contains references to the following documents. They are
a part of this section as specified and modified. In case of conflict between the
requirements of this section and those of the listed documents, the requirements of
this section shall prevail.
Reference
Title
ASTM E477-84
Standard Test Method for Laboratory Measurements of
Acoustical and Airflow Performance of Duct Liner Materials and
Prefabricated Silencers
ASTM E84-86
Standard Test Method for Surface Burning Characteristics of
Building Materials
NFPA 255-84
Standard Method of Test of Surface Burning Characteristics of
Building Materials
UL 723-83
Standard for Test for Surface Burning Characteristics of Building
Materials
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15925-2
ADDENDUM NO. 3
DUCT SILENCERS
(SOUND TRAPS)
1.03
SUBMITTALS
A.
The following submittals shall be provided in accordance with Section 01300:
1.
2.
3.
4.
1.04
Catalog data and dimensional drawings.
Combustion ratings of acoustical fill.
Construction and materials.
Silencer attenuation
ENVIRONMENTAL CONDITIONS
A.
Equipment shall be suitable for installation and service at a wastewater treatment
plant, under the environmental conditions specified in Section 01800.
PART 2--PRODUCTS
2.01
ACCEPTABLE PRODUCTS
A.
2.02
The City and Officer in Charge believe the following candidate manufacturers are
capable of producing equipment and/or products that will satisfy the requirements
of the Section. This statement, however, shall not be construed as an endorsement
of a particular manufacturer’s products, nor shall it be construed that a named
manufacture’s standard equipment or products will comply with the requirement of
this Section. Candidate manufacturers include Southwest Enclosures Inc., Industrial
Acoustics, Vibro-Acoustics or approved substitute, modified as necessary to provide the
specified features and to meet the specified operating requirements. Some silencer
lengths and insertion losses can only be achieved by Southwest Enclosures Inc. spiral
silencers. If another manufacturer is selected and the silencer length must be
increased to achieve sound performance, the contractor shall be responsible for all
resulting changes at no additional cost to the owner.
MATERIALS AND CONSTRUCTION
A.
HVAC Duct Silencers
1.
Outer casings of duct silencers shall be made of 22-gage 316 stainless steel in
accordance with ASHRAE GUIDE recommended construction for high pressure
rectangular ductwork. Seams shall be lock formed and mastic filled.
2.
Interior partitions shall be made of not less than 26-gage perforated 316
stainless steel.
3.
Filler material shall be of inorganic mineral or glass fiber of a density sufficient
to obtain the specified acoustic performance and be packed under not less
than 5 percent compression to eliminate voids due to vibration and settling.
Material shall be inert, vermin- and moistureproof.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15925-3
ADDENDUM NO. 3
DUCT SILENCERS
(SOUND TRAPS)
4.
Combustion rating for the silencer acoustic fill shall be not less than the
following when tested in accordance with ASTM E84-NFPA Standard 255, or UL
No. 723:
Flamespread classification
Smoke development rating
Fuel contribution
5.
- 25 maximum
- 15 maximum
- 20 maximum
Airtight construction shall be provided by use of a duct sealing compound on
the job site. Sound traps shall not fail structurally when subjected to a
differential air pressure of 8 inches W.C. inside to outside of casing.
PART 3--EXECUTION
3.01
INSTALLATION
A.
3.02
Installation shall be in accordance with the manufacturer's instructions.
MEASUREMENT AND PAYMENT
A.
Duct silencers shall not be paid for directly, but shall be considered incidental and
included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
15925-4
ADDENDUM NO. 3
DUCT SILENCERS
(SOUND TRAPS)
SECTION 16110
RACEWAYS, BOXES, AND SUPPORTS
PART 1 GENERAL
1.01
SUMMARY
A.
1.02
This Section covers the furnishing and installation of electrical conduits, wireways,
boxes, pull boxes, manholes, handholes, fittings and supports. Raceways shall be
provided for lighting, receptacles, power, control, instrumentation, signaling, fire
alarm, and grounding systems.
QUALITY ASSURANCE
A.
Referenced Standards: This Section incorporates by reference the latest revisions of
the following documents. They are part of this Section. In case of conflict between
the requirements of this Section and the listed documents, the Contractor shall point
out the conflict to the Officer-in-Charge; lacking a definitive answer otherwise, the
requirements of the Contract Specifications shall prevail.
Reference
Title
ANSI C80.1
Rigid Steel Conduit-Zinc Coated
ANSI C80.3
Electrical Metallic Tubing-Zinc Coated
ASTM A48 Rev A
Gray Iron Castings
ASTM A193 Rev C
Alloy-Steel and Stainless Steel Bolting Materials
for High Temperature Service
ASTM F512
Smooth-Wall Polyvinylchloride Conduit and
Fittings for Underground Installation
FEDSPEC WW-C-581E
Conduit, Metal, Rigid and Intermediate; and
Coupling, Elbow, and Nipple, Electrical Conduit;
Zinc Coated
FEDSPEC W-C-1094A
Conduit and Conduit Fitting Plastic, Rigid
NEMA ICS 6
Industrial Control and Systems Enclosures
NEMA RN 1
Polyvinyl-Chloride (PVC) Externally Coated
Galvanized Rigid Steel Conduit And Intermediate
Metal Conduit
NEMA TC2
Electrical Plastic Tubing (EPT) and Conduit (EPC
40 and EPC 80)
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-1
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
Reference
1.03
Title
NEMA TC6
PVC and ABS Plastic Utilities Duct for
Underground Installation
NEMA 250
Enclosures for Electrical Equipment (1000 volts
maximum)
NFPA 70
National Electrical Code (NEC)
NFPA 79
Electrical Standards for Industrial Machinery
UL 1
Flexible Metal Electrical Conduit
UL 6
Rigid Metal Electrical Conduit
UL 360
Liquid Tight Flexible Electrical Conduit
UL 651
Rigid Nonmetal Electrical Conduit
SUBMITTALS
A.
Procedures: Section 01300.
B.
Items to be Submitted for This Specification:
1.
Manufacturer's descriptive literature for all materials.
2.
Contractor’s certifications and calculations that the conduit support systems
meet the seismic requirements specified in Sections 16000 and 01900 and
this Section.
3.
The qualifications of the design professional to be charged with design,
inspection and certification of raceway supports and seismic restraint
systems including education, proof of registration, proof of insurance, and
previous experience in performing this type of work. The documentation
shall be sufficient to demonstrate compliance with the requirements of this
Section.
4.
Raceway layouts and layout schedule showing raceway locations for all
raceway systems in each area with respect to structures, other piping and
utilities (ductwork, etc.) and details and location of joints, anchors, supports,
fittings, connections, penetrations, fire stop barriers, supports, expansions
joints, appurtenances, and flexible couplings, as applicable. Drawings shall
be original layouts by the Contractor; photocopies of contract drawings are
not acceptable. This submittal information may be done in conjunction with
the piping support submittals specified in Section 15096.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-2
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
5.
1.04
Submit inscribe text in accordance with the requirements of Section
01300.
DESIGN OF RACEWAY SUPPORTS
A.
General: The raceway support system shall be subject to the same design
requirements as specified for piping hanger and support systems under Section
15096. The raceway system layout may be coordinated with the piping submittals to
reflect the coordination of the layout of these systems. The professional engineering
services for the piping systems may provide the engineering services for raceway
structural supports called for in this Section.
B.
Procedures: In addition to materials and labor required to construct raceway
systems, Contractor shall provide professional engineering services (“design
professional”) for the design and inspection of raceway systems work. The
Contractor shall provide the final design, inspection, and certification for the raceway
supports and seismic restraints on this project.
C.
Qualifications: The design of raceway supports and seismic restraints shall be the
product of a professional engineer retained by the Contractor and currently licensed
to practice in the state of Hawaii. The design professional shall have not less than 5
years experience in the type of raceway support, and seismic restraint design work
required for this project. This requirement, however, shall not be construed as
relieving the Contractor of overall responsibility for this portion of the Work.
Documentation demonstrating qualifications and insurance shall be submitted.
D.
Coordination with Drawings and Specifications: If a particular type of support,
anchor, seismic restraint, or expansion element is detailed on the Drawings, those
elements shall be incorporated into the Contractor’s design. Raceway system
submittals by the Contractor shall include all elements, including unscheduled
raceways.
PART 2 PRODUCTS
2.01
RACEWAY
A.
General requirements for raceway materials specified in this Section are listed in the
RACESPECS sheets at the end of this Section. The type of raceway to be used for
any given area and application shall conform to the requirements of Table A in this
Section.
B.
Field located by the Contractor, unless otherwise shown.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-3
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.02
BOXES AND FITTINGS
A.
B.
C.
D.
E.
General:
1.
Boxes larger then FD boxes shall be constructed of materials as specified in
Section 16000.
2.
At a minimum, box and gutter sizes, metal thickness, and grounding shall
comply with the National Electrical Code.
3.
Bolt-on box covers 3 feet square or larger, or heavier than 25 pounds, shall
have a rigid handle.
Non-Classified Area Boxes and Wiring Gutters: Unless specified otherwise:
1.
Enclosures outdoors shall be provided with neoprene gaskets on the hinged
doors or removable covers.
2.
Doors shall have hinges with clamp locks.
3.
Covers larger than 3 by 4 feet shall be split.
Classified Area Boxes:
1.
Copper free aluminum or stainless steel type 316.
2.
Stainless steel hinges
3.
Stainless steel cover bolts.
Terminals:
1.
Adjustable terminal strip mounting accessories shall be provided.
2.
Cabinets shall be provided with channel mounted terminal blocks rated 30A,
600 VAC, minimum.
3.
Terminals shall be as specified for power terminal blocks in Section 16000.
Classified Location Conduit Seals:
1.
Provide conduit seal fittings where required by NEC Article 500 and the AHJ.
They shall be of the EYS or EZS type with male and female hubs.
2.
Use PVC coated fittings with urethane interior coating for PVC coated RGS.
3.
The sealing compound shall be as prescribed by the manufacturer of the
sealing conduit body.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-4
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
4.
2.03
Conduit seals, including the fittings and filling compounds, shall comply with
NEC Article 500 and the AHJ.
RACEWAY AND CORD SUPPORTS
A.
Unless noted otherwise in this section, support hardware for raceways and cords
shall conform to the following:
Raceway and Cord Support Materials
Area (exposure type)
Supports, structural attachments,
fittings, and accessories
Nuts, bolts, washers, and
fasteners
Indoor dry, indoor wet,
outdoor, submerged,
and process corrosive.
Type 316 stainless steel
Type 316 stainless steel, fully
passivated1
Chemical corrosive
Fiberglass (FRP)
Type 316 stainless steel, fully
passivated1
Note: 1. Stainless steel nuts shall be provided with Tripac 2000 Blue coating, or approved
substitute.
B.
2.04
2.05
Cord grips and J-bolts supports shall be Type 316 stainless steel.
CABLE TRAY
A.
Cable tray specified in this section is for protecting pump cords.
B.
The cable tray and cover shall be Stainless steel Type 316.
C.
The cable tray shall be trough vented bottom with rungs 4” on center and the cover
shall be vented.
D.
Cable tray shall be installed and mounted per Section 16000 and Section 01900.
E.
Cable tray shall be grounded.
MANHOLES AND HANDHOLES
A.
General:
1.
Manholes and handholes shall have non-metallic cable tracks and
adjustable shelves that connect to the tracks. Conductors shall be
supported from the shelves. Conductors shall not be on the bottom of
manholes and handholes. Candidate Manufacturer: Underground Devices
Inc., or approved substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-5
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.
Manhole and handhole covers shall be inscribed. See Contract Drawing for
manhole and handhole inscribe text requirements.
3.
Dimensions as specified in the Schedules.
4.
Manholes and handholes shall be precast with the following:
a.
b.
3.
B.
C.
Solid concrete slab bottom
Slope floors to sump with drain.
Manholes and Handhole frames and covers:
a.
Frames and covers shall be fiberglass reinforced polyester or fiber
reinforced polymer. Frames and covers shall be manufactured to
meet or exceed all specifications of ASTM D3753 and designed for
HS-20 traffic applications (withstand 40,000 lbs. wheel load) at a
minimum. Covers shall be easily removed by one person and shall be
interchangeable.
b.
Frames and covers shall be manufactured from commercial grade
unsaturated polyester thermoset resin with 45-70% fiberglass
reinforcements. Material shall be corrosion resistant to sewer, sewer
gas, salt water and petrochemical hydrocarbons.
c.
Frames and covers shall have quarter turn stainless steel paddle
locks or equivalent locking system. An integrated gasket system to
reduce traffic shock, noise, and odors shall be used.
d.
Provide non-slip low profile waffle tread for covers. Slip resistance
shall be greater than 0.6 as described in ASTM C1028.
f.
Candidate Manufacturer: GMI Composites Inc., East Jordan Ironworks
Company, Fibrelite, or approved substitute.
Handholes:
1.
Designed for H-20 bridge loading.
2.
3,000 psi reinforced concrete construction.
3.
Other features as specified on the Manhole/Handhole Details.
4.
Utility vault, Jensen Precast, or approved substitute.
Manholes:
1.
Designed for H-20 bridge loading.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-6
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.06
2.07
2.
Manholes shall be precast concrete, 3,000 psi strength at 28 days.
3.
Conduit entries shall be no less than 14 inches above floor and 14 inches
below ceiling. Cables supports, clamps or racks shall be provided.
4.
Seal all joints.
5.
Other features as specified on the Details.
6.
Utility vault, Jensen Precast or approved substitute.
REINFORCED CONCRETE- DUCT BANKS
A.
Concrete used for duct banks shall be 3,000 psi with red oxide added as specified in
Section 03300.
B.
Other features as specified on the Details.
UNDERGROUND MARKING TAPE
A.
Used for early warning protection of digging around reinforced concrete duct banks.
B.
Low density polyethylene plastic, nominally 6 inches wide and 4 mil thickness.
C.
Plastic Color: Red.
D.
Imprinted continuously along the length, with message reading similar to "CAUTION –
STOP DIGGING – BURIED ELECTRIC LINE BELOW."
E.
Underground marking tape for HECO medium voltage duct bank shall be per HECO
Electrical Service Installation Manual.
E.
Acceptable Manufacturer:
1.
2.
3.
4.
F.
Brady Identoline
Services and Materials Buried Underground Tape
Somerset (Thomas & Betts) Protect-A-Line
Or Approved substitute.
Underground marking tape for directly buried conduits:
1.
6-inch-wide metallic lined tape with red polyethylene film on top and clear
polyethylene film on the bottom.
2.
The message shall be clearly printed with black over red tape and shall read
"CAUTION ELECTRIC LINE BURIED BELOW.”
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-7
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.08
NAMEPLATES
A.
B.
2.09
2.10
2.11
Provide nameplates for all boxes (scheduled or unscheduled) in accordance with the
requirements of Section 16000. White lettering on blue background. Nameplate
wording shall be as indicated on the Drawings. Nameplates for boxes may be
adhesive backed type.
1.
Junction and terminal boxes up to 4 x 4 x 4 inches: 5/16- x 1-1/2-inch
nameplate with 1/8-inch characters.
2.
Junction and terminal boxes up to 12 x 12 x 12 inches: 1/2- x 2-1/2-inch
nameplate with 3/16-inch characters.
3.
Junction and terminal boxes larger than 12 x 12 x 12 inches: 1-x 6-inch
nameplate with 9/16-inch characters
Where no wording is specified, the Contractor shall provide the functional description
of the device on the nameplate.
RACEWAY MARKERS
A.
Identify each conduit, rack and raceway with solid brass with 0.036-inch minimum
thickness.
B.
Raceway number pressure stamped in 3/16-inch minimum height characters.
C.
Attached to each end of each raceway at each manhole, pullbox, and handhole with
Type 316 stainless steel wire.
FLEXIBLE TEXTILE INNERDUCT
A.
Provide flexible textile 3-Cell innerduct full length of each optical fiber raceway.
B.
Innerduct tensile strength minimum 2,500 lbs, resistance to ground chemicals and
petroleum products.
C.
Will not spiral when installed with a swivel pulling device.
D.
Pre-lubricated for lower friction during product and cable installations.
E.
Pre-installed color pull tapes for quick identification.
F.
Each cell accepts cables up to 1.3 inches in diameter.
FIRESTOPPING
A.
As specified in Section 07841.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-8
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.12
CONDUIT SEALING
A.
Conduit Seals. For 2-inch and larger conduits at below grade penetrations in the
building exterior walls provide conduit seals. Install threaded blank unit fittings in
spare or other unused conduits at these locations. Candidate manufacture: O.Z.
Gedney Type CSM sealing fitting with double grommets, or approved substitute
B.
Foam sealant: For conduit less than 2 inch that has a below grade penetration in a
building exterior wall provide foam type sealant in both ends of conduit (at the
manhole or handhole and at the wall). For all conduits that are connected to a
manhole or handhole and that enter a building provide foam sealant if another
sealing method is not specified. Candidate manufacturers:
1.
2.
3.
2.13
CABLE BOOT
A.
2.14
Provide seal between concrete and cable pre-drilled mounting holes. Flexible seal
allows movement without damage or breaking the seal. Material made of Hygienic
White Silicone and 316 Stainless Steel. Split design with staple to allow seal to be
removed with cable in place. Candidate manufacture: CSI Type Pipetite Reboot with
PTA-1 concrete anchors or approved substitute.
CORROSIVE LOCATIONS
A.
2.15
Arnco Hydra-Seal S-60 sealant
PRC-DeSoto/Semco PR-821 sealant
Approved substitute
Refer to Section 01800 for exposure designations and environmental classifications
by area.
HECO MANHOLES AND DUCT BANKS.
A.
Manholes for HECO’s use shall be sized per HECO’s “Electrical Service Installation
Manual” and the interior dimension shall be no smaller than 6’L X 4’W X 6’D. The
manholes specified for HECO are depicted in the Manhole and Handhole Schedule.
B.
The duct banks specified for HECO’s Underground Service shall be provided per
HECO’s “Electrical Service Installation Manual” chapter on Underground Service.
The duct banks specified for HECO are depicted in the Duct Bank Schedule.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-9
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
PART 3 EXECUTION
3.01
GENERAL
A.
Table A specifies the type of raceway required for each location and application by
RACESPEC sheet, unless otherwise specified on the Drawings or Schedules.
Unscheduled conduit shall be galvanized, rigid steel, RACESPEC Type GRS, unless
otherwise specified in Table A.
Location
Indoor wet and dry
Corrosive; process
and chemicals
Outdoor
Table A
Application/Condition
RACESPEC
Exposed
GRS
Exposed
PGRS
Exposed
PGRS
Box and Enclosure
FD cast ferrous for device boxes
and junction boxes smaller than
6 inches square.
For boxes and enclosures larger
than 6 inches square, as
specified in this Section and
16000.
As specified in this Section and
Section 16000.
FD cast ferrous for device boxes
and junction boxes smaller than
6 inches square.
For boxes and enclosures larger
than 6 inches square, as
specified in this Section and
16000.
Concealed
Underground
Nonclassified
Classified
Classified and
process corrosive
Classified
Embedded in concrete
structure or beneath
slab on grade
Directly buried or in
concrete duct bank
Final connection to
equipment and light
fixtures
Exposed
PVC4
Exposed
PGRS
Final connection to
equipment
XPFS
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
PVC8
LFS
NA
GRS
As specified in this Section and
16000.
As specified in this Section and
16000.
NA
16110-10
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
Location
Architecturally
finished areas
Application/Condition
Concealed in framed
walls and ceiling
spaces
(any circuit)
Final connection to
light fixtures
Architecturally
finished areas
3.02
RACESPEC
EMT, GRS,
or MC
FLEX
Box and Enclosure
Sheet steel.
NA
CONDUIT AND BOXES
A.
B.
General:
1.
The number of directional changes of a conduit shall be limited to 270
degrees in any run between pull boxes.
2.
Conduit runs shall be limited to a maximum of 400 feet, less 100 feet or
fraction thereof, for every 90 degrees of change in direction.
3.
Label all conduits, scheduled or unscheduled.
4.
Seismic Anchorage and Bracing: Sections 16000 and 01900.
5.
Conduit for fiber optic cable bend radius shall be not less then 18 inches.
6.
Raceway hangars and supports shall be installed per the applicable
requirements specified for pipe hangars and supports specified in Section
15096.
7.
Separation requirements as follows:
a.
Electrical conduit that is parallel with pipe shall be a minimum of 12
inches from the pipe.
b.
Electrical conduit shall be a minimum of 6 inch from pipe.
c.
Plant control, data, and signal conduit be a minimum of 24 inches
from medium voltage duct conduit and minimum of 12 inches
separation from power conduit.
Indoor and Outdoor Conduit Systems:
1.
Conduits in architecturally finished type areas such as administration
facilities may utilize embedded conduit to flush mounted devices. Otherwise,
all conduit inside structures shall be exposed unless noted otherwise.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-11
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.
Unless otherwise indicated, the Contractor shall be responsible for
determining conduit routing that conforms to the installation requirements
set forth herein.
3.
Install conduit to conform to the requirements of the RACESPEC sheets and
the following:
a.
Install exposed conduit either parallel or perpendicular to structural
members and surfaces.
b.
Two or more exposed conduits in the same general routing shall be in
parallel with symmetrical bends.
c.
Exposed conduit shall be run on supports spaced not more than 10
feet apart.
d.
Where three or more conduits are located in parallel run, space them
out from the wall using framing channel.
e.
Where conduits are suspended from the ceiling, support systems
shall comply with the requirements as specified within this Section.
f.
Secure conduit rack supports to concrete walls and ceilings by
means of cast-in-place anchors or framing channel concrete inserts.
Area where conduit is routed along egress path secure conduit
directly to concrete wall.
g.
Conduits shall be at least 6 inches from high temperature piping,
ducts, and flues with temperatures higher than 90 degrees C.
h.
Install conduits between the reinforcing steel in walls or slabs which
have reinforcing in both faces. In slabs which have only a single layer
of reinforcing steel, place conduits under the reinforcement.
i.
Route conduit clear of structural openings and indicated future
openings.
j.
Flash and seal watertight those conduits which pass through roofs or
metal walls.
k.
Neatly group conduit into any openings cut into concrete and
masonry structures, and grout using nonshrink type grout.
l.
During construction, cap or plug conduits to prevent entrance of dirt,
trash, and water.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-12
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
C.
m.
Terminate exposed conduit stubs for future use with corrosion
resistant threaded caps or threaded plugs.
n.
Determine concealed conduit stubup locations from the
manufacturer's shop drawings.
o.
Terminate concealed conduit for future use in equipment or by
galvanized couplings plugged flush with structural surfaces.
p.
Where the drawings indicate future duplication of equipment wired
hereunder, provide concealed portions of conduits for future
equipment.
q.
Conduit installed horizontally shall allow headroom of at least 7 feet
except where it may be installed along structures, piping, and
equipment, or in other areas where headroom cannot be maintained
because of other considerations.
r.
Terminate all conduits that enter enclosures by fittings that ensure
that the NEMA rating of the enclosure is not affected or changed.
s.
Connect underground metallic or nonmetallic conduit that turns out
of concrete, masonry or earth to a 90-degree elbow of PVC-coated
rigid steel conduit before emergence.
t.
Provide a concrete curb at all conduit that transitions upward from a
horizontal surface (for example from a floor). See drawings for
depictions of conduit curbs.
u.
Conduit across structural joints where structural movement is
allowed shall have an O.Z. Type DX or Crouse-Hinds Type XD bonded,
weathertight expansion and deflection fitting of that conduit size.
v.
Provide conduit seal fittings where required by NEC Articles 500 and
501 and the AHJ. Classified areas are shown on the Drawings.
w.
Provide fire stop per specification 07841 at penetrations of walls or
floors that have a fire rating identified in the drawings.
Underground Conduit System: All excavation, backfilling, and concrete work shall
conform to respective sections of these specifications. Underground conduit shall
conform to the following requirements:
1.
Lighting circuit raceways may be installed direct buried for underground
circuits. Unless otherwise indicated, all other underground conduits shall be
in reinforced concrete. All concrete encasements shall be reinforced.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-13
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
2.
Concrete encasement on exposed outdoor conduit risers shall continue to
3 inches above grade, with top crowned and edges chamfered.
3.
Underground conduit bend radius shall be not less than 2 feet at vertical
risers nor less than 3 feet elsewhere.
4.
Unless otherwise indicated, underground conduits and conduit banks shall
have 2 feet minimum earth cover. Power duct banks shall not be installed
with more than 3 feet of cover unless specified as such. If deeper
installation is required, a thermal derating calculation shall be provided
indicating that the maximum allowable temperature rise of the cable or
conduit is not exceeded.
5.
Medium voltage duct banks, designated with the letter “H”, shall maintain a
2 feet separation from plant control duct banks designated with the letters:
“C, S, D, F, or PC” where possible. Medium voltage duct banks shall maintain
a 1 foot separation from low voltage duct banks designated with the letters “
or PC” where possible.
6.
Underground conduit banks through building walls shall be cast-in-place or
concreted into boxouts with waterstops on all sides of the boxout.
Waterstops shall be as specified in Section 03300.
7.
Using a special rubber gasketed sleeve and joint assemblies, or with sleeves
and modular rubber sealing elements, seal watertight those conduits not
encased in concrete and passing through walls that have one side in contact
with earth.
8.
Immediately upon completion of pouring concrete, thoroughly swab conduits
on the inside. After the concrete has set, and before backfilling, pull a
mandrel, having a diameter equal to the nominal conduit inside diameter
minus 1/2 inch, and not less than 4 inches long, through each conduit. If
the mandrel showed signs of protrusions on the inside of the conduit, repair
or replace the conduit.
9.
Provide all spare raceways with a nylon pull rope.
10.
Conduit shall be sloped to drain toward manholes or hand holes.
11.
Select borrow for electrical duct banks shall be Type C fill material per
Section 02200. Material above select borrow shall be per typical trench
section for duct banks detail.
12.
Trenching and backfilling for HECO medium voltage duct bank shall be per
HECO Electrical Service Installation Manual.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-14
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
D.
3.03
Boxes:
1.
Independently supported by galvanized brackets, expansion bolts, toggle
bolts, or machine or wood screws as appropriate.
2.
Do not use wooden plugs inserted in masonry or concrete as a base to
secure boxes nor welding or brazing for attachment.
RACESPEC SHEETS
A.
The following RACESPECS are included in this Section:
RACESPEC Symbol
Raceway Description
EMT
Electrical Metallic Tubing
FLEX
Flexible Steel Conduit
GRS
Rigid Steel Conduit
LFS
Liquidtight Flexible Steel Conduit
PGRS
PVC Coated Rigid Steel Conduit
PVC4
Schedule 40 PVC Conduit
PVC8
Schedule 80 PVC Conduit
WW
Wireway and Auxiliary Gutter
XPFS
Explosion-proof Flexible Steel Conduit
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-15
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
EMT
Description:
Electrical Metallic Tubing
Compliance:
ANSI and UL
Finish:
Electro-galvanized steel
Minimum size:
3/4 inch
Fittings:
Compression type.
Fittings Inside Concrete
Block (CMU) Walls:
Concrete-tight.
Boxes:
Electrogalvanized sheet steel.
NEMA Class 1 stamped or form-bent steel with screw covers.
Installation:
Devices installed using sheet steel boxes shall be mounted flush in
walls unless noted otherwise.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-16
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
FLEX
Description:
Flexible Steel Conduit
Application:
Final connection to lighting fixtures in architecturally finished areas
only.
Compliance:
UL 1
Construction:
Spirally wound galvanized steel strip with successive convolutions
securely interlocked.
Minimum size:
1/2 inch
Fittings:
Compression type.
Installation:
The length shall not exceed 36 inches, unless a longer length is
specified on the Instrumentation Details.
Other:
FLEX shall be provided with an internal ground wire.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-17
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
GRS
Description:
Rigid Steel Conduit
Compliance:
ANSI C80.1, UL 6
Finish:
Hot-dip galvanized after fabrication, inside and outside. Smooth
finished surfaces.
Manufacturers:
Allied Tube and Conduit Corp., Wheatland Tube Co., or approved
substitute.
Minimum size:
Unless otherwise specified, 3/4 inch for exposed, 1 inch for
embedded, encased, or otherwise inaccessible.
Fittings:
Hubs:
Insulated throat with bonding locknut, hot-dip galvanized. The hubs
shall utilize a neoprene O-ring and shall provide a watertight
connection. O.Z. Gedney, CHM-XXT, or approved substitute.
Unions:
Electrogalvanized ferrous alloy type Appleton UNF or UNY, CrouseHinds UNF or UNY, or approved substitute. Threadless fittings are not
acceptable.
Conduit Bodies:
Ferrous alloy type with screw taps for fastening covers. Gaskets shall
be made of neoprene.
Boxes:
Type and enclosure rating as specified in this Section and in Section
16000.
Elbows:
(3/4” thru 1-1/2”)
Factory fabricated or field bent.
(2” thru 6”)
Factory fabricated only.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-18
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
GRS (continued)
Conduit Bodies:
(3/4” thru 4”)
Malleable iron, hot-dip galvanized, unless otherwise noted.
Neoprene gaskets for all access plates. Tapered threads for all
conduit entrances.
(5” and 6”)
Electrogalvanized iron or cast iron box.
Expansion Fittings:
Expansion fittings in embedded runs shall be watertight and shall be
provided with an internal bonding jumper. The expansion material
shall be neoprene and shall allow for 3/4-inch movement in any
direction.
Manufacturers:
Appleton, Crouse-Hinds, Hubbel, O.Z. Gedney, or approved substitute.
Installation:
Rigid steel conduit shall be made up tight and with conductive
“coppershield” thread compound. Joints shall be made with
standard couplings or threaded unions. Steel conduit shall be
supported away from the structures using hot-dip galvanized
malleable iron straps with nesting backs.
Conduit entering boxes shall be terminated with a threaded hub with
a grounding bushing.
Exposed male threads or rigid steel conduit shall be coated with zincrich paint.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-19
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
LFS
Description:
Liquidtight Flexible Steel Conduit
Application:
Final connection to equipment subject to vibration or adjustment.
Compliance:
UL 360
Construction:
Spirally wound galvanized steel strip with successive convolutions
securely interlocked and jacketed with liquidtight plastic cover.
Minimum Size:
3/4 inch
1/2 inch for instruments
Fittings:
Hot dip or mechanically galvanized malleable iron body and gland nut
with cast-in lug, brass grounding ferrule threaded to engage conduit
spiral and O-ring seals around the conduit and box connection and
insulated throat. Where applicable, 45- and 90-degree fittings shall
be used.
Installation:
The length of flexible liquidtight conduit shall not exceed 15 times the
trade diameter of the conduit. The length shall not exceed 36
inches, unless a longer length is specified on the Instrumentation
Details.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-20
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
PGRS
Description:
Rigid Steel Conduit, Corrosion-Resistant, Polyvinyl Chloride (PVC)
Coated
Compliance:
ANSI C80.1, UL 6, NEMA RN1
Finish:
PGRS shall be hot dipped galvanized rigid steel conduit. The inside
and outside, as well as the threads shall be galvanized. A minimum
40-mil-thick PVC coating shall be bonded to the outside of the
conduit and the inside shall be coated with 2-mil urethane. Coating
shall be free of pinholes. Bending of conduit shall not damage either
the interior or exterior coating. Bond strength shall exceed the
tensile strength of the PVC coat. Elbows shall be factory made and
coated.
Minimum size:
3/4 inch
Fittings:
Ferrou
Ferrous alloy
alloy, coating the same thickness as the conduit and
provided with Type 316 stainless steel hardware. Conduit and
fittings shall be manufactured by the same company.
Hubs:
Hubs for connection of conduit to junction, device, or terminal boxes
shall be threaded and made of ferrou
ferrous alloy
alloy. Hubs shall have
insulated bushings. The hubs shall utilize a neoprene O-ring and
shall provide a watertight connection.
Boxes:
FS/FD boxes PVC coated. Type and enclosure rating as specified in
this Section and in Section 16000.
Manufacturers:
Ocal, PlastiPlasti-Bond, or approved substitute.
substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-21
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
PGRS (continued)
Installation:
PVC coated conduit shall be supported away from the structure using
PVC coated conduit wall hangers. All conduit threads shall be
covered by a plastic overlap which shall be coated and sealed per
manufacturer’s recommendations. Plastic-coated conduit shall be
made tight with special wrenches and fittings designed for tightening
PVC coated conduit. Pipe wrenches and channel locks shall not be
used for tightening plastic-coated conduits. Damaged areas shall be
patched, using manufacturer’s recommended material. The area to
be patched shall be built up to the full thickness of the coating.
Painted fittings are not acceptable.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-22
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
PVC4
Description:
Rigid Nonmetallic Conduit
Application:
Heavy wall thickness for concrete encasement .
Compliance:
NEMA TC2, UL 651
Construction:
Schedule 40, high-impact, polyvinyl chloride (PVC)
Minimum Size:
3/4 inch exposed; 1 inch embedded or encased
Fittings:
PVC solvent weld type
Installation:
Joints shall be made with standard PVC couplings.
PVC conduit shall have bell ends where terminated at walls and
boxes.
Temperature Rating:
90 degrees C
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-23
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
PVC8
Description:
Rigid Nonmetallic Conduit, extra heavy wall thickness.
Compliance:
NEMA TC2, UL 651
Construction:
Schedule 80, high-impact polyvinyl chloride (PVC)
Minimum Size:
3/4 inch exposed; 1 inch embedded or encased
Fittings:
PVC solvent weld type
Boxes:
Type and enclosure rating as specified in this Section and in Section
16000.
Installation:
PVC conduit shall have bell ends where terminated at walls.
Temperature Rating:
90 degrees C
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-24
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
WW
Description:
Wireway and Auxiliary Gutter, flanged, oiltight type with hinged covers
Compliance:
JIC EMP-1
Minimum Size:
8 by 8 inches
Finish:
Hot-dip galvanized after fabrication, inside and outside. Smooth
finished surfaces.
Application:
As indicated on the Drawings.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-25
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.03
RACEWAY SPECIFICATION SHEETS (RACESPEC)
Raceway Identification:
XPFS
Description:
Explosionproof Flexible Steel Conduit
Application:
XPFS Conduit shall be used for final connections to motors
and other equipment subject to vibration or adjustment in
Class I Division 1 classified areas
XFSC shall be suitable for use in Class I, Division 1, Groups C
and D classified areas as specified in the NEC and shall be
watertight.
Minimum size:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
1/2 inch
16110-26
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
3.04
MEASUREMENT AND PAYMENT
A.
Items in this Section shall not be paid for directly, but shall be considered incidental
and included in the lump sum bids for the respective items in the Proposal Schedule.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16110-27
ADDENDUM NO. 3
RACEWAYS, BOXES, AND SUPPORTS
SECTION 16890
FIBER OPTIC NETWORK EQUIPMENT
PART 1--GENERAL
1.01
DESCRIPTION
A.
1.02
SCOPE:
1.
This section specifies requirements for indoor/outdoor rated single-mode
fiber optic data communication cables including installation, terminations,
termination cabinets, fiber optic panels, testing, appurtenances and
accessories required to complete the fiber optic cabling system. No splicing
allowed.
2.
Provide tools, supplies, materials, equipment, test equipment and the labor
for the cable installation and testing of a complete and operable fiber optic
cabling system as specified herein on the Cable Specification Sheets.
3.
Provide fiber optic cabling and fiber optic network equipment that is
compatible with the existing fiber optic data communication system and as
specified in this Section and on Drawings. New fiber optic cabling shall be
provided as a minimum to modify the existing process control system (PCS)
network; extend the DIT network; and, add a process camera system work
station in the Administrative Building. DIT network fiber optic cabling can not
share fiber optic network equipment with the PCS fiber optic network
equipment or the process camera system fiber optic network equipment.
4
Distributed antenna system (DAS) fiber optic network cabling shall be the unit
responsibility of the Section 17711, DAS Installation Contractor.
5.
Any work associated with existing equipment including Installing or modifying
existing panels or control system equipment or network cable or equipment
requires prior approval from Edmund Lung, City and County of Honolulu ENV
before work is to commence. The request must include a detailed work plan,
drawings, and other reference information necessary for the City to
understand what work is to be performed. This request must identify the
system and schedule for the work to begin and conclude. Any system not
covered by the plan must have an additional approval request submitted
prior to work beginning. Any work preformed on existing systems as
identified in the contract documents without prior approval may be subject to
removal and re-installation at the contractor's cost.
QUALITY ASSURANCE
A.
Fiber Optic Cable Manufacturer: Cable manufacturer shall have a minimum of seven
years manufacturing experience and shall be ISO 9001 certified.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-1
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
B.
Fiber Optic Cable Installer: Installation, termination, and testing of equipment and
cabling provided under this section shall be performed by qualified and skilled
technicians who are regularly engaged in fiber optic cabling system work of similar
complexity. Installer shall be licensed and certified to perform work as specified.
C.
Reference Standards:
1.
This section contains references to the standards listed below. Where a
referenced document contains references to other standards, those
documents are included as references under this section as if referenced
directly. In the event of conflict between the requirements of this section and
those of the listed documents, the requirements of this section shall prevail.
2.
Unless otherwise specified, references to standards shall mean the
documents in effect on the effective date of the Agreement. If referenced
documents have been discontinued by the issuing organization, references to
those documents shall mean the replacement documents issued or
otherwise identified by that organization or, if there are no replacement
documents, the last version of the document before it was discontinued.
3.
The City and County of Honolulu P1830 standard for Ethernet, to be provided
by the City and County on request, shall be the primary governing document
for fiber optic material and installation standards. Where requirements
specified in that standard vary from those specified in this section, the
requirements of the P1830 standard shall prevail.
a.
ANSI/ICEA S-87-640: Standard for Optic Fiber Outside Plant
Communications Cable.
b.
AASHTO: HS-20 Truck Loading.
c.
ASTM F 512: Smooth-Wall Poly (Vinyl Chloride)(PVC) Conduit and
Fittings for Underground Installation.
d.
ANSI/ICEA S-87-640: Standard for Optic Fiber Outside Plant
Communications Cable.
e.
ANSI/TIE/EIA 568-B.3: Commercial Building Telecommunications
Cabling Standard part 3.
f.
BELLCORE GR-20-CORE: Generic Requirements for Optical Fiber and
Optical Fiber Cables.
g.
BELLCORE GR-409-CORE: Generic Requirements for Intra-building
Fiber Cable.
h.
BELLCORE GR-487-CORE: Generic Requirements for Electronic
Equipment Cabinets.
i.
ISO-9001: Quality Management Systems.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-2
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
D.
E.
1.03
j.
ITU G.652: Recommendation - Characteristics of a single-mode
optical fiber cable.
k.
ANSI/NECA 301: National Electrical Contractors Association –
Standard for Installing and Testing Fiber Optic Cables.
l.
NFPA 70: National Electric Code (NEC).
m.
TIA/EIA-455-86: FOTP-86 Fiber Optic Cable Jacket Shrinkage.
n.
TIA/EIA-455-107A: FOTP-107 Determination of Component
Reflectance or Link/System Return Loss Using a Loss Test Set.
o.
TIA/EIA-526-7: Measurement of Optical Power Loss of Installed
Single-Mode Fiber Cable Plant.
p.
TIA/EIA-598-B: Standard for Optical Fiber Cable Color Coding.
q.
P1830: City and County of Honolulu Ethernet and Ethernet/IP
Network Standard.
Fiber Optic Cable Factory Test: Manufacturer’s factory testing shall be conducted for
all fiber optic cable reels provided for this Contract. Test documentation shall include
the following:
1.
Measurement of fiber length using Optical Time Domain Reflectometer
(OTDR).
2.
Measurement of average attenuation using OTDR.
3.
Traces of OTDR measurements taken.
4.
Test for short distance cable fault detection using Visual Tracer.
Fiber Optic Cable Certification: Terminating and testing shall be conducted by Fiber
Optics Association Certified Fiber Optic Technicians (CFOT).
SUBMITTALS
A.
PROCEDURES: Section 01300 and Section 16000.
B.
SUBMITTAL ITEMS:
1.
A copy of this section, with addendum updates included and each paragraph
check-marked to indicate specification compliance or marked to indicate
requested deviations from specification requirements. A check mark shall
denote full compliance with a paragraph as a whole. If deviations from the
specifications are indicated, and therefore requested by the Contractor, each
deviation shall be underlined and denoted by a number in the margin to the
right of the identified paragraph, referenced to a detailed written explanation of
the reasons for requesting the deviation. The Officer-in-Charge shall be the final
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-3
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
authority for determining acceptability of requested deviations. The remaining
portions of the paragraph not underlined will signify compliance on the part of
the Contractor with the specifications.
2.
A copy of the contract document drawings showing fiber optic system
terminations and appurtenances, marked to show specific changes necessary
for the supplied equipment. If no changes are required, the drawings shall be
marked “No Changes Required.” Manufacturer’s specifications, data sheets,
and catalog literature for the indoor/outdoor rated fiber optic cable that
clearly and unambiguously shows that the cable meets all the requirements
specified herein.
3.
Detail work plan and drawings associated with existing equipment and
schedule to perform and complete work; submit to Edmund Lung, City and
County of Honolulu ENV and the Officer-in-Charge for approval before
commencing.
4.
Field verified drawings of the existing fiber optic network infrastructure and
fiber optic terminations as specified in this Section and in the Drawings.
5.
Manufacturer's catalog literature and catalog data sheets for the following
items, marked to indicate products proposed, as applicable to the project:
6.
a.
Fiber optic cables including manufactures’ maximum recommended
pulling tension
b.
Fiber optic cable termination connectors
c.
Fiber optic patch cords
d.
Fiber optic termination panels
e.
Fiber optic adapter plug-in
f.
Fiber optic patch cord storage
g.
Fiber optic cable clamp kit
h.
Connector/Adapter cleaning kit
i.
Innerduct including manufacturers’ maximum recommended pulling
tension and accessories
j.
Protective tubing for fiber optic patch cords
k.
Cable pulling grips, swivel, and lubricant
Shop drawings:
a.
Termination panel fabrication and layout drawings with complete list
of materials and nameplate engraving list.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-4
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
b.
Interconnection cable diagrams for the complete system, showing
each fiber and color in each cable with unique cable and fiber
numbering. Each termination point shall be clearly marked.
7.
Manufacturer's operation and maintenance information as specified in
Section 01730. Manual shall include final reviewed submittal as built to
show actual field installation.
8.
Provide a separate Fiber Optic Patch Panel Schedule for each new Fiber Optic
Patch Panel specified. Provide a separate Fiber Optic Patch Panel Schedule
for each existing Fiber Optic Patch Panel specified; include field inspection to
document the existing fiber optic network routing
routing and fiber optic patch cable
connections, and add new patch cable connections as specified. Patch
Schedule for new and existing fiber optics terminations shall include the
following as minimum:
Patch From
Patch To
Network Connector
Patch
Color
Panel
Type
DEVICE BLOCK PORT/PAIR DEVICE BLOCK PORT Label
9.
Qualifications:
a.
Contractor's experience and resumes of the personnel installing and
testing the fiber optic system, including any factory certifications.
b.
Information on five successfully performed cable installations of
comparable size and complexity with name, address, and telephone
number of facility owner, name of the project and completion date,
and type of conduit system and length of cable pulled.
c.
Proof of certification for terminating and testing personnel per
paragraph 1.02 E.
10.
Innerduct pulling plan as specified in Part 3.
11.
Fiber cable pulling plan as specified in Part 3.
12.
Submit cable samples for review that include the specified cable marking.
13.
Test plan as specified in Part 3.
PART 2--PRODUCTS
2.01
GENERAL
A.
Provide fiber optic cable jacket: free of holes, splits, and blisters with no metal
elements and of a consistent thickness.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-5
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
2.02
2.03
IDENTIFICATION TAPE
A.
Provide a 6-inch wide magnetically detectable warning tape with orange protective
polyethylene jacket. Provide polyethylene tape continuously imprinted "CAUTIONFIBER OPTIC CABLE".
B.
Identification warning tape shall be Teletrace by George Ingraham, Vikamatic, or
approved substitute.
TRACER WIRE
A.
2.04
2.05
PULL ROPE
A.
Provide a low friction, polyethylene jacketed, polypropylene rope with 1,800 psi of
tensile strength.
B.
Pull rope shall be Vikamatic "Fiber Glide" or approved substitute.
INNERDUCT
A.
2.06
2.07
Reference Section 16110.
SLACK ENCLOSURES
A.
Provide slack enclosure with minimum inside dimensions of 30 inches x 24 inches x
9-1/2 inches.
B.
Slack enclosure shall be Carlon SLK 12 or approved equivalent.
DUCT PLUGS
A.
2.08
Provide a #12 AWG XHHW insulated green stranded copper wire with a multi-pin
terminal block for termination of the tracer wire in concrete manhole / pullbox for
tracer wire access. Tracer wire is only required for non-metallic direct buried conduit.
Duct plugs shall be Jackmoon or approved equivalent.
CABLE AND PATCH IDENTIFICATION TAGS
A.
Provide identification tag on the cable as shown on Cable Route Schedule.
B.
Provide identification label on the fiber optic patch:
“FROM:_____ /BLOCK PORT:______ - TO:_____ /BLOCK PORT :_______ ”
C.
Cable identification tags shall be Brady or Thomas & Betts or approved substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-6
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
2.09
FIBER OPTIC CABLE PATCH CORDS
A.
B.
2.10
General:
1.
Provide preparation for the connections including polishing, connectors,
hardware, cleaving tool, continuity tester, visual fault locator, and supplies for
installation of connectors. Terminations shall be LC type at the patch panel
end and the type of connector on the other end shall be coordinated with
device requirements which may be SC type of LC type. Fusion-spliced pigtails
are not acceptable.
2.
Fiber optic cable connections shall be provided with ceramic ferrules,
polycarbonate not acceptable.
Single Mode Patch Cord Characteristics: Patch cords shall be 8.3 µm single 125 µm
coated duplex fiber with jacket and connectors on both ends. Attenuation shall be a
maximum of 0.2 dB. Provide length required for connection from patch panel to
equipment. Color: Aqua Blue.
FIBER OPTIC PANELS
A.
General: Fiber optic patch panels shall consist of a system of components for
routing, supporting, and terminating the fiber optic cables specified herein.
Terminations shall be LC type.
B.
Wall Mount type fiber optic patch panel description:
1.
Wall-mount type fiber optic patch panels constructed of aluminum or steel
with removable hinged metal doors. NEMA 3 rated for indoor and outdoor
non-corrosive environments. NEMA 4X rated for indoor and outdoor corrosive
environments.
2.
Mounting hardware, cable clamps and grommets, cable routers, storage
decks, connector racks, and items for a complete system.
3.
Machine printed port labeling system.
4.
Cable routers and storage decks to retain cables’ minimum bending radius.
5.
Sufficient quantity of ports to terminate the number of fiber strands specified
and blank covers for unused port spaces.
6.
One port for each fiber in accordance with the specified cable type.
7.
Panel shall be Corning Cable Systems ICH (NEMA 3), EDC (NEMA 4X) or
approved substitute.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-7
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
C.
19” Rack type fiber optic patch panel description:
1.
The panel shall be 19-inch rack mountable.
2.
Compact, Modular design, and with a cable management system.
3.
The panel shall be furnished with strain relief cable attachment points, fiber
organizers, and bend radius hardware.
4.
Adaptor must be color according to EIT/TIA 568 B.
5.
The panel shall be furnished with an integral lock to prevent unauthorized
entry.
6.
The patch panel shall have capacity for 144 LC type fiber connections as
shown in the contract drawings and fiber optic patch schedule, factoryinstalled adaptors with pigtails factory-installed on the panel.
7.
Rack shall be Corning Cable System CCH (NEMA 3) or approved substitute.
PART 3--EXECUTION
3.01
RACEWAY SYSTEM
A.
B.
Conduit Installation:
1.
Provide and install fiber cable identification tags in each access vault and
pullbox as specified above.
2.
Tracer wire shall be installed in the trench with fiber optic cable conduit and
at pullbox / manholes with ten feet of tracer wire coiled and secured as
specified herein.
Conduit System Cleaning and Testing:
1.
All conduits used for fiber cabling shall be cleaned of loose material by brush
and compressed air following the backfill placement and compaction.
Provide a test mandrel approximately 3/8 inch smaller than the inside
diameter to be passed through conduits to detect alignment and deformation
problems. Remove and replace conduit that fails the mandrel test. The
replacement conduit shall then be cleaned and tested as described herein.
2.
Cleaning and testing of the conduit shall be witnessed by the Officer-inCharge for conduit sections between adjacent pull boxes or manholes for the
entire conduit route. Provide 5-day advance notice of the cleaning schedule
and test location to the Officer-in-Charge.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-8
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
C.
D.
Innerduct Installation Pulling Plan:
1.
Develop an innerduct pulling plan with proposed pull points, the direction of
the pull, and the equipment with raceway lengths and bends included.
2.
Verify routes and pull distances using the drawings and by field inspection.
3.
Perform the pull tension calculations during the development of the pull plan
and submit with the plan for approval not later than 30 days prior to
installation.
Innerduct Installation:
1.
Conduits shall be cleaned and tested prior to installation of innerducts, where
shown. Innerduct handling and storage shall be performed in accordance
with the manufacturer’s recommendations and installed in continuous
lengths without intermediate splices inside of the conduits. The installation
personnel shall be experienced with specific knowledge of the innerduct
manufacturer's recommended procedures.
2.
Provide large diameter wheels, pulling sheaves, and cable guides to maintain
the specified bending radius. Tension monitoring shall use commercial
dynamometers or load-cell instruments. Conduits shall have a lubricant
applied at each conduit ingress and egress location and during the pull
operation. Innerducts and conduits shall be continuously lubricated during
the pulling procedures. Lubricant shall be Polywater Type F or equal.
3.
Innerduct shall be installed using a hydraulic capstan or winch equipped with
a recording running line dynameter graph which measures and records
pulling tensions and pulled in a steady continuous manner without exceeding
the bending radius of the innerduct. Tension in the innerduct during
installation shall not exceed the manufacturer’s specification for tensile
loading or bend limits.
4.
Installation equipment shall prevent preset pulling tension from being
exceeded as determined by the Innerduct manufacturer. After the innerducts
are installed, rack the three innerducts to the side wall inside of pullbox or
manhole wall with a slack enclosure (every fourth pull point) with the bottom
of the slack enclosure 3” above the highest racked innerduct.
5.
Align cable entry cutouts in the same direction as the racking. The orange
innerduct shall be laid into the cable entry cutouts on each side and not
coupled.
6.
After racking, all conduits and innerducts shall be sealed as follows:
a.
Triplex duct plugs shall be installed on conduits that have innerduct.
b.
Blank duct plugs shall be installed on empty conduits.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-9
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
E.
3.02
c.
Blank duct plugs shall be installed on innerducts that are not
coupled.
d.
The tracer wire terminal block shall be located on the inside wall near
the top of the concrete manhole ladder or pullbox and the wire routed
to the terminal block and terminated.
Innerduct Acceptance: The installation will be inspected for:
1.
Slack enclosures: properly located and secured.
2.
Racking of innerducts: complete and securely attached.
3.
Conduits and innerducts: securely plugged with the proper sized duct plug.
4.
Tracer wires: properly routed and terminated.
5.
Defective Work: corrected and the innerduct re-inspected.
FIBER OPTIC SYSTEM
A.
B.
Fiber Optic Cable Installation Plan:
1.
Submit 30 days prior to cable installation.
2.
Air assisted cable placement method using high speed air blowing, push-pull,
cable jetting plan with the procedure, the equipment setup, and a work plan.
3.
Work plan shall include the following:
a.
Tension calculations
b.
Indicate additional pull boxes required, including station number and
a written description of the location
c.
Detailed description of pull operation methods for raceways
d.
Tools and equipment for cable installation and testing
e.
Physical location of equipment setup and type
f.
Safety Plan and cable pulling operations
g.
Detailed schedule for pulling and testing cables
Fiber Optic Cable Installation:
1.
Fiber optic cable handling and storage shall be performed in accordance with
the manufacturer’s recommendations. The cable installation personnel shall
be experienced with specific knowledge of the cable manufacturer's
recommended procedures. Cable reel lagging shall remain on the cable reels
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-10
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
until they arrive at the installation site. If the lagging has been removed,
securely fasten the cable ends to avoid damage during transit. The cable
shall not be left exposed or unattended during the installation process. Verify
cable is not damaged during storage and installation.
2.
Cable tension shall not exceed the manufacturer’s specification for tensile
loading. Pulling tension shall be continuously monitored and recorded during
installation. Fiber cable shall be pulled in a steady continuous manner. The
bending radius of the cable shall not be exceeded. Cable tension monitoring
devices shall not exceed cable pull tension and bend limits.
3.
Cable shall be installed in continuous lengths without intermediate splices.
Cable shall be provided without splices. Splicing is not allowed.
4.
Additional cable shall extend to the nearest clean and level work area.
5.
Cable strength elements shall be properly attached to a pulling eye and 600
lb breakaway swivel. Kellums pulling grips are not allowed except for shortlength hand pulls.
6.
Cable and conduits shall be lubricated during the pulling procedures. Each
pullbox / concrete manhole / vault shall contain cable coiled into a slack loop
and stored in a slack enclosure.
7.
Tensile and bending limitation shall not be exceeded when power equipment
is used to install cables. Tension monitoring shall use commercial
dynamometers or load-cell instruments with chart recorder. Large diameter
wheels, pulling sheaves, and cable guides shall maintain the specified
bending radius.
8.
Cable shall be installed using a hydraulic capstan or winch equipped with a
recording running line dynamometer graph which measures and records
pulling tensions. Provide Polywater Type 5 lubricant, or equal.
9.
Cable pull records shall be documented by a graph which is annotated with
the following information:
a.
b.
c.
d.
e.
f.
10.
Reel number.
Station or pullbox from and station or pullbox to.
Date and time.
Explanations for abnormalities in readings or interruptions.
Sign-off by Contractor and Officer-in-Charge.
Submit fiber optic pull records as specified herein.
Racking shall conform to the following:
a.
Loosely secure innerduct/cables in racked position with Ty-Raps or
equal.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-11
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
C.
3.03
b.
Attach imprinted plastic coated cloth identification/warning tags to
the innerduct/cable in at least two locations in each pullbox/concrete
manhole/vault.
c.
Provide tags manufactured by Brady or Thomas & Betts.
11.
Protect coiled cable to prevent damage to the cable and fibers with racking
securing cables to brackets and racking hardware that extend from the
sidewalls of the handhole. When cables are securely racked, unused conduits
and void areas around conduit containing cables shall be sealed. In concrete
manholes and vaults, coiled cable shall be placed into a slack enclosure to
prevent damage to the cable and fibers.
12.
Provide Semco compound or equal material.
Fiber Optic Cable Terminations:
1.
Work shall be performed by trained and FOA certified technicians and in
accordance with the manufacturer’s recommendations in the performance of
installation and termination work.
2.
Active and spare fiber optic cable fibers shall be provided with a breakout kit,
and terminated with ST type terminations.
FIBER OPTIC TESTING:
A.
The Officer-in-Charge shall be notified a minimum of 5 days prior to tests and reserve
the right to witness field tests.
B.
Test Equipment:
C.
1.
Test equipment shall be traceable to NIST standards. Use the following to
perform the pre-installation and post-installation cable tests:
2.
Optical time domain reflectometer (OTDR) shall be laser precision, ALT, Inc.
Model 5200 LRFL or equal.
Pre-Installation Tests:
1.
Perform acceptance tests on the cable prior to installation to verify that the
cable conforms to the manufacturer's specifications, and is free of defects,
breaks and damages by transportation and manufacturing processes.
Perform tests on all reels of cable. Cable shall not be installed until the
Officer-in-Charge has reviewed the test report.
2.
Verify continuity and attenuation or loss for each fiber on each reel and
document results of physical inspections to identify any cable and reel
damage conditions, and any deviations from the manufacturer's
specifications.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-12
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
3.
D.
Notify the Officer-in-Charge 5 days prior to tests. Document test results and
submit the report to the Officer-in-Charge for review. Documentation shall
consist of both hard copy and electronic disk complete with application
software.
Post-Installation Tests:
1.
OTDR: Conduct the following tests on each cable segment with an OTDR
each optical fiber in the fiber cable. Tests shall be conducted at both 1310
and 1550 nm.
2.
Excess Fiber Coefficient (EFC) Test shall be made as part of the cable testing.
The following procedure shall be performed from both ends on each fiber
provided.
3.
a.
Record the fiber Index of Refraction (IOR) from the cable data
submitted by the Manufacturer.
b.
With the OTDR, set to the proper IOR and record the OTDR fiber
length.
c.
Calculate the excess fiber coefficient (EFC) according to the following
formula: EFC = OTDR length/Sheath length.
OLTS Fiber Attenuation:
a.
Measure the attenuation of each optical fiber in both directions using
a with an Optical Loss Test Set (OLTS) at both 1310 nm and 1550
nm. Test shall be conducted per TIA/EIA 526-7. Provide a reference
power level measured with a patch cord and connectors of the same
types used on the fiber cable. Measure and record the reference
power level of the Laser Light Source. Measure and record the
received power level of each optical. Repeat the same measurements
in the other direction.
b.
The measured insertion loss shall be no greater than the loss
calculated in the formula below:
IL = 2(Lc) + (La)(Length) + 0.5
where:
IL
Lc
La
Length
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
=
=
=
=
Insertion Loss
Connector face loss (maximum 0.6 dB)
Manufacturer’s cable attenuation (dB/km)
Fiber length (km)
16890-13
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
E.
F.
Cable Acceptance:
1.
OTDR traces at both 1310 nm and 1550 nm wavelengths display no
unexplained losses, reflectance events, or other discontinuities.
2.
The insertion losses measured at both 1310 nm and 1550 nm wavelengths
and in both directions do not exceed the maximum allowed values. After
cable tests, the cable installation shall be subject to a physical inspection to
verify the remaining fiber optic specification requirements have been met. If
any test requirements are not met, or in the event of fiber test failure of one
or more fibers, replace cable as necessary until tests pass.
Fiber Optic System Acceptance:
1.
Perform the inspection and establish a punch-list of the following:
a.
b.
c.
d.
e.
f.
g.
2.
3.04
Fiber: neatly organized.
Connectors: capped and undamaged.
Cabling: organized with no excessive bending.
Specified coiled cable present in the cabinet.
Cable entrances to the cabinets secured.
Unused cable delivered to the City.
Cable and fiber patches labeled as specified.
Identify cables with the directories installed in each fiber cabinet.
Discrepancies found during the inspection of the fiber system installation
shall be listed and provided on the punch-list. Inform the Officer-in-Charge
upon resolution and completion of the punch-list items.
CABLE SPECIFICATION SHEETS (CABLESPEC)
A.
B.
Type
FOC-SM
General:
1.
Cable types for different locations, service conditions and raceway systems
are specified on individual cable specification sheets. Cables that are
scheduled herein shall be installed in accordance with the CABLESPEC
SHEETS.
2.
Single mode fiber optic cables shall meet the requirements of the referenced
ANSI, ICEA, ITU, TIA, and EIA standards for outside plant data
communications cable.
3.
Cablespec Sheets:
The following CABLESPEC sheets are included in this section:
Volt
300
Product
FIBER OPTIC CABLE INDOOR/OUTDOOR
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-14
ADDENDUM NO. 3
Purpose
DATA COMMUNICATION
FIBER OPTIC NETWORK EQUIPMENT
3.04
CABLE SPECIFICATION SHEET—CABLESPEC
Cable System Identification:
FOC-SM
Description:
Single Mode Fiber Optic Data Cable; 12-pair fiber conductor:
Outdoor; Heavy Duty-MFPT; Cable Tray Rated
Loose tube construction. Optical fibers shall not adhere to the
inside of the buffer tube.
Fibers and buffer tubes shall be color coded with distinct and
recognizable colors in accordance with EIA/TIA-598-B.
Material:
8.2/125/250 micron
Jacket:
Chlorinated Polyethylene (CPE)
Color: Yellow or Black
Mark the exterior sheathing with the manufacturer's name,
month and year of manufacture, and sequential meter or foot
markings for easily determining the length of the cable at all
points along the cable run.
Provide a telecommunication handset symbol as required by
Section 350G of the National Electrical Safety Code® (NESC®),
fiber count, and fiber type.
Type:
OFNR with industrial cable tray rating and IEEE flame test rated:
802.3Z
Fiber Type: Single Mode
Clad Diameter: 125 ± 0.7 µm
Coating Diameter: 245 ± 5 µm
Core Diameter: 8.2 µm
Attenuation:
≤ 0.35 db/km @ 1310 nm
≤ 0.25 db/km @ 1550 nm
Operating Temperature Range: -40 to +70 Deg C
Maximum Tensile Loading: 600 lbf
Minimum Cable Bending Radius: 10 x diameter
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-15
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
3.04
CABLE SPECIFICATION SHEET—CABLESPEC
Cable System Identification:
FOC-SM
Manufacturers:
Corning Cable Systems
Alcoa Fujikura
Corning SMF-28e fiber
or approved substitute
Execution:
Application:
Data Communications.
Installation:
Install in accordance with manufacturers instructions and as
specified.
Testing:
Test as specified above.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-16
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
3.05
3.06
3.07
PATCH PANEL INSTALLATION
A.
Install patch panels plumb and level. Provide front and side clearance to access
inside patch panels. Ensure all work is neat and Velcro ties inside patch panel to
loosely tie up fibers.
B.
Provide a nameplate on the face of the patch panel with the panel identification
number specified on the drawings.
C.
Label all fiber patches as specified above.
D.
Install LC terminations for each fiber strand specified herein and connect to a port
inside the patch panel.
E.
Patch panels and patch cords shall be installed in accordance with the
manufacturer’s instructions.
PATCH PANEL TESTING
A.
Requirements: See paragraph 3.03 in this section.
B.
Modifying the Plant’s existing control system fiber optic network: The Plant is
automated through the control system network. Interruption of the existing network
shall minimize plant operation outages and shall be scheduled in advanced if an
outage is required. Test modifications of the fiber optic network of the installation
before terminating existing fiber. Provide the above test results before demolishing
the existing plant fiber.
MEASUREMENT AND PAYMENT
A.
All network modifications including all network cabling, installation and testing shall
not be paid for directly, but shall be considered incidental and included in the lump
sum bids for the respective line items in the Proposal Schedule.
END OF SECTION
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
16890-17
ADDENDUM NO. 3
FIBER OPTIC NETWORK EQUIPMENT
SECTION 17500
CS 102
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
1.01
1.02
PURPOSE
A.
The Mokapu Diversion Structure redirects flows from the existing Kailua IPS to the
new Mini-KIPS and TIPS facilities via the Mini-KIPS Diversion Structure.
B.
The Mokapu Diversion Structure uses a channel grinder to process the raw sewage
before it is gravity fed to the Mini-KIPS and TIPS pump stations via Mini-KIPS
Diversion Structure.
C.
This control strategy addresses operation of the channel grinder motors for the
grinder and two screens as well as the Influent and Effluent slide gates and the
channel grinder.
REFERENCES
A.
Process and Instrumentation Diagrams:
Dwg No.
P-102
B.
Instrumentation (I) Drawings:
Dwg No.
--C.
Instrumentation Drawing Description
See Section 17903 for “I” drawings associated with this control strategy.
Control Strategies:
CS No.
None
D.
Process and Instrumentation Diagram Description
MOKAPU DIVERSION STRUCTURE
Control Strategy Description
Supporting Documentation: Core supporting documentation references are listed
within this Section. Additional supporting documents for this control strategy are as
follows:
1.
Section 17901 provides references to the instruments specified in this
Control Strategy.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-102-1
ADDENDUM NO. 3
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
1.03
1.04
SYSTEM DESCRIPTION
A.
Before the commissioning of Mini-KIPS and TIPS, flows from the Mokapu Interceptor
(66” RS), the Plant Sewer South Collection System Raw Sewage (10”RS) and the
Plant Sewer Pump Station Overflow (16”) flows are diverted by a temporary stop gate
at the head of the Mokapu Diversion Structure and flow via the existing bypass
manhole 2 to the existing Kailua IPS.
B.
After start up is completed for the Mini-KIPS and TIPS, the temporary stop gate will
be permanently removed and a plug will be installed at the inlet of the bypass
manhole 2. Flows from the The Mokapu Interceptor (66” RS), the Plant Sewer South
Collection System Raw Sewage (10”RS) and the Plant Sewer Pump Station Overflow
(16”) will flow through the channel between Bypass Manholes 1 & 2 and into the
Mokapu Diversion Structure where raw sewage will be processed by a channel
grinder. Effluent flow from the structure travel by gravity to Mini-KIPS Diversion
Structure via a 48” sewage line.
C.
The Mokapu Diversion Structure channel grinder has influent and effluent gates for
isolation as well as an overflow/ bypass channel to bypass the grinder if gates are
closed or there is a backup at the grinder. There is also cutthroat flume located on
the back end of the channel grinder for grinder efficiency.
D.
This control strategy addresses operation of the channel grinder motors for the
grinder and two screens as well as the Influent and Effluent slide gates and the
channel grinder.
EQUIPMENT
A.
Grinder/Screens:
Equipment No.
GDR 100,106
SN 100,107
SN 100,108
B.
Control Valves:
Valve No.
SG 100,101
SG 100,109
C.
Equipment Description
MOKAPU Diversion Structure Channel Grinder
MOKAPU Diversion Structure Channel Grinder Screen 1
MOKAPU Diversion Structure Channel Grinder Screen 2
Valve Description
MOKAPU Diversion Structure Slide Influent Gate
MOKAPU Diversion Structure Slide Effluent Gate
Solenoid Valves:
Valve No.
None
Valve Description
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-102-2
ADDENDUM NO. 3
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
D.
Instruments:
Tag No.
None
1.05
Instrument Description
ALARMS AND STATUSES
A.
In addition to Section 17500’s common alarms; the following are alarms tags to be
configured in the operator console graphics:
Tag No.
XA 100,101
XA 100,105
IAH 100,106
TAH 100,106
IAH 100,107
TAH 100,107
IAH 100,108
TAH 100,108
XA 100,109
B.
Alarm Description
MOKAPU Diversion Structure Slide Influent Gate TROUBLE
MOKAPU Diversion Structure Channel Grinder E-STOP
MOKAPU Diversion Structure Channel Grinder JAM
MOKAPU Diversion Structure Channel Grinder Motor HIGH TEMP
MOKAPU Diversion Structure Channel Screen 1 JAM
MOKAPU Diversion Structure Channel Screen 1 Motor HIGH TEMP
MOKAPU Diversion Structure Channel Screen 2 JAM
MOKAPU Diversion Structure Channel Screen 2 Motor HIGH TEMP
MOKAPU Diversion Structure Slide Effluent Gate TROUBLE
In addition to Section 17500’s common statuses; the following are statuses tags to
be configured in the operator console graphics:
Tag No.
YI 100,101
ZIO 100,101
ZIC 100,101
HS 100,105
YI 100,106A
YI 100,106B
YI 100,106C
YI 100,107A
YI 100,107B
YI 100,107C
YI 100,108A
YI 100,108B
YI 100,108C
YI 100,109
ZIO 100,109
ZIO 100,109
Status Description
MOKAPU Diversion Structure Slide Influent Gate LOCAL\AUTO
MOKAPU Diversion Structure Slide Influent Gate OPEN
MOKAPU Diversion Structure Slide Influent Gate CLOSED
MOKAPU Diversion Structure Channel Grinder E-STOP RESET
MOKAPU Diversion Structure Channel Grinder HAND
MOKAPU Diversion Structure Channel Grinder AUTO
MOKAPU Diversion Structure Channel Grinder RUNNING
MOKAPU Diversion Structure Channel Screen 1 HAND
MOKAPU Diversion Structure Channel Screen 1 AUTO
MOKAPU Diversion Structure Channel Screen 1 RUNNING
MOKAPU Diversion Structure Channel Screen 2 HAND
MOKAPU Diversion Structure Channel Screen 2 AUTO
MOKAPU Diversion Structure Channel Screen 2 RUNNING
MOKAPU Diversion Structure Slide Effluent Gate LOCAL\AUTO
MOKAPU Diversion Structure Slide Effluent Gate OPEN
MOKAPU Diversion Structure Slide Effluent Gate CLOSED
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-102-3
ADDENDUM NO. 3
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
1.06
PROCESS DATA HISTORIAN
A.
The following points are to be logged into the process data historian:
Tag No.
GDR 100,106
SN 100,107
SN 100,108
1.07
Description
MOKAPU Diversion Structure Channel Grinder Run time
MOKAPU Diversion Structure Screen Run time
MOKAPU Diversion Structure Screen Run time
OPERATION – MOKAPU DIVERSION STRUCTURE
A.
General: Normal operation of the Mokapu Diversion Structure has the influent and
inlet gates open, channel grinder motors all are set in AUTO mode at the local control
station (ICS 100,105) and the system in AUTO mode at the plant control system HMI.
B.
The channel grinder motors can be controlled locally at ICS 100,105 and remotely at
the PCS HMI.
C.
An ESTOP is located at the diversion structure near the channel grinder on ICS
100,105. ESTOP stopss operation of all motor associated with the channel grinder.
D.
Channel Grinder motors has a jamming routine to help clear obstructions through
the PCS. When high current is detected on the grinder motor or at either screen
motor, the motor experiencing the high current is immediately stopped and is run in
reverse for 2 seconds then stopped and run in forward again. If obstruction is
cleared, normal operation resumes. For the grinder motor, if a JAM routine is
required 3 times within 30 seconds, a FAIL condition results. For the screens, if a
JAM routine is required 2 times within 30 seconds, a FAIL condition results. Note the
above times and repetition of routines is adjustable at the HMI; final values and time
and repetition of routine ranges to be determined during field testing.
E.
After an ESTOP, FAIL or HI TEMP condition at the channel grinder, the RESET must be
pressed at MCC3 or the RESET on the PCS HMI to return to normal operation.
F.
After an overload condition at a channel grinder motor, the OL RESET must be
pressed at MCC3 to return to normal operation.
G.
Manual Control for all Slide Gates:
1.
Local: All Mini-KIPS Diversion Structure Slide Gate actuators have
LOCAL/REMOTE hand switches located on the actuators. When the
actuators are put in LOCAL, the OPEN/STOP/CLOSE hand switch, also
located on the actuator, may be used to OPEN, STOP or CLOSE the
associated slide gate locally.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-102-4
ADDENDUM NO. 3
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
2.
H.
Manual Control for all Channel Grinders:
1.
2.
I.
PCS Manual Control: When the LOCAL/REMOTE hand switch located on
actuator is in REMOTE. Operator may manually OPEN or CLOSE the slide
gates from a plant control system HMI.
Local Field:
a.
ESTOP located at the channel grinder shall STOP all motors of a
channel grinder (Grinder, Screen 1 and Screen 2). Channel grinder
shall be reset by resetting the ESTOP and pressing the RESET button
located on Grinder Bucket on MCC 3 in the Kailua IPS Building.
b.
Each channel grinder motor has HAND/OFF/AUTO and
FORWARD/OFF/REVERSE hand switches
es and each channel grinder
screen motor has HAND/OFF/AUTO and FORWARD/OFF/ REVERSE
hand switches
es at ICS 100,105. In the HAND position the motor runs
continuously in either FORWARD or REVERSE.
REVERSE In the OFF position,
the motor does not run. In AUTO position, the grinder runs based on
the PCS. In AUTO position, the screens run when the grinder runs.
However, all motor only stop when the ESTOP is pressed, all other
conditions shall not affect the operation of the other motors. For
example a JAM, FAIL, HI TEMP or OL condition that stops the grinder
will not stop the screens from operating in AUTO if the grinder is in
HAND or in AUTO and the PCS is telling the system to run.
PCS Manual Control: When the grinder is in AUTO mode, the operator can run
the grinder manually from the HMI. If the screens are in AUTO at the MCC
the screens will also run at the same time as the grinder as screens in AUTO
always run when the grinder is commanded to run.
PCS Automatic Control:
1.
PCS: With all channel grinder motors in AUTO position at ICS 100,105 and
the channel grinder system set in AUTO mode, the channel grinder motors
runs in a timed routine. Every 2 hours the channel grinder will run for 60
minutes (times are adjustable at the HMI; final values and time ranges to be
determined during field testing). All motors must be in AUTO mode to put
system in AUTO mode.
2.
No Automatic control for slide gates.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-102-5
ADDENDUM NO. 3
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
J.
Interlocks:
1.
2.
PCS (Software): Note the below times and repetition of routines are
adjustable at the HMI; final values and time and repetition of routine ranges
to be determined during field testing.
a.
FAIL condition after 3 JAM routines within 30 seconds for the grinder.
Fail condition stops grinder.
b.
FAIL condition after 2 JAM routines within 30 seconds for the
screens. Fail condition stops screen.
c.
JAM condition stops motor moving forward and reverses for 2
seconds. Then resumes forward for normal operation.
d.
If any motor has a continuous high temperature for 5 seconds, a HI
TEMP condition is alarmed and the motor shall stop. Operator must
RESET from MCC or PCS HMI to restart.
e.
All HAND and AUTO operation of the channel grinder motors is
handled through the PLC. Motor coils run through PLC in all modes.
Local (Hardwired):
a.
K.
ESTOP switch located at the channel grinder stops all motors. Must
be RESET at the MCC or at the PCS HMI.
Restart:
1.
When a power failure occurs while the grinder and screens are operating, the
grinder and screens shall resume operation once power is restored.
2.
When a power failure occurs while the grinder or screen is in a FAIL
condition, once power is restored the FAIL indicator shall reactivate and
remain until RESET at MCC 3.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-102-6
ADDENDUM NO. 3
CONTROL STRATEGY
MOKAPU DIVERSION STRUCTURE
SECTION 17500
CS 302
CONTROL STRATEGY
HEADWORKS GRIT
1.01
PURPOSE
A.
1.02
The Headworks (HDWKS) Grit process captures and removes fine grit from the
previously screened wastewater flow. The grit system is composed of two identical
parallel trains. A hydraulic grit settler separates grit from the screened wastewater
stream. The grit slurry from the settler is pumped via a constant speed grit pump to
a grit concentrator unit, which washes the grit and removes remnant organics from
the grit slurry. The grit is discharged to a grit classifier unit, in which the grit settles
and is dewatered by way of a motor-driven belt escalator. Dewatered grit is
discharged to a screw conveyor system which transports grit, along with screenings,
to the dumpsters.
REFERENCES
A.
Process and Instrumentation Diagrams:
Dwg No.
P-321
P-322
P-323
B.
Instrumentation (I) Drawings:
Dwg No.
--C.
CS No.
CS 202
CS 301
CS 304
D.
Process and Instrumentation Diagram Description
HEADWORKS, GRIT REMOVAL P&ID
HEADWORKS, GRIT PROCESSING P&ID – 1
HEADWORKS, GRIT PROCESSING P&ID – 2
Instrumentation (I) Drawings Description
See Section 17903 for “I” drawings associated with this control strategy.
Control Strategies:
Control Strategy Description
TIPS WET WELL TOTAL PLANT FLOW CONTROL
HEADWORKS SCREENINGS
HEADWORKS CONVEYANCE SYSTEM
Supporting Documentation: Core supporting documentation references are listed
within this Section. Additional supporting documents for this control strategy are as
follows:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-1
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
1.
1.03
Section 17901 provides references to the instruments specified in this
Control Strategy.
SYSTEM DESCRIPTION
A.
Each of the two grit removal/processing trains is composed of a packaged system,
including a grit settler, a grit concentrator, and a grit classifier, operating in
conjunction with a grit pump. The Plant Control System (PCS) coordinates the
operation of each packaged system with the other equipment in the HDWKS grit
removal/processing system.
B.
Motor-operated slide gates at the grit settler influent channels route screened
wastewater to one or both grit settlers, as needed. Motor-operated slide gates at the
HDWKS effluent channel route flows through two channels to the existing Primary
Treatment Facility.
C.
The grit settlers are stacked-tray type units installed in concrete basins which
operate passively to quickly settle grit out of the incoming wastewater flow. There
are no controls associated directly with the grit settlers; however, collected grit must
be continuously fluidized by an RW2 water line while the grit settler is in service.
Fluidizing water lines are controlled by a solenoid valve and monitored for a low-flow
condition. A single grit settler will be capable of handling the majority of plant flows
under normal conditions. Under high-flow conditions, a second grit settler shall be
put into operation to maintain efficient grit removal. In automatic operation, the PCS
will coordinate operation of one or two grit settlers based on calculated total flows to
HDWKS. To prevent damage to the grit settler’s trays, each grit removal chamber is
level-monitored via a float switch to ensure that a grit settler is not put into service
while the chamber is empty. An empty chamber must be slowly filled manually in
order to allow operation of the grit settler.
D.
Each grit settler is served by a constant-speed grit pump, which transports the
fluidized grit slurry from the grit settler to the grit concentrator continuously or
intermittently for 10 to 15 minutes. Grit pump operation shall be interlocked with
the seal water control units via hardwired relays/contacts to ensure seal water is
always supplied to the pumps while running. Motor-operated isolation valves at each
pump discharge along with a motorized crossover valve allow each grit pump to
transport grit slurry to either grit concentrator unit in the event of failure of one of the
grit pumps or the grit processing equipment in one train. In automatic mode, the
coordination of isolation and crossover valving is handled by the PCS. Grit pump
discharges are outfitted with position-monitored check valves to identify pump
trouble.
E.
Each grit concentrator is physically mounted to the grit classifier, and each combined
concentrator/classifier unit is controlled by local selector switches and push buttons
located in its packaged system control panel (PSCP) specified in Section 11149 and
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-2
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
in automatic mode, the unit is controlled through the PCS. In automatic mode, the
PCS sequences supply water, backwash water and blowdown as well as coordinates
operation with the grit pumps and other equipment in the grit train.
F.
1.
During operation, a small volume of concentrator grit slurry continuously
underflows from the grit concentrator/classifier unit. Control of the grit slurry
underflow rate is via the hydraulic valve mounted on the bottom of the unit.
A portion of the system water is continuously introduced to the hydraulic
valve.
2.
Periodically, (typically twice per hour during heavy grit loads and typically
once per hour during light grit loads), a backwash sequence is initiated, by
cycling solenoid valves, which flushes the grit underflow gap inside the unit.
Frequency and duration of backwash cycles is adjustable.
3.
Periodically, (typically once every 4 backwashes), a blowdown sequence is
initiated to flush accumulations of debris inside the unit. Blowdown is
accomplished by stopping the influent to the grit concentrator/classifier
unit, cycling solenoid valves, and resuming operation. Frequency and
duration of blowdown cycles is adjustable.
4.
The grit classifier belt runs whenever grit slurry is being transported to the
unit.
5.
While the grit classifer’s dewatering unit is running, water is directed to the
tail roller self cleaning mechanism and grit rinse system.
6.
The belt speed is adjustable via a manual speed control potentiometer on
the VFD or by remote signal from the PCS.
7.
A motion sensor installed on the side of the grit classifier’s dewatering
escalator take-up frame and detects movement of the head roller scraper
arm. Lack of motion of the head roll scraper arm indicates lack of belt
movement, drive unit failure and/or scraper arm overload. Lack of belt
movement or scraper arm overload interrupt signal from the motion sensor
to the timer. If the motion sensor fails to reset the timer, the grit dewatering
escalator stops and the failure is alarmed.
8.
After a system shut down the grit dewatering escalator continues to operate
for a pre-determined amount of time to allow for the removal and dewatering
of all grit accumulated in the unit. The off delay timer is adjustable from 0-60
minutes with a typically delay off time of 15 minutes in the PCS.
All controls, statuses, and alarms available at the PSCP for the grit concentrators and
grit classifiers shall also be replicated or monitored through the PCS.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-3
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
1.04
EQUIPMENT
A.
Pumps/Classifiers/Concentrators/Settlers:
Equipment No.
MME 300,210
P 300,220
MME 300,230
MME 300,240
MME 300,310
P 300,320
MME 300,330
MME 300,340
B.
Control Valves/Gates:
Valve/Gate No.
SG 300,161
SG 300,211
V 300,224
CV 300,225
CV 300,251
SG 300,311
V 300,324
CV 300,325
C.
Valve/Gate Description
HDWKS EFFLUENT GATE
HDWKS GRIT REMOVAL INFLUENT GATE 1
HDWKS GRIT PUMP 1 DISCHARGE CHECK VALVE
HDWKS GRIT PUMP 1 EFFLUENT PLUG VALVE
HDWKS GRIT PROCESSING CROSSOVER VALVE
HDWKS GRIT REMOVAL INFLUENT GATE 2
HDWKS GRIT PUMP 2 DISCHARGE CHECK VALVE
HDWKS GRIT PUMP 2 EFFLUENT PLUG VALVE
Solenoid Valves:
Valve No.
SV 300,212
SV 300,220
SV 300,312
SV 300,320
D.
Equipment Description
HDWKS GRIT SETTLER 1
HDWKS GRIT PUMP 1
HDWKS GRIT CONCENTRATOR 1
HDWKS GRIT CLASSIFIER 1
HDWKS GRIT SETTLER 2
HDWKS GRIT PUMP 2
HDWKS GRIT CONCENTRATOR 2
HDWKS GRIT CLASSIFIER 2
Valve Description
HDWKS GRIT SETTLER 1 FLUIDIZING SOLENOID VALVE
HDWKS GRIT PUMP 1 SEAL WATER CONTROL UNIT
HDWKS GRIT SETTLER 2 FLUIDIZING SOLENOID VALVE
HDWKS GRIT PUMP 2 SEAL WATER CONTROL UNIT
Instruments:
Tag No.
LSL 300,210
FSL 300,213
ZSC 300,224
ZSO 300,224
LSL 300,310
FSL 300,313
Instrument Description
HDWKS GRIT REMOVAL CHAMBER LOW LEVEL SWITCH
HDWKS GRIT SETTLER 1 FLUIDIZING WATER LOW FLOW SWITCH
HDWKS GRIT PUMP 1 DISCHARGE CHECK VALVE CLOSED POSITION SWITCH
HDWKS GRIT PUMP 1 DISCHARGE CHECK VALVE OPEN POSITION SWITCH
HDWKS GRIT REMOVAL CHAMBER LOW LEVEL SWITCH
HDWKS GRIT SETTLER 2 FLUIDIZING WATER LOW FLOW SWITCH
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-4
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
Tag No.
ZSC 300,324
ZSO 300,324
1.05
Instrument Description
HDWKS GRIT PUMP 2 DISCHARGE CHECK VALVE CLOSED POSITION SWITCH
HDWKS GRIT PUMP 2 DISCHARGE CHECK VALVE OPEN POSITION SWITCH
ALARMS AND STATUSES
A.
In addition to Section 17500’s common alarms; the following are alarms tags to be
configured in the operator console graphics (tags designated by asterisk are PCS
logic generated):
Tag No.
LAL 300,210
LAL 300,310
SAL 300,240
XA 300,240
SAL 300,340
XA 300,340
B.
Alarm Description
HDWKS GRIT REMOVAL CHAMBER LOW LEVEL ALARM
HDWKS GRIT REMOVAL CHAMBER LOW LEVE L ALARM
HDWKS GRIT CLASSIFIER 1 PROX
HDWKS GRIT CLASSIFIER 1 ESTOP
HDWKS GRIT CLASSIFIER 2 PROX
HDWKS GRIT CLASSIFIER 2 ESTOP
1.
See Section 17315 for alarms monitored by the Ethernet VFD and CSS data
link for the pumps and classifiers listed in paragraph 1.04 of this Control
Strategy.
2.
See Section 17315 for alarms monitored by the DeviceNet MVOC and MVM
data link for the control valves and gates listed in paragraph 1.04 of this
Control Strategy.
3.
Bypass of any PCS interlocks shall be configured to alarm.
In addition to Section 17500’s common statuses; the following are statuses tags to
be configured in the operator console graphics:
Tag No.
ZIC 300,224
ZIO 300,224
YI 300,230A
YI 300,230B
YI 300,230C
YI 300,230D
YI 300,230E
YI 300,240A
ZIC 300,324
ZIO 300,324
YI 300,330A
YI 300,330B
Status Description
HDWKS GRIT PUMP 1 DISCHARGE CHECK VALVE CLOSED
HDWKS GRIT PUMP 1 DISCHARGE CHECK VALVE OPEN
HDWKS GRIT CONCENTRATOR 1 WET MODE
HDWKS GRIT CONCENTRATOR 1 WET/DRY AUTO MODE
HDWKS GRIT CONCENTRATOR 1 SUPPLY VALVE IN AUTO MODE
HDWKS GRIT CONCENTRATOR 1 BACKWASH VALVE IN AUTO MODE
HDWKS GRIT CONCENTRATOR 1 BACKWASH PB CM
HDWKS GRIT CLASSIFIER 1 AUTO MODE
HDWKS GRIT PUMP 2 DISCHARGE CHECK VALVE CLOSED
HDWKS GRIT PUMP 2 DISCHARGE CHECK VALVE OPEN
HDWKS GRIT CONCENTRATOR 2 WET MODE
HDWKS GRIT CONCENTRATOR 2 WET/DRY AUTO MODE
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-5
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
Tag No.
YI 300,330C
YI 300,330D
YI 300,330E
YI 300,340A
YL 300,240
YL 300,340
1.06
Status Description
HDWKS GRIT CONCENTRATOR 2 SUPPLY VALVE IN AUTO MODE
HDWKS GRIT CONCENTRATOR 2 BACKWASH VALVE IN AUTO MODE
HDWKS GRIT CONCENTRATOR 2 BACKWASH PB COMMAND
HDWKS GRIT CLASSIFIER 2 AUTO MODE
HDWKS GRIT CLASSIFIER 1 RUNNING
HDWKS GRIT CLASSIFIER 2 RUNNING
1.
See Section 17315 for other statuses monitored by the Ethernet VFD and
CSS data link for the pumps and classifiers listed in paragraph 1.04 of this
Control Strategy.
2.
See Section 17315 for statuses monitored by the DeviceNet MVOC and MVM
data link for the control valves and gates listed in paragraph 1.04 of this
Control Strategy.
PROCESS DATA HISTORIAN
A.
The following points are to be logged into the process data historian:
Tag No.
P 300,220_RT_HRS
MME 300,240_RT_HRS
P 300,320_RT_HRS
MME 300,340_RT_HRS
1.07
Description
GRIT PUMP 1 RUN TIME
GRIT CLASSIFIER 1 RUN TIME
GRIT PUMP 2 RUN TIME
GRIT CLASSIFIER 2 RUN TIME
OPERATION – GRIT REMOVAL INFLUENT GATES
General: Where hard wired interlocks are monitored they shall also be programmed in the software
as software interlocks.
A.
Manual Control (Local):
1.
2.
B.
Local: Local/Off/Remote selector switch.
Local: Open/Stop/Close selector switch.
PCS Manual Control:
1.
PCS: PCS MANUAL MODE select. Enables manual open/close of the gate via
the PCS interface when the LOR switch is in Remote.
a.
PCS: Open/Stop/Close select.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-6
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
C.
PCS Automatic Control:
1.
D.
1.08
PCS: PCS AUTO MODE select. Enables automatic open/close of the gate as
part of its grit removal/processing train when the LOR switch is in Remote.
PCS shall automatically open the gate when its associated train is selected
as Duty, and close the gate when its train is selected as standby or taken
offline.
Interlocks: General: Interlocks shall be configured through the PCS and shall only be
active when the gate’s LOR switch is in Remote.
1.
PCS: If associated train is selected as Duty, gate shall open. Gate shall not be
allowed to close while its train is in Duty mode.
2.
PCS: If associated train is selected as Standby or taken offline, gate shall
close. Gate shall not be allowed to open while its train is in Standby.
3.
PCS: If grit settler low level switch is active, the associated grit removal
influent gate shall close if open and not be allowed to open while LOR switch
is in Remote.
OPERATION – GRIT PUMPS
General: Where hard wired interlocks are monitored they shall also be programmed in the software
as software interlocks.
A.
Manual Control (Local):
1.
2.
B.
PCS Manual Control:
1.
C.
Local (Field): Hand/Off/Auto selector switch.
Local (MCC): Reset pushbutton.
PCS: PCS MANUAL MODE select. Enables manual operation of the grit pump
via the PCS interface when pump’s HOA switch is in Auto.
a.
PCS: Ethernet CSS Control. See Section 17315 for all control
functions required for this control type.
b.
PCS: Reset select. Allows pump to resume normal operation
following an interlock trip.
PCS Automatic Control:
1.
PCS: PCS AUTO MODE select. Enables automatic coordination and operation
of the grit pump when its HOA switch is in Auto based on input from the grit
concentrator/grit classifier control panel. The PCS shall signal the grit pump
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-7
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
to run after receiving the Grit Pump Call-to-Run input from the associated grit
concentrator/grit classifier control panel. The grit pump shall stop running
when the PCS no longer receives the Grit Pump Call-to-Run input.
D.
Interlocks: General: The grit pump shall have both hardwired interlocks and
interlocks configured in the PCS. PCS interlocks shall only be active when the grit
pump’s HOA switch is in Auto.
1.
2.
1.09
Hardwired:
a.
Any time the grit pump is called to run (Hand or Auto), the seal water
solenoid valve shall be triggered to open first, preceding the grit
pump motor starting by an adjustable time period, initially 10
seconds.
b.
Any time the grit pump stops running (Hand or Auto), closing of the
seal water solenoid valve shall be delayed by an adjustable time
period, initially 10 seconds, after the pump motor contacts open.
c.
When the grit pump motor high temperature switch opens, the grit
pump shall continue running for an adjustable time period, initially 5
seconds, after which the motor contacts shall open. The grit pump
must be manually reset via the Reset pushbutton at the MCC in order
to resume normal operation.
PCS (Software):
a.
When the grit pump’s HOA switch is in Auto mode, it is running, and
the discharge check valve position switch indicates that the check
valve is closed, the grit pump motor shall stop running after an
adjustable time period, initially 3 seconds. Reset through the PCS
shall be required to resume normal pump operation. Local
troubleshooting may be required to determine the cause of
shutdown.
b.
When the grit pump’s HOA switch is in Auto mode, the grit pump is
running, and the seal water control unit low flow switch trips, the grit
pump shall stop running after an adjustable time period, initially 3
seconds. Reset through the PCS shall be required to resume normal
pump operation.
OPERATION – GRIT CONCENTRATORS AND GRIT CLASSIFIERS
General: Where hard wired interlocks are monitored they shall also be programmed in the software
as software interlocks.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-8
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
A.
B.
Manual Control (Local): Local control is at the packaged system control panel (PSCP).
1.
PSCP: Emergency Stop pushbutton shuts down the grit classifier when
activated.
2.
PSCP: Grit concentrator Supply Valve Open/Close/Auto selector switch allows
local open and close control independent of the PCS.
PCS
3.
PSCP: Grit concentrator Backwash Valve Open/Close/Auto selector switch
allows local open and close control independent of the PCS.
PCS
4.
PSCP: Grit Classifier Hand/Off/Auto selector switch allows local start (Hand)
and stop (off) control independent of the PCS.
PCS Speed can be set at the VFD
independent of the PCS.
PCS.
5.
PSCP: Grit classifier Supply Valve Open/Close/Auto selector switch allows
local open and close control independent of the PCS.
PCS
6.
PSCP: Additional manual controls available at the packaged system control
panel are detailed in Section 11149.
PCS Manual Control: General: PCS Manual Control shall only be available when grit
concentrator valves, grit classifier supply valve and grit classifier HOA and LOR
switches are in Auto or Remote.
1.
PCS: GRIT PROCESSING MANUAL MODE select. Enables manual control of
the grit concentrator and grit classifier via the PCS interface.
a.
PCS: GRIT CONCENTRATOR/GRIT CLASSIFIER RUN select. PCS shall
signal to Run according to programmed sequences.
b.
PCS: GRIT CONCENTRATOR/GRIT CLASSIFIER WET/DRY select.
Selection of Wet or Dry operation modes signals to adjust
programmed cycle times. The PSCP Wet/Dry/Auto
Auto selector switch
must be set to Auto position for the PCS to select WET or DRY
operation modes.
c.
PCS: GRIT CLASSIFIER BELT SPEED set point.
d.
PCS: The programmed sequence includes the following modes for the
Grit concentrator:
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-9
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
Mode
Start-up
(Run)
Backwash
Step
1
Actions Required
Start grit pump or issue call-torun.
2
Open supply water valve.
3
Open backwash valve for
operator entered time (default
20 seconds). Close backwash
valve after time elapsed.
4
Keep grit pump running and
supply water valve open.
1
Initiate backwash at operator
entered intervals (default every
2 hours for Dry Mode and every
1 hour for Wet Mode).
Send steady discrete output to
PSCP Backwash/Blow
Backwash/Blow Down ON
pilot light.
Manual
Backwash
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
2
Keep grit pump running and
supply water valve open.
3
Open backwash valve for
operator entered backwash time
(default 20 seconds). Close
backwash valve after time
elapsed.
4
Track numbers of backwashes
using a backwash counter.
5
Return to Start-up step 4.
1
Initiate backwash when the
PSCP backwash button is
pressed. Follow the Backwash
control mode steps 2, 3, and 4.
CS-302-10
ADDENDUM NO. 3
Permissive
Receive
feedback grit
pump is
running after
issuing callto-run. If
pump is not
running then
shutdown.
If the PCS is
operating two
grit concentrators then
hold
backwash
until the
other grit
concentrator
is in not in
Backwash or
Blow Down.
See
Backwash
Permissive
CONTROL STRATEGY
HEADWORKS GRIT
Mode
Blow
Down
Shut
Down
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
Step
1
Actions Required
Initiate blow down at operator
entered intervals based on
number of backwashes (default
every 4th backwash for Dry
Mode and every 2nd backwash
for Wet Mode).
2
Send pulse discrete output to
PSCP Backwash/Blow
Down ON
Backwash/
pilot light.
3
Close supply water valve.
4
Stop the grit pump.
5
Open backwash valve for
operator entered blow down
time (default 20 seconds).
Close backwash valve after time
elapsed.
6
Hold control for operator entered
time (default at 4 minutes).
Remove discrete output to PSCP
Blow Down ON pilot light after
hold time has elapsed.
7
Reset backwash counter and
return to Start-Up (skip step 3).
1
Stop the grit pump.
2
Open backwash valve for
operator entered shut down time
(default 20 seconds). Close
backwash valve after time
elapsed.
3
Close supply water valve after
operator entered time (default 5
minutes).
4
Reset Backwash Interval and
backwash counter.
CS-302-11
ADDENDUM NO. 3
Permissive
If the PCS is
operating two
grit concentrators then
hold blow
down until
the other grit
concentrator
is in not in
Backwash or
Blow Down.
CONTROL STRATEGY
HEADWORKS GRIT
e.
PCS: The programmed sequence includes the following modes for the Grit
Classifier.
Mode
Run
Shut
Down
Fault
C.
Step
1
Actions Required
Open supply water valve.
2
Sequence the grit classifier on
and off for operator entered run
and stop times (default run for 2
minutes and stop for 15 minutes
on Dry Mode; and run for 5
minutes and stop for 5 minutes
in Wet Mode). Limit starts to a
maximum of 6 per hour. Allow
stop time to be set to zero for
continuous operation of the grit
classifier.
1
Initiate operator entered shut
down timer (default 15 minutes).
Stop classifier after timer has
elapsed.
2
Close supply water valve.
1
Initiate operator entered fault on
delay timer (default for 70
seconds) when grit classifier is
running,
2
Reset on delay timer each time
the proximity switch is present
showing the classifier belt is
moving. If the on delay timer
elapses then alarm fault and go
to shut down (bypassing step 1).
Permissive
Receive
feedback grit
classifier is
running after
issuing callto-run. If
classifier is
not running
then shut
down
bypassing
step 1 timer.
PCS Automatic Control: PCS automatic control shall only be available for a grit train
when grit concentrator valves, grit classifier supply valve and grit classifier HOA and
LOR switches are in Auto or Remote.
1.
PCS: GRIT PROCESSING AUTO MODE select. Enables automatic coordination
of a grit removal/processing train by the PCS when all equipment in the train
is in Auto mode.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-12
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
D.
a.
PCS: DUTY select. Either of the two grit trains may be selected as
Duty so long as all equipment in the train is in auto mode, the grit
bins are available, and there are no active alarms for any equipment
in the train. Upon selection as Duty, the PCS shall coordinate startup
by opening the grit removal influent gate, opening the grit pump
effluent plug valve, and signaling the grit concentrator/grit classifier
to Run as described above for PCS: GRIT PROCESSING MANUAL
MODE.
b.
PCS: GRIT CONCENTRATOR/GRIT CLASSIFIER WET/DRY select.
Selection of Wet or Dry operation modes signals to adjust
programmed cycle times. The PSCP Wet/Dry/Remote selector switch
must be set to Remote position for the PCS to select WET or DRY
operation modes.
c.
PCS: GRIT CLASSIFER BELT SPEED set point.
d.
PCS: GRIT HIGH FLOW set point. Initially 30 MGD. Operatoradjustable flow set point which is the transition point from one grit
removal/processing train to two trains. Set point shall default to the
previous input value upon resuming operation in Grit Processing Auto
Mode.
e.
PCS: GRIT LOW FLOW set point. Initially 25 MGD. Operatoradjustable flow set point which is the transition point from two grit
removal/processing train to one train. Set point shall default to the
previous input value upon resuming operation in Grit Processing Auto
Mode.
Interlocks: General: Interlocks shall be configured through the PCS and shall only be
active when both the grit concentrator and grit classifier HOA switches are in Auto.
1.
PCS (Software):
a.
Following operator’s selection of one grit train for Duty in Grit
Processing Auto Mode, the PCS shall automatically designate the
second train as Standby, Local, or Trouble.
1)
STANDBY if all equipment in the train is in Auto and no
alarms are active for any equipment in the train. Standby
train’s influent gate shall remain closed and the packaged
system control panel shall not be signaled to run.
2)
LOCAL if not all equipment in the train is in Auto. Local train
shall not run and shall not be available to select as Duty.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-13
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
3)
1.10
TROUBLE if any alarms are active for equipment in the train.
Trouble train must have all alarms resolved and inactive
before it is reassigned by the PCS.
b.
While in Grit Processing Auto Mode, the PCS shall bring a second grit
train online as Duty when total calculated flows to HDWKS (see CS
202) exceed the Grit High Flow set point.
c.
While in Grit Processing Auto Mode with two grit trains in service, the
PCS shall remove the secondary grit train from service when total
calculated flows to HDWKS (see CS 202) fall below the Grit Low Flow
set point.
d.
A secondary grit train is the one brought online by the PCS and it shall
be taken out of service, when no longer necessary, as follows:
1)
When the primary Duty train grit pump is running, the
secondary Duty train’s influent gate shall be closed.
2)
Following complete closure of the influent gate, the PCS shall
stop signaling the packaged system panel to run.
3)
The secondary grit train shall be designated as in Interlock 1
a, above.
e.
While in Grit Processing Auto Mode, if the secondary grit train is in
Standby, a Duty train may be removed from service when any of the
following occur: 1) grit pump trouble alarm, 2) grit pump discharge
check valve closed alarm, 3) grit settler fluidizing water low flow
alarm, 4) grit concentrator/grit classifier trouble alarm. If the
secondary grit train is not in Standby and any of these alarms occur,
the PCS shall alarm and require direction from the operator.
f.
Any time a grit train is switched out of Grit Processing Auto Mode, all
equipment in the train shall be maintained in the same mode of
operation (e.g. running or not running) until directed otherwise by the
operator.
OPERATION – GRIT PROCESSING CONTROL VALVES
General: Where hard wired interlocks are monitored they shall also be programmed in the software
as software interlocks.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-14
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
A.
Manual Control (Local):
1.
2.
B.
Local: Local/Off/Remote selector switch.
Local: Open/Stop/Close selector switch.
PCS Manual Control:
1.
PCS MANUAL MODE select. Enables manual open/close of the gate via the
PCS interface when the LOR switch is in Remote.
a.
C.
PCS Automatic Control:
1.
D.
PCS: Open/Stop/Close select.
PCS AUTO MODE select. Enables automatic open/close of the valve as part
of its grit removal/processing train when the LOR switch is in Remote. Under
normal conditions, a grit pump shall pump to the grit concentrator/grit
classifier of the same train. The grit train crossover valve CV 300,251 shall
remain Closed, and the two grit pump effluent plug valves CV 300,225 and
CV 300,325 shall remain Open. See Interlocks below for conditions of
crossover operation.
Interlocks: General: Interlocks shall be configured through the PCS and shall only be
active when the valve’s LOR switch is in Remote and valve is in PCS Auto Mode.
1.
PCS (Software): While both grit trains are in Grit Processing Auto Mode, a
Trouble alarm at the grit concentrator/grit classifier of a Duty train shall
activate crossover operation as follows:
a.
PCS: If the secondary grit train is not running, the PCS shall signal the
packaged system control panel to Run.
b.
PCS: Crossover valve CV 300,251 shall open.
c.
PCS: Grit pump effluent plug valve of the secondary train shall open.
d.
PCS: Grit pump effluent plug valve of the Trouble train shall close.
e.
PCS: Grit pump shall continue to pump to the secondary grit
concentrator until all alarms have been resolved and the primary grit
concentrator/grit classifier unit is in Auto mode.
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-15
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
1.11
POWER LOSS RESTART
A.
If a power loss occurs while the Headworks Grit System is operating through the PCS
then the Headworks Grit System shall return to normal operation when power is
restored (running as dictated by the permissive and programmed run sequence). See
Section 17500 – CS 401.
B.
When a power loss occurs while a piece of equipment is in a FAIL or OVERLOAD
condition, once power is restored the FAIL indicator reactivates and remain until
RESET.
**END OF SECTION**
KAILUA RWWTP TUNNEL INFLUENT
PUMP STATION AND HEADWORKS
FACILITY, JOB NO. W1-13
CS-302-16
ADDENDUM NO. 3
CONTROL STRATEGY
HEADWORKS GRIT
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